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COMBIACX & ACEX

1. Page 58 81 AFCZP0BB COMBIACX amp ACEX User Manual 11 5Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level 100 and the Discharge Voltage Level 10 These two settings are the Bat Max Adj and the Bat Min Adj It is possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Battery Discharged Detection occurs when the battery is not totally discharged it is necessary to reduce the Bat Min Adj setting as indicated in the figure below 48V NOMINAL BATTERY VOLTAGE A 24V NOMINAL BATTERY VOLTAGE A AFCZPOBB COMBIACX amp ACEX User Manual Page 59 81 Page 60 81 The Battery Charge detection follows this algorithm 1 2 3 4 5 Battery voltages is read when the Battery current is zero that is when the output power stage is not driven Vbatt is the mean of the least samples measured by the microcontroller converter the samples are took on key input Vbatt is compared with a threshold value function of the actual charge percentage in a table and with comparison is found a new charge percentage Thresholds value can be changed with parameters Bat Max Adj and Bat Min Adj After key on battery charge can be only increased if the battery charge computed after key on is greater than the last value stored in Eeprom the bat
2. Module 2 Module 3 The red lines are can wires The black boxes are different modules for example traction controller pump controller and display connected by Canbus The black lines are the power cables This is apparently a good layout but can bring to errors in the can line The best solution depends on the type of nodes modules connected in the network If the modules are very different in terms of power then the preferable connection is the daisy chain Correct Layout Module 1 Module 2 Module 3 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the DATT post of the controller that works with the highest current and the others are connected in a decreasing order of power Otherwise if two controllers are similar in power for example a traction and a pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration AFCZPOBB COMBIACX ACEX User Manual A Correct Layout Module 1 Module 2 Module 3 Note Module 1 power Module 2 power gt Module 3 power In this case the power cables starting from the two similar controllers must be as short as possible Of course also the diameter of the cable concurs in the voltage drops described before higher diameter means lower impedance so in this last example the cable between the min
3. Running microswitches are in open position Low battery charge when the battery charge is low the maximum current is reduced to the half of the maximum current programmed additionally an alarm message is displayed Protection against accidental Start up A precise sequence of operations are necessary before the machine will start Operation cannot begin if these operations are not carried out correctly Requests for drive must be made after closing the key switch AFCZPOBB COMBIACX ACEX User Manual 4 3 2 Safety Features A ZAPI controllers are designed according to the EN13849 1 specifications for safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions Furthermore ZAPI is available to develop new SW or HW solutions to improve the safety of the machine according to customer requirements Machine manufacturer holds the responsibility for the truck safety features and related approval 4 4 EMC A EMC and ESD performances of an electronic system are strongly influenced by the installation Special attention must be given to the lengths and the paths of the electric connections and the shields This situation is beyond ZAPI s control Zapi can of
4. Step1 Step2 Step3 Step4 Step5 Step6 Step7 Step8 Connect a potentiometer in the range 0 5 to 10Kohms to modify the wished speed between 12V 5V CNC 8 and GND CNA 3 The potentiometer wiper is connected to CPOTTR CNC 4 Connect two travel demand switches The FWD travel demand must be connected between a battery key voltage and CNB 4 The REV travel demand must be connected between a battery key voltage and CNB 8 Only one of them can be active at the same time They become active when connected to a key Connect a tiller or seat switch enabling disabling the truck motion between CNC 6 and a key voltage It becomes active enabling the motion when closed to a key voltage Connect the encoder in the motor shaft between CND 2 VDD CND 5 GND CND 1 CHA CND 4 CHB The VDD voltage may be 12V or 5V depending on a jumper inside the controller Connect the plus battery voltage through a key switch at the KEY input CNC 1 This is the input for the controller supply Connect the Main Contactor Coil to CNC 1 and CNB 6 The contactor must connect the battery positive to the BATT power terminal of the ACEX COMBIACX Connect the motors and the minus battery to the corresponding power terminals of the ACEX COMBIACX Connect the Electromechanical Brake coil between CNB 1 and CNB 5 when the tiller switch opens the electromechanical brake gets de energized braking the truck The Steps from 1 to 8 describ
5. Watchdog One of two or both Watchdog circuit outputs Valve pump traction start up stby Key re cycle MDI CAN 08 becomes high due to an HW or SW problem stopped Lc opened Eb traction applied AFCZPOBB COMBIACX ACEX User Manual i Smart driver is open not able to valve pump traction stopped i provide EB positive Lc opened I 1 i 1 1 Key re cycle om shorted MDICAN Key off signal is low at Key on Ke traction stopped start up Key re cycle Ge driv short MDI CAN Evp driver is failed shorted always valve pump traction stopped start up stby valve or pump or ON mismatch between the valve Lc opened Eb applied raction request set point and its feedback Pump Vmn Low MDI Pump motor output is too low with valve pump traction stopped start up stby valve or pump or CAN 28 respect to pwm applied Lc opened Eb applied during pump raction request function Pump Vmn High MDI Pump motor output is too high valve pump traction stopped during pump alve or pump or CAN 29 with respect to pwm applied Lc opened Eb applied function raction request Wrong Zero MDI CAN The outputs of the amplifiers used valve pump traction stopped fini valve or pump or code alarm 53 to measure the motor voltage are Lc opened Eb applied raction request cheked this alarm occurs when voltage signals gt 3V or lt 2V at the init The Evp1 coil is not connected valve pump traction stopped A valve or
6. EV3 on off valve driver shorted On off valves stopped start up stby valve on off request MDI CAN 74 always ON Pump I NO zero Pump chopper current sensor Pump motor stopped start up stby pump request MDI CAN 56 feedback is out of permitted stby range Pump 0 ever Pump current feedback is always Pump motor stopped pump function pump request MDI CAN 52 OA even when pump motor is running Cont Drv Ev1 MDI Driver of Ev1 is open not able to Ev1 stopped during Ev valve Ev1 request CAN 75 close function Cont Drv Ev2 MDI Driver of Ev2 is open not able to Ev2 stopped during Ev2 valve Ev2 request CAN 75 close function Cont Drv Ev3 MDI Driver of Ev3 is open not able to Ev3 stopped during Ev3 valve Ev3 request CAN 75 close function Pump Vacc not OK The pump accelerator value is Pump stopped Continuous Pump request MDI CAN 89 higher than the minimum value recorded and the lift lower switches are open Sens Mot Temp The motor temperature sensor is Performance highly Continuous AAA recycle KO MDI CAN 67 damaged reduced Vacc out range The voltage on CNC 4 is out of the Traction stopped Continuous Program ici MDI CAN 85 parameters range Stall rotor MDI The traction rotor is stuck or the Traction stopped Continuous Key on recycle CAN 11 encoder is not working EVP driver open The EVP driver isdamaged or the EVP stopped Continuous Key on recycle MDI CAN 48 EVP coil impedance is too low Many pump reqs T
7. ssc 34 10 1 Adjustments via e 34 10 2 Description of console hand set amp connection sssseseseeeereseerrererrrnesssrrrrerrrrese 34 10 3 Description of the console menu 35 10 3 1 COMBIAGX ACEX MeTTlisi nioiassinsana idea 35 10 4 Function configuration EE 36 10 4 1 Config menu SET OPTIONS functions Wet enan 36 10 4 2 Config menu ADJUSTMENTS functions et 39 10 4 3 Main menu PARAMETER CHANGE functions list 43 10 4 4 Zapi menu SPECIAL ADJUSTMENTS functions list 49 10 4 5 Main menu TESTER functions Weit 50 11 OTHER FUNCTIONS rin 54 11 1 Description of console SAVE function ssssssrresrrrrrrrrrrrrrtrrrrtrtrtrrrtrrrrrrrrrrrennt 54 11 2 Description of console RESTORE Tunchon nn 55 11 3 Description of console PROGRAM VACO uncton 56 11 4 Description of the throttle regulatioN oommonicicnnnnnnnesmnonacorrerrrnnananananrerrnrnarnanna 58 11 5 Description of the battery charge detection Setting oonooonccccnnnnnnncnnnnccoccnccnnnnnnnnnnns 59 12 COMBIACX ACEX ALARMS LIST ccinsirinaniar t Cadena eeke 61 12 1 Faults diagnostic EE 61 12 2 Alarms E 62 12 3 gn e Ee 72 12 4 Analysis and troubleshooting Of warnings cece cette cent eter ee eeeeeenaaaeeeeeeeeeeeeeaea 74 13 RECOMMENDED SPARE PARTS sissessissscsestesnsnndcacasaccsencssacctansteaindostasasnnaneisantnniadaraadsraanens
8. EVP TYPE in SET OPTION menu is set ANALOG or DIGITAL but no load is connected between the output and PAUX positive Troubleshooting A Itis suggested to check the harness in order to verify if EVP coil is connected to the right connector pin and if it is not interrupted B If even connecting the coil to the right pin or replacing it the alarm is still present than the problem is inside the controller logic board replace it 29 AUX BATT SHORT Cause A The coil on the aux output is not correctly connected B The smartdriver inside the controller is damaged Troubleshooting Itis suggested to check that the coil is correctly connected between B1 and B5 If no problem is found on the coil the problem is inside the controller 30 PEV NOT OK Cause The PEV connector B2 is not connected to the battery or the voltage is different This alarm occours if one output between EV1 EV2 EV3 HORN is present or AUX OUT FUNCTION is PRESENT if POSITIVE EB 0 or 2 In other words one of the output load is connected to PEV All the valves EVP EV1 EV2 EV3 are stopped Horn is stopped Traction is stopped if the AUXOUT is used for an electrobrake and PEV is indispensable for it AUX OUT FUNCTION PRESENT POSITIVE EB 0 or 2 Pump is stopped if EV1 EV2 or EV3 are used PRESENT Troubleshooting Check B2 connector it must be connected to the battery voltage after the main contactor
9. The driver of the electromechanical brake coil is not able to drive the load Troubleshooting Replace the controller 12 POS EB SHORTED Cause The output of the built in Smart Driver which supplies the positive to the Electromechanical brake coil is high when the Tiller and the H amp S switch are open Troubleshooting A Itis suggested to check the harness in order to verify if a positive is connected to the Smart driver output CNB 1 B If even disconnecting the wire from the connector pin the output stays at high value the problem is inside the controller and the Smart Driver is probably shorted 13 LOGIC FAILURE 1 This fault is displayed when the controller detects an overvoltage or undervoltage condition Overvoltage threshold is 35V undervoltage threshold is 9 5V in the 24V controller In 36 48V controller overvoltage threshold is 65V Page 66 81 AFCZPOBB COMBIACX ACEX User Manual undervoltage threshold is 9 5V Troubleshooting of fault displayed at startup or in standby in these cases it is very likely the fault is due to an undervoltage so it is suggested to check A Key input signal down going pulses below undervoltage threshold due to external loads like DC DC converters starting up relays or contactor switching solenoids energizing de energizing B If no voltage transient is detected on the supply line and the alarm is present every time the key is switched ON the fail
10. 0 to 100 This parameter determines the maximum current applied to the EVP when the position of the potentiometer is at the maximum This parameter also determines the current value when the EVP is programmed like an ON OFF valve 39 EVP OPEN DELAY Seconds It determines the acceleration ramp on EVP The parameter sets the time needed to increase the current to the maximum possible value 40 EVP CLOSE DELAY Seconds It determines the deceleration ramp on EVP The parameter sets the time needed to decrease the current from the maximum possible value to zero AFCZPOBB COMBIACX amp ACEX User Manual Page 47 81 INVERSION BRAKING A From 0 to 10 sec resolution of 0 1 DECEL BRAKING From 0 to 10 sec resolution of 0 1 PEDAL BRAKING Sec From 0 to 10 sec resolution of 0 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 PU DECELER DEL Sec From 0 to 10 sec resolution of 0 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 1 From 0 to 100 resolution of 0 1 From 0 to 100 resoluti
11. 100 means the sine wave width is close to the actual battery voltage 0 means the sine wave width is null 3 VOLTAGE BOOSTER Percentage value It is the booster contribute to the voltage really supplied to the motor expressed in per cent of the actual battery voltage Note when DC_LINK COMPENSATION is set ON the VOLTAGE BOOSTER reading will not match perfectly the booster setting because this latest one is calculated respect to the nominal battery voltage VOLTAGE BOOSTER is expressed respect to the actual battery voltage 4 FREQUENCY Hz value This is the frequency of the sine waves the inverter is supplying 5 ENCODER Hz value This is the speed of the motor measured with the encoder and expressed in the same unit of the FREQUENCY reading 6 SLIP VALUE Hz value This is the slip between the frequency and the speed of the motor SLIP VALUE FREQUENCY ENCODER 7 CURRENT RMS Ampere value Root Mean Square value of the line current in the motor 8 BATTERY CHARGE Percentage value It supplies the residual charge of the battery as a percentage of the full charge level 9 TEMPERATURE C value This is the temperature of the inverter base plate This temperature is used for the HIGH TEMPERATURE alarm detection AFCZPOBB COMBIACX amp ACEX User Manual 10 MOTOR TEMPERATURE C value This is the temperature of the motor windings picked up with an analog sensor inside the motor Normally this sensor is a PTC Philips
12. Belly request is not active 17 DI2 H amp S CUTBACK ON OFF This is the level of the digital input CNC 7 for the Hard amp Soft request With the H amp S service is possible to turn the truck moving at reduced speed only by acting the H amp S switch and the accelerator without to let down the tiller ON VB When it is closed to a battery key voltage the H amp S request is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the H amp S request is not active 18 DI3 FORWARD SWITCH ON OFF This is the level of the digital input CNB 4 for the forward travel demand ON VB When it is closed to a battery key voltage the Forward Travel demand is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Forward Travel demand is not active AFCZPOBB COMBIACX amp ACEX User Manual Page 51 81 Page 52 81 19 DI4 BACKWARD SW ON OFF This is the level of the digital input CNB 8 for the backward travel demand ON VB When it is closed to a battery key voltage the Backward Travel demand is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Backward Travel demand is not active 20 DI5 HORN SWITCH ON OFF This is the level of the digital CNA 4 ON VB When it is closed to a battery key voltage the HORN request is active OFF GND When it is not closed
13. Contacts should be checked every 3 months Check the Foot pedal or Tiller microswitch Using a suitable test meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound Microswitches should be checked every 3 months Check the Battery cables cables to the inverter and cables to the motor Ensure the insulation is sound and the connections are tight Cables should be checked every 3 months Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requirements should be made after consulting a Zapi Agent The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual During periodic checks if a technician finds any situation that could cause damage or compromise safety the matter should be bought to the attention of a Zapi Agent immediately The Age
14. KTY84 130 or a KTY83 It depends on SET MOT TEMP option 11 PUMP CURRENT Ampere It is the continuous current in the pump motor 12 PUMP VMN It is the voltage applied to the pump motor Expressed in percentage of the maximum voltage 13 ACCELERATOR From 0 0V to 5 0V The voltage on the wiper of the accelerator CPOT on CNC 4 is halved inside the controller and then recorded on this reading That means the actual wiper voltage is in the range 0 to 10V meanwhile the corresponding ACCELERATOR reading is in the range 0 0 to 5 0Vdc 14 LIFTING CONTROL From 0 0 to 5 0V The voltage on the wiper of the accelerator CPOTLIFT on CNC 9 is halved inside the controller and then recorded on this reading That means the actual wiper voltage is in the range 0 to 10V meanwhile the corresponding ACCELERATOR reading is in the range 0 0 to 5 0Vdc 15 DIO TILLER SWITCH ON OFF This is the level of the digital input CNC 6 for the Tiller input ON VB When it is closed to a battery key voltage the Tiller input is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Tiller input is not active 16 DI1 BELLY SWITCH ON OFF This is the level of the digital input CNC 2 belly button ON VB When it is closed to a battery key voltage the request of the Belly to stop the movement is active OFF GND When it is not connected to a battery key voltage or it is connected to GND the
15. Menu 24v 165A OONAN 2 Press Top Left amp Right Buttons to enter EOE CONFIG MENU ooo CONFIG MENU 3 The Display will show SET MODEL SET MODEL 4 Press ROLL UP button until ADJUSTMENTS MENU appears Of oo oo CONFIG MENU ADJUSTMENTS 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS MENU AFCZPOBB COMBIACX amp ACEX User Manual Page 39 81 Page 40 81 7 The display will show SET BATTERY TYPE 8 Press ROLL UP or ROLL DOWN button until moo the desired parameter is reached goog e TROTTLE O ZONE 9 The desired parameter appears 10 Press SET UP or SET DOWN button to modify O 11 Press OUT 12 Press ENTER to confirm UR the adjustment eg TROTTLE O ZONE 7 ooo O Was O Wes ooo 13 Repeat the same from 5 to 12 points for the 1 2 3 4 5 6 7 other adjustments SET BATTERY TYPE Selects the nominal battery voltage ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller THROTTLE 0 ZONE Establishes a dead band in the accelerator input curve THROTTLE X POINT This parameter together with the THROTTLE Y POINT changes the characteristic of the accelerator input curve when the accelerator is de pressed to X point per cent the corresponding truck speed is Y point per cent of the Maximum truck speed The relationship between the accelerator position and the truck speed is linear between the THROTTLE 0
16. This is a warning for an incorrect starting sequence Troubleshooting The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting A A travel demand active at key on B Presence man sensor active at key on Check the wirings Check the micro switches It could be also an error sequence made by the operator A failure in the logic is possible too so when all of the above conditions were checked and nothing was found replace the controller VACC NOT OK Cause The test is made at key on and after 20sec that both the travel demands have been turned off This alarm occurs if the ACCELERATOR reading in the TESTER menu is 1 0V higher than PROGRAM VACC min acquisition when the accelerator is released Troubleshooting Check the mechanical calibration and the functionality of the potentiometer TH PROTECTION Cause This alarm occurs when the temperature of the base plate is higher than 85 Then the maximum current decreases proportionally with the temperature increases from 85 up to 105 At 105 the Current is limited to O Amps Troubleshooting Improve the air cooling of the controller If the alarm is signalled when the controller is cold the possible reasons are a thermal sensor failure or a failure in the logic card In this case it is necessary to replace the controller AFCZPOBB COMBIACX amp ACEX User Manual 6 BATTERY LOW Cause It occurs w
17. cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 25 PUMP VACC NOT Ok Cause The minimum of the lift potentiometer is not correctly set Troubleshooting It is suggested to repeat a PROGRAM VACC procedure 26 SENS MOT TEMP KO Cause A The motor temperature sensor is not correctly connected to D3 B The motor temperature sensor is damaged Troubleshooting Check the correct connection of the motor temperature sensor If the current sensor is correctly connected replace it Ifthe problem persist it is due to the controller AFCZPOBB COMBIACX amp ACEX User Manual Page 77 81 Page 78 81 27 VACC OUT RANGE Cause The voltage on CNC 4 is outside of the parameters range Troubleshooting Please re acquire the VACC parameters with a PROGRAM VACC procedure 28 STALL ROTOR Cause The traction rotor is stuck or the encoder signal is not correctly received by the controller Troubleshooting Please check if the sign of FREQUENCY and ENCODER on the tester menu are the same and different than zero during a traction request 29 EVP DRIVER OPEN Cause The EVP driver is damaged or the EVP coil impedance is too law Troubleshooting Please check the EVP coil impedance If the EVP impedance is OK the problem is inside the controller 30 MANY PUMP REQS Cause More than one pump functions were requested at
18. logic level of Key Off signal during Start Up diagnosis Troubleshooting It is very likely the fault is due to an under voltage so it is suggested to check A Key input signal down going pulses below under voltage threshold due to external loads like DC DC converters starting up relays or contactor switching solenoids energizing de energizing B Check the connection of power cables to the battery terminal positive and negative to MC and to controller Batt and Batt which must be screwed with a torque comprised in the range 5 6Nm 8 4Nm C If no voltage transient is detected on the supply line and the alarm is present every time the key is switched ON the failure is probably in the controller hardware so it is necessary to replace the logic board 24 EVP DRIV SHORT Cause A The EVP driver is shorted B The microcontroller detects a mismatch between the valve set point and the diver voltage measured on the LOWER EVP output Troubleshooting Check if there is a short or a low impedance between the negative of the coil and BATT Otherwise the driver circuit is damaged and the controller must be replaced 25 PUMP VMN LOW Cause The pump motor output is lower than expected considering the pwm applied Troubleshooting A If the problem occurs at start up the LC does not close at all check Motor internal connections ohmic continuity Motor power cables connections If the motor connection
19. main groups of faults ALARMS these are the faults which open the power section which means the power bridge is opened and when possible the LC is opened and EB is applied These are faults related to failures in the motor controller that the power system is not anymore able to drive the truck safety related failures WARNINGS these are faults which do not stop the truck or stop it by a controlled regen braking In other words the controller is working well but it has detected conditions to reduce the performances or to stop the truck without opening the power devices These warnings are related to wrong operator sequences conditions which require performance reduction like high temperatures AFCZPOBB COMBIACX amp ACEX User Manual Page 61 81 12 2 Alarms overview Page 62 81 Machine status Restart Error Code Description when the test is done procedure Power capacitors voltage does not increase Valve pump traction start up Valve or pump or stopped Lc opened Eb traction request applied Vmn low MDI Motor output voltage lower than expected Valve pump traction start up traction Valve or pump or CAN 72 stopped Lc opened Eb traction request applied Vmn high Motor output voltage higher than expected Valve pump traction start up traction Valve or pump or MDI CAN 31 stopped Lc opened Eb traction request applied Short circuit on the power mosfets Valve pump traction Valve
20. not connected to a battery key voltage or it is connected to GND the 2ND request is not active 26 DI11 CUTBACK1 ON OFF This is the level of the CNA 7 digital input ON GND When CNA 7 is not closed to GND the CUTBACK1 request not is active AFCZPOBB COMBIACX amp ACEX User Manual OFF VB When is not connected to GND or it is connected to battery the CUTBACK1 request is active 27 DI12 CUTBACK 2 ON OFF This is the level of the digital input CNA 14 ON GND When CNA 14 is not closed to GND the CUTBACK2 request not is active OFF VB When is not connected to GND or it is connected to battery the CUTBACK2 request is active 28 SET POINT EVP This parameter shows the setpoint of EVP valve 29 EV1 FEEDBACK ON OFF This parameter shows the feedback of EV1 valve 30 EV2 FEEDBACK VOLTAGE This parameter shows the feedback of EV2 valve 31 EV3 FEEDBACK VOLTAGE This parameter shows the feedback of EV3 valve 32 OUTPUT EV1 ON OFF This is the EV1 output command 33 OUTPUT EV2 This is the EV2 output command voltage 34 OUTPUT EV3 This is the EV3 output command voltage 35 OUTPUT HORN ON OFF This is the HORN output command 36 MAIN CONT VOLT This is the main contactor output command voltage 37 ELEC BRAKE VOLT This is the electrobrake output command voltage AFCZPOBB COMBIACX amp ACEN User Manual Page 53 81 11 OTHER FUNCTIONS 11 1 D
21. pump or between PAUX and EVP output Lc opened Eb applied i raction request and the parameter EVP TYPE in the set option menu is set Analog or Digital Aux Batt Short MDI CAN When the positive of the AUX valve pump traction stopped start up stby code alarm 74 OUTPUT is driven by the tiller the Lc opened Eb applied positive is high and the tiller is released Pev not OK MDI CAN The PEV connector B2 is not valve stopped eventually continuous code alarm 98 connected to the battery or the pump stopped eventually voltage is different traction stopped eventually Lc opened and MC applied Flash Checksum MDI The software is corrupted or the valve pump traction stopped continuous flash on the inverter is damaged Lc opened Eb applied The software is not compatible with valve pump traction stopped key recycle Lc opened Eb applied valve pump traction stopped key recycle Motor output voltage lower than Lc opened Eb applied amn oW E MRI GANG expected before driving the bridge valve pump traction stopped ikey recycle Init vmn high Motor output voltage higher than Lc opened Eb applied MDI CAN 31 expected before driving the bridge valve pump traction stopped key recycle Pump vmn not ok Pump motor output voltage is Lc opened Eb applied MDI CAN 32 different than expected AFCZPOBB COMBIACX amp ACEN User Manual Page 63 81 Page 64 81 Analysis and troubleshooting
22. signal is a square wave which is overlapped to the proportional valves set point In this way the proportional valves response to set point variations is optimized This parameter is a percentage of the valves maximum current It can be adjusted in the 0 to 20 3 by nine levels Setting the parameter to 0 means the dither isn t used DITHER FREQUENCY It is the dither signal frequency It can be used one of three 0 the dither signal frequency is 62 5 Hz 1 the dither signal frequency is 83 Hz 2 the dither signal frequency is 125 Hz AFCZPOBB COMBIACX amp ACEX User Manual Page 49 81 10 CAN BUS SPEED It determines the baudrate for the CAN communication 20 20 kbaud sec 50 50 kbaud sec 125 125 kbaud sec 250 250 kbaud sec 500 500 kbaud sec 10 4 5 Main menu TESTER functions list Page 50 81 The TESTER functions are a real time feedback measurements of the state of the controller motor command devices It is possible to know the state active off of the digital I Os the voltage value of the analog inputs and the state of the main variables used in the motor and hydraulics control Enter the home page in the hand set display and roll for the TESTER item 1 BATTERY VOLTAGE Voltage value with 1 decimal digit Battery voltage value measured at the key on 2 MOTOR VOLTAGE Percentage value It is the voltage generated by the inverter expressed in percent of the actual battery voltage
23. the same time Troubleshooting Just one pump function at a time can be requested Please reset all the requests and try again 31 PUMP INC START Cause This is a warning for a pump incorrect starting sequence Troubleshooting The possible reasons for this alarm are A Pump request active at keyon B Pump request active without man presence Check the wirings Check the micro switches It could also be an error sequence made by the operator A failurw logic is possible too When all of the above conditions were checked and nothing was found replace the controller 32 PUMP VACC RANGE Cause The voltage on CNC 9 is outside of the parameters range Troubleshooting If the EVP TYPE parameter is set to ANALOG please acquire again the values of MINLOWER and MAX LOWER If the controller is in Combiacx configuration and the PROPORTION LIFT parameter is set to ON please acquire again also the values of MIN LIFT and MAX LIFT 33 PARAM RESTORE Cause This warning appears when the controller restored the default values Troubleshooting If a CLEAR EEPROM was mode before the last keyon recycle this warning just means that the EEPROM was correctly cleared A travel demand or a pump AFCZPOBB COMBIACX amp ACEX User Manual request cancel the alarm If this alarm appears at keyon without any CLEAR EEPROM request by the operator there could be a problem inside the controller 34 WAIT MOT P STILL Caus
24. the speed of the 2ND function Percentage of the voltage applied to the pump motor for the 2ND function If it is set 0 the motor don t work when the 2ND request is ON 32 DESCENT SPEED From 0 to 100 It limits the maximum speed of the descent function Percentage of the maximum voltage applied to the pump motor for the descent function If it is set 0 the motor don t work when the descent request is ON 33 CREEP SPEED Percentage It sets the minimum speed percentage of voltage applied for the pump motor Percentage of the maximum voltage applied to the pump motor when the Lift SW is closed 34 COMPENSATION From 0 to 100 This parameter sets the voltage compensation AV applied to the motor when the proportional lifting function is active The value of this AV applied to the motor is a function of the motor current Aim of this function is to reduce as for as possible the speed difference between the truck loaded and unloaded 35 HYD SPEED FINE Percentage Fine adjustment of the pump motor steering function speed 36 HYDRO COMPENSATION Percentage Adjustment of the compensation function when the pump motor steering function is active 37 MIN EVP 0 to 100 This parameter determines the minimum current applied on the EVP when the position of the potentiometer is at the minimum This parameter is not effective if the EVP is programmed like a On Off valve AFCZPOBB COMBIACX amp ACEX User Manual 38 MAX EVP From
25. to a battery key voltage or connected to GND the HORN request is not active 21 DIG LOWERING SW ON OFF This is the level of the digital input CNA 1 1 ON VB When it is closed to a battery key voltage the request of the Lowering request is active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Lowering request is not active 22 DI7 LIFT SWITCH ON OFF This is the level of the digital input CNA 5 ON VB When it is closed to a battery key voltage the voltage the LIFTING request is active OFF GND When it is not closed to a battery key voltage or connected to GND the voltage the LIFTING request is not active 23 DI8 1ST P SPEED ON OFF This is the level of the digital input CNA 12 ON VB When it is closed to a battery key voltage the 1ST request is active OFF GND When it is not closed to a battery key voltage or it is connected to GND the 1ST request is not active 24 DI9 LIFT CUTBACK ON OFF This is the level of the digital input CNA 6 ON GND When it is closed not to a battery key voltage or it is connected to GND the PUMP CUTBACK request is not active OFF VB When it is closed to a battery key voltage the PUMP CUTBACK request is active 25 DI10 2ND P SPEED ON OFF This is the level of the digital input CNA 13 ON VB When is closed to a battery key voltage the digital the 2ND request is active OFF GND When is
26. 31 FLASH CHECKSUM Cause The software was not correctly written into the flash memory or the flash memory is damaged Troubleshooting This type of fault is not related to external components replace the controller 32 INIT VMN LOW Cause Before switching the LC on the software checks the power bridge voltage without driving it The software expects the voltage to be at a steady state value AFCZPOBB COMBIACX amp ACEX User Manual If it is too low this alarm occours Troubleshooting Please check Motor internal connections ohmic continuity Motor power cables connections Motor leakage to truck frame If the motor connections are OK the problem is inside the controller 33 INIT VMN HIGH Cause Before switching the LC on the software checks the power bridge voltage without driving it The software expects the voltage to be at a steady state value If it is too high this alarm occours Troubleshooting Please check Motor internal connections Motor power cables connections Motor leakage to truck frame If the motor connections are OK the problem is inside the controller 34 PUMP VMN NOT Ok Cause Before switching the LC on the software checks the output voltage on P connector and expects it to be at a steady state value if TRUCK TYPE options is set to LEVEL 1 If the voltage is too low this alarm occours Troubleshooting Plea
27. 7 V SAVE PARAMETER AV RESTORE PARAMETER AY BATTERY VOLTAGE MOTOR VOLTAGE VOLTAGE BOOSTER FREQUENCY ENCODER SLIP VALUE CURRENT RMS ERY CHARGE BA TEMPERATURE MOTOR TEMPERAT PUMP CURRENT PUMP VMN ACCELERATOR LIFTING CONTROL DIO TILLER SW DI1 BELLY SW DI2 H amp S CUTBACK DI3 FORWARD SW DI4 BACKWARD SW DIS HORN DI6 LOWERING SW DI7 LIFT SW DIB 1ST P SPEED SW DI9 LIFT CUTBACK DI10 2ND P SPEED DI11 CUTBACK1 DI12 CUTBACK2 SET POINT EVP EVI FEEDBACK EV2 FEEDBACK EV3 FEEDBACK OUTPUT EV1 OUTPUT EV2 OUTPUT EV3 OUTPUT HORN MAIN CONT VOLT ELEC BRAKE VOLT lt lt S gt SSN ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF AY ADJUSTMENTS y CONNECTED TO N a a A lt lt gt Y A gt lt TILLER SWITCH EB ON TILLER BRK HOUR COUNTER EVP TYPE BATTERY CHECK STOP ON RAMP QUICK INVERSION SET MOT TEMP EPS INVERSION MOD Ev1 EV2 EV3 DIAG PEDAL WIRE HYDRO FUNCTION MC FUNCTION AUX OUT FUNCT DISPLAY TYPE H amp S SWITCH PROPORTION KO PUMP HANDLE SEAT DEADMAN ON OFF RUNNING KEY ON ANALOG DIGITAL NONE LEVELO LEVEL1 LEVEL2 LEVELS ON OFF BELLY TIMED NONE ANALOG DIGITAL OPTION 1 OPTION 2 NONE OPTION 1 OPTION 2 ON OFF PRESENT ABSENT PRESENT ABSENT PRESENT ABSENT PRESEN
28. 80 14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 81 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N AFCZPOBB Edition November 2010 Page 4 81 AFCZPOBB COMBIACX amp ACEX User Manual 1 INTRODUCTION The COMBIACX ACEX inverter has been developed to perform all the electric functions that are usually presents in walkie and rider pallet trucks stackers low level order pickers The controller can perform the following functions Controller for AC 600W to 2 kW AC motors Pump controller for series wounded DC motors up to 5 kW only for COMBIACX Driver for Line Contactor coil Drivers for ON OFF electrovalves and for one proportional valve electro distributor Low side and high side short circuit protected drives for electric brake coil Canbus interface Interface for Canbus tiller Zapi patented sensorless and sense coil control 192 kBytes Flash memory embedded Software downloadable via Serial link internal connectors or Canbus external connector ESD protection on Canbus inputs CANL and CANH AFCZPOBB COMBIACX amp ACEX User Manual Page 5 81 2 SPECIFICATION 2 1 Technical specifications COMBIACX ACEX EY Inverter for traction AC asynchronous 3 phase motors plus chopper for DC series pump motors Regenerative braking functions Digital contr
29. ARAMETER GHANGE MAIN MENU PROGRAM VAGG VACC SETTING 4 8 4 8 MIN VACO MAX 0 6 ood O Wei 4 4 ARE YOU SURE MAIN YES ENTER NO 0UT O Wei O Wei MENU PROGRAM VAGG ood O Wei Page 57 81 11 4Description of the throttle regulation This regulation applies a not linear relationship between the position of the accelerator and the speed of the truck The main goal is to increase the resolution for the speed modulation when the truck is slowly moving Three adjustments are used for the throttle regulation 1 THROTTLE 0 ZONE 2 THROTTLE X POINT 3 THROTTLE Y POINT THROTTLE 0 ZONE the speed of the truck remains at frequency creep meanwhile the voltage from the accelerator potentiometer is lower than this percentage of the MAX VACC setting This adjustment define the width of a dead zone close to the neutral position THROTTLE X POINT amp THROTTLE Y POINT the speed of the truck grows up with a fixed slope linear relationship from the THROTTLE 0 ZONE up to THROTTLE X POINT This slope is defined by the matching between the X point percentage of the MAX VACC setting with the Y point percentage of the full truck speed From the X point up to the MAX VACC point the slope of the relationship between the truck speed and the accelerator position is different see figure below to match the full speed in the truck with the MAX VACC voltage in the accelerator position SP Hz
30. Page 9 81 3 5 Speed feedback The motor control is based upon the motor speed feedback sensored software The speed transducer is an incremental encoder with two phases shifted at 90 The encoder can be of different types power supply 12V 5V electric output open collector NPN push pull COMBIACX ACEX can also operate without encoder this using a sensorless control This solution has to be discussed with Zapi technicians E Note 1 The encoder resolution and the motor poles pair the controller can handle is specified in the home page display of the handset showing following headline ADXZ2A ZP1 00 That means ADXZ COMBIACX Zapi controller 2 motor s poles pair number A 32 pulses rev encoder The encoder resolution is given by the second last letter in the following list A 32 pulses rev K 48 pulses rev B 64 pulses rev C 80 pulses rev Page 10 81 AFCZPOBB COMBIACX amp ACEX User Manual 4 INSTALLATION HINTS EY A In the description of these installation suggestions you will find some boxes of different colours they mean These are informations useful for anyone is working on the installation or a deeper examination of the content These are Warning boxes they describe operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Materia
31. T ABSENT KEY ON RUNNING NONE PRESENT ABSENT PRESENT ABSENT 0 1 2 3 4 PRESENT ABSENT ON OFF lt gt BATTERY TYPE ADJUST BATTERY THROTTLE O ZONE THROTTLE X POIN THROTTLE Y POINT BAT MIN ADJ BAT MAX ADJ BD ADJ START UP SET 24V 36V 48V AW ALARMS gt ODE SPECIAL ge lt h N C ADJUSTMENTS PROGRAM VACC VACC SETTING MIN MAX AFCZPOBB COMBIACX amp ACEX User Manual LOAD HM FROM MDI ON OFF CHECK UP DONE ON OFF CHECK UP TYPE OPTION 0 1 2 MIN LIFT V MAX LIFT vV MIN LOWER v MAX LOWER v MC VOLTAGE MC VOLTAGE RED EB VOLTAGE EB VOLTACE RED lt lt gt ADJUSTMENT 01 ADJUSTMENT 02 SET CURRENT aul SET TEMPERATURE T ADJUSTMENT 03 SET CURRENT PUMP HIGH ADRESS DITHER AMPLITUD DITHER FREQUENCY CAN BUS SPEED Ei Z Hz A W gt lt Page 35 81 10 4Function configuration 10 4 1 Config menu SET OPTIONS functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons Then roll until the SET OPTION item appears on the Page 36 81 hand set display Push the ENTER button Opening Zapi Display Push ROLL UP SET UP simultaneously to enter CONFIG MENU The Display will show SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear The Display will show SET OPTIONS Press ENTER to go
32. The output of the controller thermal sensor is out of range Troubleshooting This type of fault is not related to external components replace the controller 10 CHECK UP NEEDED Cause This is just a warning to call for the time programmed maintenance Troubleshooting It is just enough to turn the CHECK UP DONE option to level ON after the maintenance is executed 11 DATA ACQUISITION Cause Acquisition of the current gains Troubleshooting The alarm ends when the acquisition is done 12 TILLER OPEN Cause Warning when the tiller is released after a fixed period of time of standby 30 seconds the main contactor open Troubleshooting AFCZPOBB COMBIACX amp ACEX User Manual Page 75 81 At the next travel request the warning disappear 13 CURRENT GAIN Cause The Maximum current gain parameters are at the default values which means the maximum current adjustment procedure has not been carried out yet Troubleshooting Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters 14 WAITING FOR NODE Cause The controller receives from the CAN the message that another controller in the net is in fault condition as a consequence the ACEX COMBIACX controller itself cannot enter an operative status but has to WAIT for the other controller coming out from the fault status 15 COIL SHOR EV Cause One of the electrovalve
33. UT to return to the Opening Zapi Display i a E AFCZPOBB COMBIACX amp ACEX User Manual EY NOTE in reality the SAVE and RESTORE function requires the Windows PC Console 11 2Description of console RESTORE function The RESTORE PARAM function allows transfer of the Console s stored data into the memory of the controller This is achieved in a fast and easy way using the method previously used with the SAVE PARAM function The data that is available on the RESTORE PARAM Function are listed here below All Parameter Values PARAMETER CHANGE Options SET OPTIONS The level of the Battery ADJUST BATTERY ATTENTION When the RESTORE operation is made all data in the controller memory will be written over and replaced with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console ADXT2B ZP1 00 Opening Zapi Display 24V 165A 00000 O Wei Press ENTER to go into the General menu The Display will show MAIN MENU PARAMETER GHANGE Press ROLL UP or ROLL DOWN button until Boog RESTORE PARAM appears on the display moo MAIN MENU RESTORE PARAM The Display will show Press ENTER to go into the RESTORE PARAM S fe function ood The Display shows the type of Model stored with a SELECT MOD 00 Code Number ACEX ZAPI V1 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the S Display SELECT MOD 00 AGEX
34. V Azam ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma 59 42028 POVIGLIO RE ITALY Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it EN User Manual COMBIACX amp ACEX Copyright 1975 2011 Zapi S p A All rights reserved The contents of this publication is a ZAPI S p A property all related authorizations are covered by Copyright Any partial or total reproduction is prohibited Under no circumstances will Zapi S p A be held responsible to third parties for damage caused by the improper use of the present publication and of the device devices described in it Zapi spa reserves the right to make changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the characteristics of the product as a result of updating VA YAPI is a registered trademark property of Zapi S p A NOTES LEGEND EY The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention DA The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page 2 81 AFCZPOBB COMBIACX ACEX User Manual Conten
35. ZAPI V1 Press ENTER to commence the Restore operation ARE YOU SURE YES ENTER NO 0UT The Display will ask ARE YOU SURE AFCZPOBB COMBIACX amp ACEX User Manual Page 55 81 EY Press ENTER for YES or OUT for No You can see the items that are being stored in the chopper memory whilst the RESTORE routine is BRE ea pai happening ini MAIN MEHU When finished the Console shows S ee a ek Press OUT to return to the Opening Zapi Display NOTE in reality the SAVE and RESTORE function requires the Windows PC Console 11 3 Description of console PROGRAM VACC function MG GAA Page 56 81 This enables adjustment of the minimum and maximum useful signal level in either direction This function is unique when it is necessary to compensate for asymmetry with the mechanical elements associated with the potentiometer especially relating to the minimum level The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer A A A A A A A e Z Gi N Y Z Yj E F Y z j Z 2 LA This function looks for and
36. ZONE and the X point and also between the X point and the maximum accelerator position but with two different slopes THROTTLE Y POINT This parameter together with the THROTTLE X POINT changes the characteristic of the accelerator input curve see also paragraph 13 5 when the accelerator is de pressed to X point per cent the corresponding truck speed is Y point per cent of the Maximum truck speed The relationship between the accelerator position and the truck speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slope BAT MIN ADJ Adjust the lower level of the battery charge table Level 0 to 9 BAT MAX ADJ Adjust the upper level of the battery charge table Level 0 to 9 AFCZPOBB COMBIACX amp ACEX User Manual 8 BDI ADJ START UP It selects the type of algorithm used to estimate the battery discharge Each level corresponds to a different set of parameters of the algorithm 9 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the MDI CAN connected to CAN BUS network 10 CHECK UP DONE It can be ON OFF If it is ON it is possible to reset the last maintenance hour counter and the CHECK UP NEEDED warning 11 CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEENED warning OPTION 1 CHECK UP NEENED warning show
37. arameter appears it s possible to change the Level by pressing either SET UP or SET DOWN buttons 9 The Display will show the new level ee eg ee LEVEL 2 10 When you are satisfied with the result of the ooo changes you have made press OUT omo ARE YOU SURE 11 The Display asks ARE YOU SURE YES ENTER NO OUT 12 Press ENTER to accept the changes or press OUT to discard them MAIN MENU PARAMETER GHANGE 13 The Display will show 1 ACCELER DELAY Seconds It determines the acceleration ramp The parameter sets the time needed to speed up the traction motor from OHz to 100Hz 2 RELEASE BRAKING Seconds It controls the deceleration ramp when the travel request is released The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ AFCZPOBB COMBIACX amp ACEX User Manual Page 43 81 Page 44 81 3 TILLER BRAKING Seconds It controls the deceleration ramp when the tiller is in braking position released The parameter sets the time needed to decelerate the traction motor from 100Hz to OHz 4 INVERS BRAKING Seconds It controls the deceleration ramp when the direction switch is inverted during travel The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ 5 DECEL BRAKING Seconds It controls the deceleration ramp when the accelerator has turned down but not completely released The parameter sets the time needed to decelerat
38. are OK the problem is inside the controller B If the problem occurs after closing the LC the LC closed and then opens back again check Motor connections If motor windings cables have leakages towards truck frame If no problem are found on the motors the problem is inside the controller C If the alarm occurs during motor running check Motor connections If motor windings cables have leakages towards truck frame That the LC power contact closer properly with a good contact If no problem are found on the motors the problem is inside the controller 26 PUMP VMN HIGH Cause This test is carried out when the pump motor is turning pwm applied The pump motor output is higher than expected considering the pwm applied Troubleshooting It is suggested to check A Motor connections B If motor windings cables have leakages towards truck frame C If no problem are found on the motors the problem is inside the controller AFCZPOBB COMBIACX amp ACEN User Manual Page 69 81 Page 70 81 27 WRONG ZERO Cause The outputs of the amplifiers used to measure the traction motor voltage are checked to be included into a range This alarm occurs when the voltage signals gt 3V or lt 2V at the init Troubleshooting This type of fault is not related to external components replace the controller 28 EVP COIL OPEN Cause This fault appears when the LOWER EVP output is used parameter
39. celerates because CNC 6 was deactivated whilst moving E Note if the positive of the EB is coming from the tiller input this option is meaningless because EB is applied mechanically as soon as CNC 6 becomes OFF 3 HOUR COUNTER This option specifies the hour counter mode It can be set one of two RUNNING The counter registers travel time only KEY ON The counter registers when the key switch is closed controller supplied 4 EVP TYPE Analog digital defines the type of the EVP electrovalve current controlled Analog the related output manages a proportional valve current controlled Digital the related output manages an on off valve 5 BATTERY CHECK This option specifies the handling of the low battery charge detection There are tree levels Level 0 Nothing happens the battery charge level is calculated but is ignored it means no action is taken when the battery is discharged Level 1 BATTERY LOW alarm is raised when the battery level is calculated being less than or equal to 10 of the full charge The BATTERY LOW alarm reduces the maximum speed down to 24 of the full soeed and reduces the maximum current down to 50 of the full current Level 2 BATTERY LOW alarm is raised when the battery level is calculated being less or equal to 10 of the full charge Level 3 BATTERY LOW alarm is raised when the battery level is calculated being less or equal to 10 of the full charge The BATTERY LOW alarm reduces the
40. e If TRUCK TYPE option is set to LEVEL 1 the software expects the voltage on P output to be at a steady state value before switching the LC on If the voltage is different it could be due to the fact that the motor connected to P is not still For this reason the software waits 30 seconds for the voltage to be at the steady state value and for the pump motor to be still After this time the software assumes that the problem is not due to the fact that the pump motor is not still and show the PUMP VMN NOT OK alarm see in the alarms chapter Troubleshooting If the motor connected to P is still moving just wait for it to be still If not in 30 seconds the alarm PUMP VMN NOT OK will appear Please see the alarms chapter AFCZPOBB COMBIACX amp ACEX User Manual Page 79 81 13 RECOMMENDED SPARE PARTS C16604 Protected 100A strip fuse ACEX 36 48V C16529 Protected 125A strip fuse ACEX 24V C16502 Protected 160A strip fuse ACEX PW 24 36 48V C16591 Protected 175A strip UL fuse C16504 Protected 300A strip fuse COMBIACX 24 36 48V C16587 Protected 300A strip UL fuse C16505 Protected 355A strip fuse COMBIACX PW 24 36 48V C16588 Protected 350A strip UL fuse C16520 10A 20mm control circuit fuse Page 80 81 AFCZPOBB COMBIACX ACEX User Manual 14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors moving and fixed contacts Electrical
41. e 111 Po CZP1AC AF I Disegno n Drawing n PROI ZAPI G UNCTIONAL DRAWIN Y ALLOWED USE IS THAT RELATIVE TO THE REPAI pz Lu A O o uw Lil E A 6 H Ela o DER pe 2 E SU gt ie E El 2z E Z z gt S x gt lt ElO E SI g m a gt SS AO a a A ZAPI s p a PROPERTY ITS REPRC VING IS THIS Y AFCZPOBB COMBIACX amp ACEX User Manual Page 29 81 8 4 Connection drawing ACEX v 3 34 E E RB 5 5 gt t gt x E 8 a lt S E lt i a m Disegno n Drawin AFCZPIB lt 3 8 B D g SO 0 3 a E le o a a 2 w Z E o gt lt E CG lt Tv Slav ECH Wd CO D e gt gt DE 2 8 EZ a O rO Pha t di a H Su 5 E j 2 y w E Tey ro Z voi zna E Lil H KI lt e Aad o ak ZC OWN JE 5 H ZS RE r gH L lt Su S SUP CONS HIN De E S w EC ESG x a n 2 E D lt RER ERTY ITS ate Page 30 81 AFCZPOBB COMBIACX amp ACEX User Manual 9 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure To move the truck needs a minimum I O outfit that it is mandatory this minimum outfit is listed in the Steps from 1 to 8 below
42. e alarm In these cases try to replace the encoder D If the problem is still present after replacing the encoder the failure is in the controller 20 TILLER ERROR Cause Mismatch between the H amp S input and the tiller input Troubleshooting Check the harness related to CAN 1 and CAN 29 with a voltmeter If the state of these inputs is right then it could be a problem inside the controller which has to be changed 21 WATCHDOG Cause This is a safety related test It is a self diagnosis test within the logic The watch dog circuit is composed by two monostable multivibrators so there is a double check of software execution Troubleshooting This alarm could be caused by an hardware failure in one of two or both multivibrator or due to a software execution problem For both cases it is an internal fault of the controller which must be replaced 22 SMART DRIVER KO Cause The built in smart driver is open not able to provide the electro mechanic brake positive Troubleshooting A Itis suggested to check the harness in order to verify if the Smart driver output CNB 1 is shorted to Batt B If even disconnecting the wire from the connector pin the output stays at low value the problem is inside the controller and the Smart Driver is probably damaged 23 KEYOFF SHORTED Cause Page 68 81 AFCZPOBB COMBIACX ACEX User Manual This fault is displayed when the controller detects a low
43. e displayed this output is OFF AFCZPOBB COMBIACX amp ACEX User Manual Page 23 81 A10 A11 A12 A13 A14 GND DI6 DI8 DI10 DI12 6 1 2 CNB external connector B1 B2 B3 B4 B5 B6 B7 B8 PEB PEV NEVP DI3 NEB NLC HORN DI4 6 1 3 CNC external connector Page 24 81 C1 C2 C3 KEY DI1 NPOT This is the ground of the logic board Input of the switch DI6 The input is activated when it is connected to Batt The default function is the controller LOWER enable input Input of the switch DI8 The input is activated when it is connected to Batt The default function is the controller 1ST input the pump motor turn at a defined speed Input of the switch DI10 The input is activated when it is connected to Batt The default function is the controller 2ND input the pump motor turn at a defined speed Input of the switch DI12 The input is activated when the external switch is opened to ground The default function is the controller CUTBACK2 input opening the switch truck speed is reduced In the Sense Coil version this input is connected to the AC motor sense coil This pin outputs the positive supply equal to Batt of the electromechanical brake coil Depending on hardware configuration this pin can be controlled by the microcontroller or tied to the B2 input or to the C6 input See connection drawing for more details Co
44. e first second defined by the previous parameter 18 EB VOLTAGE This parameter stores the PWM value applied to EB coil during the first second of the output activation It is expressed in percentage of battery voltage AFCZPOBB COMBIACX amp ACEX User Manual Page 41 81 19 EB VOLTAGE RED This parameter stores the PWM value applied to EB coil after the first second of the output activation It is expressed in percentage of the voltage applied during the first second defined by the previous parameter 20 PWM EV2 This parameter stores the PWM value applied to the EV2 coil It is expressed in percentage of battery voltage 21 PWM EV3 This parameter stores the PWM value applied to the EV3 coil It is expressed in percentage of battery voltage Page 42 81 AFCZPOBB COMBIACX amp ACEX User Manual 10 4 3 Main menu PARAMETER CHANGE functions list To enter the MAIN MENU it is just necessary to push the ENTER button from the home display in the hand set ADXT2B ZP1 00 1 Opening Zapi Menu ga fos GANAT 2 Press ENTER to go into the General Menu 3 The Display will show PARAMETER CHANGE elei ele Ne 4 Press ENTER to go into the Parameter Change menu oo O N oo 5 The Display will show the first parameter 6 Press either ROLL UP and ROLL DOWN to display the next parameter 7 The names of the Parameters appear on the RELEASE BRAKING Display LEVEL 5 8 When the desired P
45. e nearest Zapi Service Centre DA Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause MOS failure A lower voltage may prevent the logic operating 4 2 3 Wirings CAN connections and possible interferences EP CAN Stands for Controller Area Network It is a communication protocol for real time control applications CAN operates at data rate of up to 1 Megabits per second lt was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic modules of a vehicle connected as illustrated in this image CAN Controller Transceiver 12012 The best cable for can connections is the twisted pair if it is necessary to increase the immunity of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded In a system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted through the can wires In the following figures there is an overview of wrong and right layouts of the cables routing AFCZPOBB COMBIACX amp ACEX User Manual Page 13 81 A Page 14 81 Wrong Layout Module 1
46. e the installation operations that is mandatory to do in order your truck moves Obviously the ACEX COMBIACX may execute a wider set of optional services as 1 to handle some speed reductions requests 2 to handle an analog sensor inside the motor 3 to handle a proportional braking 4 to handle a proportional forks lowering valve 5 to handle a pump motor by a chopper 6 to handle a belly switch for truck quick inversion 7 to handle a proportional input for the forks lifting lowering 8 to handle a number of on off E valves driving a protected drivers 9 to handle an Horn driving a protected driver You must fill your I O outfit with your optional functions The optional functions are shown in the connecting drawing and described in detail inside this manual The index may help you AFCZPOBB COMBIACX amp ACEX User Manual Page 31 81 9 1 Sequence for Ac Inverter traction setting EY Page 32 81 This section of the manual describes the basic ACEX COMBIACX set up procedure To complete this procedure it is necessary to use the Zapi console Since the COMBIACX ACEX has no external serial connector the Zapi console has to be connected through a remote module like a Zapi tiller card of a Zapi display This module has to be connected to the same Canbus line of the inverter Otherwise it is possible to connect a pc to the Canbus line and use the PC CAN Console software This tool is more powerful than the
47. e the traction motor from 100Hz to OHZ 6 PEDAL BRAKING Seconds This parameter determines the deceleration ramp when the travel request is released and the brake pedal switch is closed It sets the time needed to decelerate the traction motor from 100Hz to OHZ 7 SPEED LIMIT BRK Seconds It controls the deceleration ramp when a speed reduction has been activated The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ 8 EPS STEER BRAK Seconds It controls the deceleration ramp when a steer cutback is applied The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ If EPS option is set to NONE this parameter is useless 9 MAX SPEED FORW Percentage It determines the maximum speed in forward direction 10 MAX SPEED BACK Percentage It determines the maximum speed in backward direction 11 CUTBACK SPEED 1 Typically from 10 to 100 It determines the percentage of the max speed applied when the cutback switch CNA 7 connector is active When set to 100 the speed reduction is ineffective 12 CUTBACK SPEED 2 Typically from 10 to 100 It determines the percentage of the max speed applied when the cutback switch CNA 14 connector is active When set to 100 the speed reduction is ineffective 13 H amp S CUTBACK Typically from 10 to 100 It determines the percentage of the max speed applied when the Hard amp Soft function CNC 7 connector is active When set
48. eafult parameters Traction motor temperature sensor is The maximum current continuous opened if digital or has overtaken is reduced to half and MDI CAN 65 the threshold of 150 C if analog speed is reduced Thermic sens The output of the controller thermal The maximum current continuous ko MDI CAN sensor is out of range is reduced to half and 61 E is reduced Check up Maintenance time is reached needed Maximum current adjustment Traction is D stand by Traction procedure is in progress NOTE this request procedure has to be done only by Zapi test department The truck is in stby with tiller switch LC opens standby Valve or pump MDI CAN 51 opened for more than 30s or traction request Current gain The Maximum current gain Controller works but start up stanby MDI CAN 92 parameters are the default values with low maximum which means the maximum current current adjustment procedure has not been carried out yet A Canbus network node is in alarm continuous condition uC is waiting for it to resolve its error condition AFCZPOBB COMBIACX ACEX User Manual Machine status a E Restart Error code Description procedure Drv Shor EV1 dri EV1 on off valve drivers shorted On off valves stopped start up stby valve on off request MDI CAN 74 always ON Drv Shor EV2 EV2 on off valve driver shorted On off valves stopped start up stby valve on off request MDI CAN 74 always ON Drv Shor EV3
49. electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device There are well defined tests which the machine has to be exposed to These tests are carried out at determined levels of electromagnetic fields to AFCZPOBB COMBIACX amp ACEN User Manual Page 19 81 Page 20 81 3 simulate external undesired disturbances and verify the electronic devices response The second type of immunity ESD concerns the prevention of the effects of electric current due to excessive electric charge stored in an object In fact when a charge is created on a material and it remains there it becomes an electrostatic charge ESD happen when there is a rapid transfer from a charged object to another This rapid transfer has in turn two important effects this rapid charge transfer can determine by induction disturbs on the signal wiring and thus create malfunctions this effect is particularly critical in modern machines with serial communications canbus which are spread everywhere on the truck and which carry critical informations in the worst case and when the amount of charge is very high the discharge process can determine failures in the electronic devices the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device IMPORTANT NOTE it is always much easi
50. eleration parabolic form ends 23 AUXILIARY TIME Time units value Seconds For the encoder version it determines the time duration the truck is hold on the ramp if the STOP ON RAMP option is ON 24 HYDRO TIME Sec It determines the time duration the pump motor is driven after the hydraulic request is released 25 PUMP IMAX Level 0 to 9 Set the maximum current for the pump motor 26 PUMP ACCELERATION DELAY In seconds Set the acceleration ramp for the pump motor AFCZPOBB COMBIACX amp ACEX User Manual Page 45 81 Page 46 81 27 PUMP DECELERATION DELAY In seconds Set the deceleration ramp for the pump motor 28 MAX SPEED LIFT From 0 to 100 It limits the maximum speed of the lift function Percentage of the maximum voltage applied to the pump motor for the lift function If it is set 0 the motor does not work when the lift request is ON 29 LIFT CUTBACK From 0 to 100 It reduces the maximum speed of the lift function when the pump cutback switch CAN 6 connector is active When set to a percentage which is higher than MAX SPEED LIFT the pump speed reduction is ineffective If set 0 the motor is stopped when the pump cutback switch is ON 30 1 PUMP SPEED From 0 to 100 It limits the speed of the 1ST function Percentage of the voltage applied to the pump motor for the 1ST function If it is set 0 the motor don t work when the 1ST request is ON 31 2 PUMP SPEED From 0 to 100 It limits
51. er and cheaper to avoid ESD from being generated than to increase the level of immunity of the electronic devices There are different solutions for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 4 5 6 EMISSIONS Three ways can be followed to reduce the emissions A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using shielded cables C LAYOUT a good layout of the cables can minimize the antenna effect cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and bypass capacitors ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD A PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase B ISOLATION use anti static containers when transferring ESD sensitive material C GROUNDING when a complete isolation cannot be achieved a
52. escription of console SAVE function Page 54 81 The SAVE function allows the operator to transmit the Parameter values and Configuration data of the controller into the Console memory It is possible to load 64 different programmes The information saved in the Console memory can then be reloaded into another controller using the RESTORE function The data that is available via the SAVE function are listed here below All Parameter Values PARAMETER CHANGE Options SET OPTIONS The Level of the Battery ADJUST BATTERY Flow Chart showing how to use the SAVE function of the Digital Console ADXT2B ZP1 00 24V 165A 00000 Press ENTER to go into the General menu MAIN MENU PARAMETER GHANGE Opening Zapi Display The Display will show Press ROLL UP or ROLL DOWN button until SAVE poo PARAM appears on the display ma B The Display will show MAIN MENU SAVE PARAMETERS Press ENTER to go into the SAVE function If this feature has been used before the type of controller data stored appears on the top Main with a 2 digit reference SELECT MOD OO FREE Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility SELECT FR Press ENTER to commence SAVE routine You can see the items that are being stored whilst READING the SAVE routine is happening ACCEL DELAY ECC SELECT MOD Di When finished the Console shows FREE Press O
53. f 90 The encoder power supply can be 5V or 12V It can have different electronic output D2 5V 12V positive of encoder power supply D5 GND negative of encoder power supply D1 A phase A of encoder D4 B phase B of encoder 2 Connection of encoder with open collector output 5V and 12V power supply NX d Se VERY IMPORTANT It is necessary to specify in the order the type of encoder used in terms of power supply electronic output and n of pulses for revolution because the logic unit must be set in the correct way by Zapi The n of pulses revolution the controller can handle is given by the second last letter in the software release name see 3 5 AFCZPOBB COMBIACX amp ACEX User Manual 4 2 6 Main contactor and key connection The connection of the main contactor can be carried out following the drawing in the figure n The connection of the battery line switches must be carried out following ZAPI instructions Ifa mechanical battery line switch is installed it is strongly recommended that the key supply to the inverter is open together with power battery line see picture below if not the inverter may be damaged if the switch is opened during a regenerative braking An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 40 more than the battery nominal voltage or if the key is switched off before the battery power line is disc
54. fer assistance and suggestions based on its years experience on EMC related items However ZAPI declines any responsibility for non compliance malfunctions and failures if correct testing is not made The machine manufacturer holds the responsability to carry out machine validation based on existing norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetical energy generated or received by an electrical device So the analysis works in two directions 1 The study of the emission problems the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy we talk about conduction issues when guiding structures such wires and cables are involved radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy but wires and cables have the key role to propagate the disturbs because they works as antennas so a good layout of the cables and their shielding can solve the majority of the emission problems 2 The study of the immunity can be divided in two main branches protection from electromagnetic fields and from electrostatic discharge The
55. ge feedback is tested if it is lower than commanded value fault status is entered Troubleshooting A If the problem occurs at start up the LC does not close at all check Motor internal connections ohmic continuity Motor power cables connections Motor leakage to truck frame If the motor connections are OK the problem is inside the controller B If the alarm occurs during motor running check Motor connections If motor phases windings cables have leakages towards truck frame That the LC power contact closer properly with a good contact AFCZPOBB COMBIACX amp ACEX User Manual If no problem are found on the motors the problem is inside the controller 3 VMN HIGH Cause 1 Before switching the LC on the software checks the power bridge it turns on alternating the Low side Power Mosfets and expects the phases voltage to decrease down to Batt If the phases voltage do not decrease this alarm occurs Cause 2 This alarm may occur also when the start up diagnosis is overcome and so the LC is closed In this condition the phases voltages are expected to be lower than 1 2 Vbatt If it is higher than that value fault status is entered Troubleshooting A If the problem occurs at start up the LC does not close at all check Motor internal connections ohmic continuity Motor power cables connections Ifthe motor connection are OK the problem is inside the controller B If the proble
56. good grounding can divert the discharge current trough a safe path the frame of a truck can works like a local earth ground absorbing excess charge So it AFCZP0BB COMBIACX amp ACEX User Manual is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator who is most of the time the source of ESD 4 5 Various suggestions Never combine SCR low frequency choppers with COMBIACX ACEX modules The filter capacitors contained in the COMBIACX ACEX module would change the SCR chopper operation and subject to excessive workload If it is necessary to use two or more control units like the chopper should be of the Zapimos family During battery recharge the COMBIACX ACEX must be completely disconnected from the battery Beside changing the charging current seen by the battery charger the module can be damaged by higher than normal voltages supplied via the charger AFCZPOBB COMBIACX amp ACEX User Manual Page 21 81 5 OPERATIONAL FEATURES Speed control Optimum behaviour on a slope if the speed feedback is used 1 The motor speed follows the accelerator starting a regenerative braking if the speed overtakes the speed set point 2 The system can perform an electrical stop on a ramp the machine is electrically hold on a slope for a programmable time if encoder is used Stable speed in every position of the accelerator Regenerative release braking based up
57. gt wo E s E Sie TE cer 6Sn N S a F 8 o l o E3 3 D A 8 2 E z m D m x Ki a Q Y Y AFCZPOBB COMBIACX amp ACEX User Manual Page 27 81 8 2 Mechanical drawing ACEX 28 Sl cl C 081 C ezo Geet A a E Z 0789 en D BE F d T N 3 3 q JL W J E A k l y ll een LI WW L o 1 Y a o anbio Buruy WN y L F Z Menge ajen OEXOW X p YIM Jauo MOLEX MiniFit Jr 14 Pos _ MOLEX MiniFit Jr 8 Pos MOLEX MiniFit Jr 10 Pos MOLEN MiniFit Jr 6 Pos se AFCZPOBB COMBIACX amp ACEX User Manual 28 81 Page 8 3 Connection drawing COMBIACX key 12V ACC POTI V B a A 1 S OMBIACX Co YOL ZNA FIC gt 3 LAVAS t bi i SS EN e O E do E Ll bel Ll SE it van T Lie 4 IT ITT O OT EI eem Dim HIN ede ara n e 6 5 e e gina Pag
58. hen the battery charge is calculated being less than or equal to 10 of the full charge and the BATTERY CHECK setting is other than 0 refer to SET OPTION menu Troubleshooting Get the battery charged If it doesn t work measure with a voltmeter the battery voltage and compare it with the value in the BATTERY VOLTAGE parameter If they are different adjust the value of the ADJUST BATTERY function 7 EEPROM KO Cause It s due to a HW or SW defect of the non volatile embedded memory supporting the controller parameters This alarm does not inhibit the machine operations but the truck will work with the default values Troubleshooting Try to execute a CLEAR EEPROM operation refer to Console manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously stored parameters will have been replaced by the default parameters 8 MOTOR TEMPERATURE Cause This warning occurs when the temperature sensor is opened if digital or has overtaken the threshold of 150 C if analog Troubleshooting Check the thermal sensor inside the motor use the MOTOR TEMPERATURE reading in the TESTER menu check the sensor ohmic value and the sensor wiring If the sensor is OK improve the air cooling of the motor If the warning is present when the motor is cool then the problem is inside the controller 9 THERMIC SENS KO Cause
59. here are too many pump requests Pump stopped Continuous Remove request MDI CAN 49 at the same time Pump inc start MDI Incorrect pump starting sequence Pump stopped SC stand Pump request CAN 79 Pump Vacc range The voltage on CNC 9 is out of the Pump stopped EVP Gates Pump request MDI CAN 90 parameters range stopped Param Restore A parameters set restore was No effect start up Traction pump or MDI CAN 13 made since the last keyoff EVP request Wait mot P still The software waits for the motor Valve pump traction start up None MDI CAN 63 pump to stop stopped LC opened Eb applied AFCZPOBB COMBIACX amp ACEN User Manual Page 73 81 12 4 Analysis and troubleshooting of warnings Page 74 81 1 2 3 4 5 SLIP PROFILE Cause There is an error on the choice of the parameters of the slip profile Troubleshooting Check in the hardware setting menu the value of those parameters FORW BACK Cause This alarm occurs when both the travel demands Fwd and Bwd are active at the same time Troubleshooting Check the wiring of the Fwd and Rev travel demand inputs use the readings in the TESTER to facilitate the troubleshooting Check the microswitches for failures A failure in the logic is possible too So when you have verified the travel demand switches are fine working and the wiring is right it is necessary to replace the controller INCORRECT START Cause
60. ide of next figure potentiometer on one end at rest in combination with a couple of Travel demand switches On request it is also possible the handling in the Right side of next figure potentiometer in the middle at rest still in combination with a couple of Page 8 81 AFCZPOBB COMBIACX ACEX User Manual Travel demand switches The Procedure for automatic potentiometer signal acquisition is carried out using the Hand Set This enables adjustment of the minimum and maximum useful signal level in either direction 3 3 Other analogue control unit If the Zapi can tiller is not used input CNC 9 can be used as analogue input whose typical application is a proportional command to enable a lifting lowering function It is possible to use this input for an alternative function like a proportional braking It should be in a 3 wire configuration Potentiometer value should be in the 0 5 10 kOhm range Generally the load should be in the 1 5mA to 30 mA range The CPOTL CNA 9 signal range is from 0 to 10V Use CNC 8 positive and CNA S3 negative to supply it 3 4 Analog motor thermal sensor input Input CND 3 is an analogue input to receive an analogue thermal sensor signal to measure the Traction Motor Winding Temperature The analogue device installed in the motor has to be specified in order to insert the correct look up table in the software A digital device can also be used AFCZPOBB COMBIACX amp ACEX User Manual
61. in the SET OPTIONS MENU The Display will show the first OPTION Press SET UP or SET DOWN button in order to modify the OPTION The Display will show the new option Press OUT to exit the menu The Display will ask ARE YOU SURE Press ENTER for YES or OUT for No The Display will show SET OPTIONS Press OUT again Display now will show the opening Zapi menu ADXT2B ZP1 00 24V 165A 00000 CONFIG MENU SET MODEL CONFIG MENU SET OPTIONS O Wei eg 0 0 HOURCOUNTER RUNNING HOURCOUNTER KEYON ood O Wei ARE YOU SURE YES ENTER NO 0UT CONFIG MENU SET OPTIONS AFCZPOBB COMBIACX ACEX User Manual 1 TILLER SWITCH This option handles the input CNC 6 This input opens when the operator leaves the truck tiller released It is connected to a key voltage when the operator is present There are two levels HANDLE CNC 6 is managed as tiller input no delay when released and INCORRECT START if the input is active at startup SEAT CNC 6 is managed as seat input with a delay when released gt de bouncing function and NO INCORRECT START if the input is active at startup DEADMAN CNC 6 is managed as deadman input with the same delay of a seat input but with INCORRECT START if the input is active at startup 2 EB ON TILLER BRK ON The EB is applied when the traction decelerates because CNC 6 was deactivated whilst moving OFF The EB is NOT applied when the traction de
62. iod when the calculated battery charge is between 10 and 30 and it stays on when the calculated battery charge is lt 10 Input of the switch DI5 The input is activated when it is connected to Batt The default function is the controller HORN input closing the switch the horn output is activated Input of the switch DI7 The input is activated when it is connected to Batt The default function is the controller LIFT enable input Input of the switch DI9 The input is activated when the external switch is opened The default function is the controller PUMP CUTBACK input opening the switch pump speed is reduced Input of the switch DI11 The input is activated when the external switch is opened to ground The default function is the controller CUTBACK input opening the switch truck speed is reduced In the Sense Coil version this input is connected to the AC motor sense coil Output of the protected ON OFF electrovalve driver 1 5 A maximum continuous current driving to Batt Built in freewheeling diode to B2 This output is activated when the 2ND function input A13 is request Auxiliary output Internal 330R resistance in series to the driver driving to Batt Max continuous current 35mA Typical function to drive a led This output blinks with a 1 sec period when a warning is displayed by the controller It also blinks with a 0 5 sec period when an alarm is displayed when no alarm ar
63. l overview Before starting it is necessary to have the required material for a correct installation Otherwise a wrong choice of cables or other parts could lead to failures misbehaviour bad performances 4 1 1 Connection cables For the auxiliary circuits use cables 0 5mm section at least For power connections to the motor and to the battery use cables having a minimum section of 15 mm For the optimum inverter performance the cables to the battery should be run side by side and be as short as possible 4 1 2 Contactors IT IS STRONGLY RECCOMENDED TO USE A MAIN CONTACTOR to connect and cut off the battery to the controller Depending on the setting of a parameter in the controller the output which drives the main contactor coil is on off the coil is driven with the full battery voltage the output which drives the main contactor coil is switched at high frequency 1 kHz with a programmable duty cycle this feature is useful to decrease the power dissipation of the contactor coil The EN1175 states the main Contactor is not mandatory under proper conditions anyway it is recommended to protect the inverter against reverse battery polarity and to cut off the battery from the power mosfets when a failure in the three phase bridge occurs AFCZPOBB COMBIACX amp ACEX User Manual Page 11 81 4 1 3 Fuses Use a 6 3 10A Fuse for protection of the auxiliary circuits For protection of the power unit refer
64. le to drive the load cannot close Page 76 81 AFCZPOBB COMBIACX amp ACEX User Manual Troubleshooting The device or its driving circuit is damaged replace the controller 20 PUMP NO ZERO Cause In standby condition pump motor not driven the feedback coming from the current sensor in the pump chopper gives a value out of a permitted range because the pump current is not Zero Troubleshooting This type of fault is not related to external components replace the controller 21 PUMP I 0 EVER Cause This test is carried out when the pump motor is running and it verifies that the current feedback sensor is not constantly stuck to 0 Troubleshooting A Check the motor connection that there is continuity If the motor connection is opened the current cannot flow so the test fails and the error code is displayed B If everything is ok for what it concerns the motor the problem could be in the current sensor or in the related circuit 22 CONT DRV EV Cause The EV1 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 23 CONT DRV EV2 Cause The EV2 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 24 CONT DRV EV3 Cause The EV3 valve driver is not able to drive the load
65. m occurs after closing the LC the LC closed and then opens back again check Motor connections If motor phases windings cables have leakages towards truck frame If no problem are found on the motors the problem is inside the controller 4 POWER MOS SHORT Cause Before switching the LC on the software checks the power bridge it turns on alternating the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT increase up to Batt If the phases voltage do not follow the comands this alarm occurs Troubleshooting This type of fault is not related to external components replace the controller 5 COIL SHOR MC EB Cause This alarm occurs when there is a short circuit of one of the coils connected to outputs of the COMBIACX ACEX LC coil or EB coil After the overload condition has been removed the alarm exits automatically by releasing and then enabling a travel demand Troubleshooting A The typical root cause for this error code to be displayed is in the harness or in the load coil So the very first check to carry out concerns connections between controller outputs and loads B In case no failures problems have been found externally the problem is in the controller which has to be replaced 6 DRIVER SHORTED Cause The driver of the main contactor coil is shorted or the coil is disconnected Troubleshooting A Check if there is a short or a low i
66. maximum speed down to 24 of the full speed 6 STOP ON RAMP Only when the encoder is present it is possible to electrically hold the truck on a slope when the accelerator is released but the tiller is not released ON The stop on ramp feature truck electrically hold on a ramp is managed AFCZPOBB COMBIACX amp ACEX User Manual Page 37 81 Page 38 81 7 8 9 for a time established by AUXILIARY TIME parameter OFF The stop on ramp feature is not performed That means the truck comes down slowly during the AUXILIARY TIME After this auxiliary time the electromechanical brake is applied and the 3 phase bridge is released if the electromechanical brake is not present the truck comes down very slowly see the AUX OUTPUT 1 option programming and see also 13 4 QUICK INVERSION It can be set NONE The quick inversion function is not managed no effect when CNC 2 switches over TIMED The quick inversion function is timed BELLY The quick inversion function is managed but not timed SET MOTOR TEMPERATURE It can be set _OPTION 1 An analog sensor for the control of the motor temperature is connected to CND 3 The temperature sensor is a KTY 84 130 PTC positive thermal coefficient resistance OPTION 2 An analog sensor for the control of the motor temperature is connected to CND 3 The temperature sensor is a KTY 83 PTC 1 DIGITAL A digital on off sensor for the motor tempera
67. mmunication supply To connect this pin to GND E8 for software download via serial communication Serial communication negative reference This connector cannot be reached without removing the cover It is used by Zapi for software download with Zapi Flasher for communicating with a Zapi Handset or a lap top for controller setup and for diagnosis AFCZPOBB COMBIACX amp ACEX User Manual Page 25 81 7 DESCRIPTION OF POWER CONNECTIONS View of the power bars B Negative of the battery B Positive of the battery P Output of the Pump Motor COMBIACX only U V W Connection bars of the three motor phases follow this sequence and the indication on the motor Page 26 81 AFCZPOBB COMBIACX amp ACEX User Manual 8 DRAWINGS 8 1 Mechanical drawing COMBIACX W SIP E i cy fil I SS W II 1 8 E f T Af a l L 8 LAA INN A ry LITT m I BERE I Lt yy i d Lid E ae HE ER Ul g s LI S db 4 JA A d Y Y Y S Y L 138 60 5 126 0 2 o Qq o v S 2 o 2 FR S 5
68. mpedance pull down between NLC CNB 6 and DATT B The driver circuit is damaged in the controller which has to be replaced C The wires to the LC coil are interrupted or not connected so check the coil related harness AFCZPOBB COMBIACX amp ACEX User Manual Page 65 81 7 CONTACTOR DRIVER Cause The LC coil driver is not able to drive the load The device itself or its driving circuit is damaged Troubleshooting This type of fault is not related to external components replace the controller 8 CONTACTOR OPEN Cause The main contactor coil has been driven by the controller but the contactor does not close Troubleshooting It could be also a problem of the contact in the LC that is not working does not pull in try replacing the LC 9 CONTACTOR CLOSED Cause Before driving the LC coil the controller checks if the contactor is stuck The controller drives the bridge for some tens milliseconds trying to discharge the capacitors bank If they don t discharge the fault condition is entered Troubleshooting It is suggested to verify the power contacts of LC to replace the LC is necessary 10 AUX DRIV SHRT Cause The driver of the electromechanical brake coil is shorted Troubleshooting A Check if there is a short or a low impedance pull down between NEB CNA 4 and DATT B The driver circuit is damaged in the controller which has to be replaced 11 AUX DRIV OPEN Cause
69. n on the hand set and MDI DISPLAY after 300 hours OPTION 2 Equal to OPTION 1 but Speed reduction after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 12 MIN LIFT This parameter stores the minimum voltage of lifting potentiometer output connected to CNC 9 The min value acquisition is done closing the Lift SW and bringing the potentiometer in its min output position 13 MAX LIFT This parameter stores the maximum voltage of lifting potentiometer output connected to CNC 9 The max value acquisition is done closing the Lift SW and bringing the potentiometer in its max output position 14 MIN LOWER This parameter stores the minimum voltage of lowering potentiometer output connected to CNC 9 The min value acquisition is done closing the LOWER SW DI6 and bringing the potentiometer in its min output position 15 MAX LOWER This parameter stores the maximum voltage of lifting potentiometer output connected to CNC 9 The min value acquisition is done closing the LOWER SW DI6 and bringing the potentiometer in its min output position 16 MC VOLTAGE This parameter stores the PWM value applied to MC coil during the first second of the output activation It is expressed in percentage of battery voltage 17 MC VOLTAGE RED This parameter stores the PWM value applied to MC coil after the first second of the output activation It is expressed in percentage of the voltage applied during th
70. nnect the positive supply of all electrovalves EV1 EV2 EV3 LOWER EVP HORN OUT to this pin Take the positive supply immediately after main contactor Output of the lower proportional electrovalve driver driving to Batt Built in freewheeling diode to B2 Input of the switch DI3 The input is activated when it is connected to Batt The default function is the controller FORWARD request input closing this input truck moves in forward direction Electro mechanic brake coil driver output PWM controlled 2 54 maximum continuous current driving to Batt Built in freewheeling diode to B1 Min Contactor coil driver output PWM controlled 1A maximum continuous current driving to Ban Built in freewheeling diode Negative of the protected horn electrovalve driver driving to Ban Built in freewheeling diode to B2 Input of the switch DI4 The input is activated when it is connected to Batt The default function is the controller REV request input closing this input truck moves in backward direction Input of the key switch signal Input of the switch DI1 The input is activated when it is connected to Batt The default function is the controller BELLY input closing the switch quick inversion function is activated Potentiometers negative reference GND AFCZPOBB COMBIACX ACEX User Manual C4 C5 C6 C7 C8 Cg C10 CPOTTR CANH DIO DI2 PPOT CPOTL CANL 6 1 4 CND e
71. nt will then take the decision regarding operational safety of the machine Remember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER DA IMPORTANT NOTE ABOUT WASTE MANAGEMENT This controller has both mechanical parts and high density electronic parts printed circuit boards and integrated circuits If not properly handled during waste processing this material may become a relevant source of pollution The disposal and recycling of this controller has to follow the local laws for these types of waste materials Zapi commits itself to update its technology in order to reduce the presence of polluting substances in its product AFCZPOBB COMBIACX amp ACEX User Manual Page 81 81
72. of microcontroller alarms To Enter the MAIN MENU push the Enter button at the Home Page of the hand set display and Roll for the ALARMS item Here is the ALARMS list 1 CAPACITOR CHARGE Follows the charging capacitor system 2 When the key is switched ON the inverter tries to charge the power capacitors through a power resistance and check if the capacitor are charged within a timeout If they do not charge an alarm is signalled the main contactor is not closed Troubleshooting A There is an external load in parallel to capacitor bank which sinks current from the controller capacitors precharging circuit thus preventing the caps from charging Check if a lamp or a dc dc converter or a auxiliary load is placed in to capacitor bank B The charging resistance is opened insert a power resistance across line contactor power terminals if the alarm disappears it means the controller internal charging resistance is damaged C The charging circuit has a failure inside the controller D There is a problem in the controller power section VMN LOW Cause 1 start up test Before switching the LC on the software checks the power bridge it turns on alternating the High side Power Mosfets and expects the phases voltage to increase toward the rail capacitor value If the phases voltage does not increase this alarm occurs Cause 2 Motor running test When the motor is running power bridge is ON the motor volta
73. ol based upon microcontroller Viel Te MEET 24 36 48V Inverter maximum current GAN 165A RMS for 2 Continuous output current GAN 70A RMS continuous Inverter maximum current 36 48V ciiiciii iiic 140 RMS for 2 Continuous output current 36 48 VW aseeseen 60A RMS continuous Inverter operating freqUenCY iiiiiiicccciccciciiccacsscsisienanasasasees 8kHz Dc chopper Maximum current 24V 1 cooooooccoccccccnnncccconananancnnnncnnnnannno 280A for 2 Dc chopper Maximum current GOIN 240A for 2 Chopper Operating mequeney l EE 16kHz External temperature working rangGe cccceeeeeeeeeeeeceeeeeeeeeeeeees 40 C 40 C Maximum heatsink temperature start of the thermal cutback 85 C Note 1 The DC chopper specifications are related to COMBIACX only 2 2 Technical specifications COMBIACX Power ACEX Power Page 6 81 Inverter for traction AC asynchronous 3 phase motors plus chopper for DC series pump motors Regenerative braking functions Digital control based upon microcontroller Voltage EE 24 36 48V Inverter maximum Current GAN 240A RMS for 2 Continuous output current GAN 90A RMS continuous Inverter maximum current OGVIAON iiic ciii cir r 210A RMS for 2 Continuous output current 36V 48V a e 80A RMS continuous Inverter operating freqU eNCY iciiiiiii ciii c cnn rre 8kHz Dc chopper Ma
74. on deceleration ramps Regenerative braking when the accelerator pedal is partially released deceleration Direction inversion with regenerative braking based upon deceleration ramp Regenerative braking and direction inversion without contactors only the main contactor is present The release braking ramp can be modulated by an analogue input so that a proportional brake feature is obtained Optimum sensitivity at low speeds Voltage boost at the start and with overload to obtain more torque with current control The inverter can drive an electromechanical brake High efficiency of motor and battery due to high frequency commutations Modification of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and temperature displayed on the console Test function within console for checking main parameters Direct communication between traction AC inverter and pump DC chopper 5 1 Diagnosis Page 22 81 The microcontrollers continually monitor the inverter and the chopper and carry out diagnostic procedures on the main functions The diagnosis is made in 4 points 1 2 3 4 Diagnosis at start up that checks watch dog Current Sensors Capacitor charging phase s voltages pump motor output contactor drivers can bus interface presence of a start requirement connection with the Can Tiller Standby Diagnosis tha
75. on of 0 1 Page 48 81 AFCZPOBB COMBIACX amp ACEX User Manual 10 4 4 Zapi menu SPECIAL ADJUSTMENTS functions list EY Note the below set up description is for skilled persons only if you aren t please keep your hands off To enter this Zapi hidden menu a special procedure is required Ask for this procedure directly to a Zapi technician In the SPECIAL ADJUSTMENTS functions list there are factory adjusted parameters only 1 2 3 4 5 6 7 ADJUSTMENT 01 Factory adjusted value This is the Gain of the first Current Sensing Amplifier of traction motor NOTE only Zapi technicians should change this value ADJUSTMENT 02 Factory adjusted value This is the Gain of the second Current Sensing Amplifier of traction motor NOTE only Zapi technicians should change this value SET CURRENT Factory adjusted This is the traction motor maximum current SET TEMPERATURE Set the temperature offset to have the correct value reading This is a fine calibration of the controller temperature sensor ADJUSTMENT 03 Factory adjusted value This is the gain of the Current Sensing Amplifier of pump motor SET CURRENT PUMP Factory adjusted This is the pump motor maximum current HIGH ADDRESS To be used to have access to special memory address NOTE only Zapi technicians should change this value 8 9 DITHER AMPLITUDE It is the dither signal amplitude The dither
76. onnected Deeg 4 2 7 Insulation of truck frame A As stated by EN 1175 Safety of machinery Industrial truck chapter 5 7 there shall be no electrical connection to the truck frame So the truck frame has to be isolated from any electrical potential of the truck power line AFCZPOBB COMBIACX amp ACEX User Manual Page 17 81 4 3 Protection and safety features 4 3 1 Protection features Page 18 81 The COMBIACX ACEX is protected against some controller injuries and malfunctions Battery polarity inversion It is necessary to fit a LINE CONTACTOR to protect the controller against reverse battery polarity and for safety reasons Connection Errors All inputs are protected against connection errors Thermal protection If the controller temperature exceeds 85 C the maximum current is reduced in proportion to the thermal increase The temperature can never exceeds 105 C External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65 Nevertheless it is suggested to carefully study controller installation and position With few simple shrewdness the degree of controller protection can be strongly increased Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic or Canbus interface is not functioning perfectly The Can Tiller is not operating correctly
77. or pump or stopped Lc opened Eb traction request applied Coil short MC Shortcircuit on LC or EB coil Valve pump traction stby traction Valve or pump or EB MDI CAN stopped Lc opened Eb traction request 76 applied Driver shorted Driver of LC coil is shorted so itis not able to open Valve pump traction start up Valve or pump or MDI CAN 74 the LC or LC coil is disconnected stopped Lc opened Eb traction request applied Contactor Driver of LC coil is damaged not able to close Valve pump traction stby traction Valve or pump or Driver MDI stopped Lc opened Eb traction request applied The LC coil has been driven but LC does not close Valve pump traction stby traction Valve or pump or stopped Lc opened Eb traction request applied LC contact is stuck Valve pump traction start up Valve or pump or stopped Lc opened Eb traction request applied Aux driv Shrt When the mos of EB is shorted Valve pump traction start up stby marcia Valve or pump or MDI CAN 40 stopped Lc opened Eb traction request applied Driver of EB coil is damaged not able to close Valve pump traction stby traction Valve or pump or stopped Lc opened Eb traction request applied Output of built in Smart Driver which supplies Eb coil Valve pump traction start up Valve or pump or positive is high batt when the tiller switch is stopped Lc opened Eb traction request applied Logic Failure Overvoltage Undervoltage condition ha
78. ould be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle CONTROLLER WITH FINNED HEATSINK Sometimes the base plate installation cannot be adopted Due to positioning problems or to the lack of a thick enough truck frame it is necessary to adopt a finned dissipation combined with one or more fans The air flux should hit the fins directly to maximize the cooling effect In addition to fans also air ducting systems can be used to maintain low the temperature of the controller Itis necessary to ensure that cold air is taken from outside the controller compartment and hot air is easily pushed away from the controller compartment Itis mandatory to avoid that the cooling air is recirculated inside the controller compartment 4 2 2 Wirings power cables Page 12 81 The power cables length must be as short as possible to minimize power losses AFCZPOBB COMBIACX amp ACEX User Manual They must be tightened on controller power posts with a Torque of 7 1 4 Nm The COMBIACX module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact th
79. paragraphs describe the controller configuration in the case the operator is using the Zapi console 10 2 Description of console hand set 8 connection 1 PARAM IMax T S BRAKING RK PENS 2 TESTER 3 SAVE 4 RESTORE V PO L TEMP V BATT v MoT VMN MOT M SW TEST 5 ALARMS 6 ACCELERATOR 7 MOTOR DATA tt amp Gt SUTTONS ROLL ENTER SET ROL on ee 2 L elt y Baur Page 34 81 AFCZPOBB COMBIACX amp ACEX User Manual 10 3 Description of the console menu 10 3 1 COMBIACX ACEX Menu HEADIN MAIN MENU PARAMETER CHANGE ACCELERATION DELAY RELEASE BRAKING TILLER BRAKING INVERS BRAKING DECEL BRAKING PEDAL BRAKING SPEED LIMIT BRK EPS STEER BRAK MAX SPEED FORW MAX SPEED BACK CUTBACK SPEED 1 CUTBACK SPEED 2 H amp S CUTBACK EPS STEER CUTBACK FREQUENCY CREEP MAXIMUM CURRENT ACC SMOOTH INV SMOOTH STOP SMOOTH BRK SMOOTH STOP BRK SMOOTH AUXILIARY TIME HYDRO TIME PUMP IMAX PU ACCELER DEL PU DECELER DEL MAX SPEED LIFT LIFT CUTBACK 1ST PUMP SPEED 2ND PUMP SPEED DESCENT SPEED SPEED CREEP COMPEI HYDRO S FINE HYDRO COMPENS MN EVP MAX EVP EVP OPEN DELAY EVP CLOSE DELAY ooo D 0000 ec E CONFIG MENU VV SET MODEL AY SET OPTIONS N S 5 S S S S S E H X
80. remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function AFCZPOBB COMBIACX ACEX User Manual Flow Chart showing how to use the PROGRAM VACC function of the Digital Console Opening Zapi Display Press ENTER to go into the General menu The Display will show Press ROLL UP or ROLL DOWN button until PROGRAM VACC the display The Display will show Press ENTER to go into the PROGRAM VACC function The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown Press ENTER to clear these values Display will show 0 0 Select Forward Direction close any interlock switches that may be in the system Slowly depress the accelerator pedal or tiller butterfly to its maximum value The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction Select the Reverse Direction and repeat Item 10 When finished press OUT The Display will ask ARE YOU SURE Press ENTER for yes or OUT for NO When finished the Console shows Press OUT to return to the Opening Zapi Display AFCZPOBB COMBIACX amp ACEN User Manual ADXZ2A ZP1 00 24V 165A 00000 E o MAIN Bo Od MENU P
81. s EV coil is shorted Troubleshooting Check if there is a short or low impedance between the negative of the EV coil and BATT Otherwise the controller is damaged and it must be replaced 16 DRV SHOR EV Cause Electrovalve EV1 driver is shorted Troubleshooting Check if there is a short or a low impedence between the negative of one of those coils and DATT Otherwise the driver circuit is damaged and the controller must be replaced 17 DRV SHOR EV2 Cause Electrovalve EV2 driver is shorted Troubleshooting Check if there is a short or a low impedance between the negative of this coil and BATT This warning occurs also if the external load is not present and the parameter EV2 in the Set Options menu is set PRESENT in this case the warning disappears setting the EV2 parameter ABSENT Otherwise the driver circuit is damaged and the controller must be replaced 18 DRV SHOR EV3 Cause Electrovalve EV3 driver is shorted Troubleshooting Check if there is a short or a low impedance between the negative of this coil and BATT This warning occurs also if the external load is not present and the parameter EV3 in the Set Options menu is set PRESENT in this case the warning disappears setting the EV3 parameter ABSENT Otherwise the driver circuit is damaged and the controller must be replaced 19 CONT DRV EV Cause One or more on off valve drivers is not ab
82. s been Valve pump traction start up Valve or pump or 1 MDI CAN detected stopped Lc opened Eb traction request 54 applied Logic Failure Motor voltage feedback circuits are damaged Valve pump traction stby immediately Valve or pump or 2 MDI CAN stopped Lc opened Eb after Lc closing traction request 55 applied Logic failure Failure in the high current HW protection circuit valve pump traction start up stby Valve or pump or 3 MDI CAN stopped Lc opened Eb traction request 17 applied Stby i high In stby condition no current applied to the traction Valve pump traction start up stby Valve or pump or MDI CAN 53 motor the current feedbacks are aout of permitted stopped Lc opened Eb traction request stby range applied Wrong Battery The battery voltage is too low or too high lt 0 8 Vbatt Valve pump traction start up stand by Valve or pump or stopped Lc opened Eb only immediately traction request applied after Lc closing Analog input Problem on the A D conversion of uC Valve pump traction traction Valve or pump or MDI CAN 96 stopped Lc opened Eb traction request applied Encoder Error Problem on the encoder Valve pump traction traction Valve or pump or MDI CAN 82 stopped Lc opened Eb traction request applied Tiller error Input mismatch between hard amp soft switch input and Traction stopped Eb applied start up stby Valve or pump or MDI CAN G4 tiller input traction traction request
83. s within a window around the nominal value Troubleshooting A Check that the controller SET BATTERY parameter value matches the battery nominal voltage B Check that the TESTER MENU BATTERY VOLTAGE parameter shows same value as the battery voltage measured with a voltmeter If it is does not match then do a ADJUST BATTERY function C Replace the battery 18 ANALOG INPUT AFCZPOBB COMBIACX amp ACEN User Manual Page 67 81 Cause This alarm occurs when the A D conversion of the analog inputs gives frozen value on all of the converted signals for more than 400msec The goal of this diagnosis is to detect a failure of the A D converter or a problem in the code flow that omits the refreshing of the analog signal conversion Troubleshooting If the problem occurs permanently it is necessary to substitute the controller 19 ENCODER ERROR Cause This fault is signalled in following conditions the frequency supplied to the motor is higher than 40 Hz and the signal feedback from the encoder has a jump higher than 40 Hz in few tens mSec This condition is related to a malfunctioning of the encoder Troubleshooting A Check both the electric and the mechanical encoder functionality the wires crimping B Check the encoder mechanical installation if the encoder slips inside its compartment raising this alarm condition C Also the electromagnetic noise on the sensor bearing can be a cause for th
84. se check The motor connected to P must be completely still before this alarm occours The software waits 30 seconds before showing this alarm During this time it shows the WAIT MOTOR STILL warning see in the warnings chapter Motor internal connections Motor power cables connections Motor leakage to truck frame If the motor connections are ok the problem is inside the controller AFCZPOBB COMBIACX amp ACEN User Manual Page 71 81 12 3 Warnings overview Page 72 81 Machine status Restart Error code Description when the test is procedure Slip profile Error on the parameters of the slip Traction is stopped start up stand by Traction MDI CAN 99 profile setting request Forwtbackwa The travel demands are active in both Traction is stopped start up stand by Traction es MDI CAN directions at the same time Vacc not ok The acceleretor value is higher than MDI CAN 78 the minimum value recorded and the direction enable switches are opened Th Protection The controller has reached the Traction controller continuous MDI CAN 62 _ thermal cutback temperature 85 C reduces the maximum current linearly from Imax 85 C down to OA 105 C Battery low Battery is lt 10 when the The maximum current continuous parameter BATTERY CHECK is set is reduced to half and speed is reduced if CHECK OPTION 1 MBAN espn management pontut parameters MDI CAN 71 eeprom management D
85. standard serial console When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display Home Display For the setting of your truck use the procedure below If you need to reply the same setting on different controller use the Save and Restore sequence as described in the 13 1 and 13 2 paragraphs Remember to re cycle the Key Switch if you make any changes to the chopper s configuration Step1 Fill your setting with the Options you need Step2 Select the Battery Voltage Step3 Check the correct installation of all wires Use the Console s TESTER function to assist Step4 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on paragraph 13 3 Step5 Set the MAXIMUM CURRENT Current parameter Step6 Set the ACCELERATION DELAY requirements for the machine Test the parameters in both directions Step7 Set the FREQUENCY CREEP level starting from 0 6 Hz The machine should just move when the accelerator micro switch is closed Increase the Level accordingly Steps Set the Speed Reductions as required Use the parameters of the cutback speed family in the PARAMETER CHANGE menu to specify the reduced maximum truck speed as a percentage of the MAX SPEED FWD and MAX SPEED REV Step9 RELEASE BRAKING Operate the machine at full speed Release the accelerator Adjust the level to your requiremen
86. switch opens The DI11 and DI12 which are not available in the Sense Coil version are activated closing the external microswitch to Batt 3 1 1 DIO DI10 technical details 24 V system Switching threshold 4V 0 5V Input impedance 4 5kOhm 0 5kOhm 3 1 2 DIO DI10 technical details 36 48 V system Switching threshold 4 2V 0 5V Input impedance 13 5kOhm 1kOhm 3 1 3 Microswitches It is suggested that microswitches have a contact resistance lower than 0 10hm and a leakage current lower than 100A When full load connected the voltage between the key switch contacts must be lower than 0 1V Ifthe microswitch to be used has different characteristic it is suggested to discuss them and their application with Zapi technicians 3 2 Analog unit The analog input can be connected to an accelerator unit if the Zapi CAN or serial tiller is not used The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration The potentiometer is supplied through CNC 8 Potentiometer output signal must be input to CPOT1 CNC 4 signal range is from 0 to 10V The negative supply of the potentiometer has to be taken from NPOT CNC 3 Potentiometer value should be in the 0 5 10 KOhm range generally the load should be in the 1 5mA to 30mA range Faults can occur if it is outside this range The standard connection for the potentiometer is the one in the Left s
87. t If the machine is a forklift check the performance with and without load Step10 INVERSION BRAKING Operate the machine at 25 full speed While travelling invert the Direction Switch Set the suited Level of Inversion Braking When satisfactory operate the machine at Full Speed and repeat If the machine is a Forklift repeat the tests and make adjustments with and without load The unloaded full speed condition should be the most representative condition Step11 Set the parameter MAX SPEED FORW AFCZPOBB COMBIACX amp ACEX User Manual Step12 Set the parameter MAX SPEED BACK Reverse Step13 Test the truck on the maximum ramp specification at full load Step14 Make the choice for the truck behaviour on a slope If the Stop on ramp option is ON set the desired value of auxiliary time parameter AFCZPOBB COMBIACX amp ACEX User Manual Page 33 81 10 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 10 1 Adjustments via console E To access and adjust all parameters it is necessary to use the Zapi console Since the COMBIACX ACEX has no external serial connector the Zapi console has to be connected through a remote module like a Zapi tiller card of a Zapi display This module has to be connected to the same Canbus line of the inverter E Otherwise it is possible to connect a pc to the Canbus line and use the PC CAN Console software This tool is more powerful than the standard serial console The following
88. t checks watch dog phase s voltages pump motor output Contactor Drivers Current Sensors can bus interface Driving diagnosis that checks Watchdog Current sensors Contactor s can bus interface Continuos Diagnosis that checks power stage temperature motor temperature Battery Voltage Error codes are provided in two ways The digital console can be used which gives a detailed information about the failure the failure code is also sent on the Can Bus AFCZPOBB COMBIACX amp ACEX User Manual 6 DESCRIPTION OF THE CONNECTORS 6 1 Connectors of the logic The COMBIACX ACEX inverter use four Molex Minifit connectors 6 1 1 CNA external connector A1 A2 A3 A4 A5 A6 AT A8 A9 EV1 EV3 NAUX2 DI5 DI7 DI9 DI11 EV2 NAUX1 Output of the protected ON OFF electrovalve driver 1 5 A maximum continuous current driving to Batt Built in freewheeling diode to B2 This output is activated when the 1ST function input A12 is request Output of the protected ON OFF electrovalve driver 1 5 A maximum continuous current driving to Batt Built in freewheeling diode to B2 This output is activated when the LIFT function input A5 is request Auxiliary output Internal 330R resistance in series to the driver driving to Batt Max continuous current 35mA Typical function to drive a led If the BATTERY CHECK option is different than zero this output blinks with a 1 sec per
89. tactor and key connection iiiiiii iiic iiis 17 4 2 7 Insulation of truck frame 17 4 3 Protection and safety features 222 cccccceeeesssececeeeeeeeeeeessseeeeeseeeeeseseeseeeeneneeeennees 18 4 3 1 Protection features ooooccccciccnnccnnccnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnninss 18 4 3 2 Safety Features se tecetaeeibateecotateamciasuadakuatebecs 19 4A EMO eai EE 19 e GE Ee E 21 5 OPERATIONAL E as ca Cendet 22 5 1 DIAGNOSIS EE 22 6 DESCRIPTION OF THE CONNECTORS eener see EES 23 6 1 Connectors OF the EEN 23 6 1 1 CNA external connector icccciiiiiiiiii ciii iii iiiiiinnni 23 6 1 2 CNB external connector EE 24 6 1 3 CNC external Tee 24 6 1 4 OND external e le 25 6 1 5 CNE ie EE 25 7 DESCRIPTION OF POWER CONNECTIONS wisi c lt coicscisoncicincccocionisiasa nncininecnnncisicinancciicicns 26 re 27 8 1 Mechanical drawing COMDBIAC 3 27 8 2 Mechanical drawing ACER EN 28 AFCZPOBB COMBIACX amp ACEX User Manual Page 3 81 8 3 Connection drawing COMBIACA cccitcmciinaci n i nica lc iii riacd s 29 8 4 Connection drawing ACEX EE 30 9 ONE SHOT INSTALLATION PROCEDURE c isiccci n soonnancionncinanacisancaio sanan narasacr n 31 9 1 Sequence for Ac Inverter traction Setting ooooccnnnnncnonncccnnnnnnccnnnnnacnncncncnnnnnnnnnnns 32 10 PROGRAMMING 8 ADJUSTMENTS USING DIGITAL CONSOLE
90. tery charge value is updated otherwise the Battery charge is not updated AFCZP0BB COMBIACX amp ACEX User Manual 12 COMBIACX ACEX ALARMS LIST The ALARMS logbook in the MAIN MENU records the alarms of the controller It has a FIFO First Input First Output structure that means the oldest alarm is lost when the database is full and a new alarm occurs The logbook is composed of five locations getting possible to stack five different type of alarms with the following information 1 The alarm code 2 The times that each alarm occurs consecutively 3 The Hour Meter value when the first event of every alarm occurred 4 And the inverter temperature when the first event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revised E NOTE if the same alarm is continuously happening the controller does not use new memory of the logbook but only updates the last memory cell increasing the related counter point 2 of previous list Nevertheless the hourmeter indicated in this memory refers to the first time the alarm occurred In this way comparing this hourmeter with the controller hourmeter it is possible to determine When this alarm occurred the first time How many hours are elapsed from the first occurrence to now How many times it has occurred in said period 12 1 Faults diagnostic system The fault diagnostic system of COMBIACX ACEX controller is divided into 2
91. the EV3 output is NOT driven 14 HORN PRESENT ABSENT If set PRESENT the HORN output is driven When set ABSENT the HORN output is NOT driven 15 HYDRO FUNCTION KEY ON RUNNING NONE Defines the activation of hydraulic steering fuction KEY ON the function is activated at key on RNNING the function is activated during a traction or braking request NONE the function is never activated 16 M C FUNCTION PRESENT ABSENT When is set PRESENT the Main Contactor is closed after the controller key on if the initial diagnosis pass If is set ABSENT the diagnosis are masked and M C is not closed after controller Key on 17 AUX OUT FUNCTION PRESENT ABSENT When is set PRESENT the Electro mechanic Brake is driven after a traction request if all the related diagnosis pass If is set ABSENT the diagnosis are masked and E B is not closed after a traction request 18 PROPORTION PUMP ON OFF When is set ON the lift functions are proportional The pump motor speed increase if the analog value of CPOTL increase If is set ABSENT the analog value CPOTL is not read and the speed of pump motor is set maximum when the digital input is closed LIFT 10 4 2 Config menu ADJUSTMENTS functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons Then roll until the ADJUSTMENTS item appears on the hand set display Push the ENTER button ADXT2B ZP1 00 1 Opening Zapi
92. to 100 the speed reduction is ineffective 14 H amp S CUTBACK Typically from 10 to 100 If H amp S SWITCH option is PRESENT and POSITIVE EB option is not LEVEL 1 it determines the percentage of the max AFCZPOBB COMBIACX amp ACEX User Manual speed applied when the Hard amp Soft function CNC 7 connector is active When set to 100 the speed reduction is ineffective 15 EPS STEER CUTBCK Tipically from 1 to 100 It determines the percentage of the maximum speed when the wheel is completely turned tipiccally 90 degrees If the wheel angle is a percentage of the maximum angle the steer cutback is applied proportionally Note the wheel angle is coming from EPS If EPS option is set to NONE this parameter is useless 16 FREQUENCY CREEP Hz value This is the minimum speed applied when the forward or reverse switch is closed but the accelerator is at its minimum 17 MAXIMUM CURRENT Maximum level of the current percentage of the maximum current of the controller 18 ACCELERATION SMOOTH It gives a parabolic form to the acceleration ramp 19 INVERSION SMOOTH It gives a parabolic form to the acceleration ramp after a direction inversion 20 STOP SMOOTH Hz It sets the level of frequency where the smooth effect of the acceleration parabolic form ends 21 BRK SMOOTH It gives a parabolic form to the deceleration ramp 22 STOP BRK SMOOTH Hz It sets the level of frequency where the smooth effect of the dec
93. to chapter 13 Recommended spare parts for inverter The Fuse value shown is the maximum allowable For special applications or requirements these values can be reduced For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow 4 2 Installation of the hardware A Before doing any operation ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety After operation even with the Key Switch open the internal capacitors may remain charged for some time For safe operation we recommend that the battery is disconnected and a short circuit is made between Battery Positive and Battery Negative power terminals of the chopper using a Resistor between 10 Ohm and 100 Ohm Minimum 5 Watts 4 2 1 Positioning and cooling of the controller CONTROLLER WITH BASE PLATE Install the controller with the base plate on a flat metallic surface that is clean and unpainted suggested characteristics are PER 0 05 mm and rugosity 1 6 um Apply a light layer of thermo conductive grease between the two surfaces to permit better heat dissipation The heat generated by the power block must be dissipated For this to be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system sh
94. ts WT re ewen dn cia a ae a da 5 2 SPEGIFIGA TON scrii enter ae oaae eaa ees 6 2 1 Technical specifications COMBIACX ACEX oooooccccccccccconncnnnnononnnnnnnnnnnonnnnnnnnnccinnnnnnnss 6 2 2 Technical specifications COMBIACX Power ACEX Power 6 2 3 Block ANN EE 7 2 3 1 Traction Control 7 2 3 2 Pump control ciccccccciciiiciiiiiiiiiiiiiii 2222222222220222 0 002 n nnn annen neen 7 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 8 3 1 Kiel e EE 8 3 1 1 DIO DI10 technical details 24 V system cece eeeeeeettteeeeeeeeeeeeeee 8 3 1 2 DIO DI10 technical details 36 48 V system ie 8 3 1 3 AO 8 32 AMOO Ee EE 8 3 3 Other analogue ege RE 9 3 4 Analog motor thermal sensor Imput ciii c iiiiiciii ii iiiiiccces iie irriine 9 3 5 Speed feedback occcccccccccccccncncnnconnnonnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 10 4 INSTALLATION HINTS 20222662 a ae ree 11 4 1 Material OVerVieW A 11 4 1 1 e AMA 11 4 1 2 AN 11 AS EE 12 4 2 Installation of the hardware ccccccccciiiiiiiiiiiiiiiiiiiiiiiiiiiii ennenen 12 4 2 1 Positioning and cooling of the controller cici irn 12 4 2 2 A 12 4 2 3 Wirings CAN connections and possible interferences 13 4 2 4 da cc iiiiiiia esses 15 42 5 Connection of the encoder iciciiiiiiiiii nacer 16 4 2 6 Main con
95. ture monitoring is connected to CND 3 input 2 NONE No temperature sensor is connected EPS It can be set NONE NO EPS is present on the truck CombiACX does not wait for CAN messages by the EPS and it does not apply EPS and braking steer cutback OPTION 1 EPS is present and it is an EPS ACO ENCODER TOGGLE SWITCHES type OPTION 2 EPS is present and it is an EPS ACO POT ENCODER type 10 INVERSION MODE ON OFF This parameter sets the logic of the Quick Inversion input If set ON the Quick Inversion switch is Normally Closed function active when switch opens If set OFF the Quick Inversion switch is Normally Open function active when switch closes 11 EV1 PRESENT ABSENT If set PRESENT the EVT output is driven and the diagnosis EV1 DRIVER SHORTED relative to the load connected to CNA 1 is activated When set ABSENT the diagnosis is not implemented and the EV1 output is NOT driven 12 EV2 PRESENT ABSENT If set PRESENT the EV2 output is driven and the diagnosis EV2 DRIVER SHORTED relative to the load connected to CNA 8 is activated When set ABSENT the diagnosis is not implemented and the EV2 output is NOT driven 13 EV3 PRESENT ABSENT If set PRESENT the EV3 output is driven and the AFCZPOBB COMBIACX amp ACEX User Manual diagnosis EV3 DRIVER SHORTED relative to the load connected to CNA 2 is activated When set ABSENT the diagnosis is not implemented and
96. ure is probably in the controller hardware so it is necessary to replace the controller Troubleshooting of fault displayed during motor driving in this case it can be an undervoltage or a overvoltage condition A If the alarm happens during traction acceleration or driving hydraulic functions it is very likely it is an undervoltage condition check battery charge condition power cable connection B If the alarm happens during release braking it is very likely it is due to overvoltage condition check line contactor contact battery power cable connection 14 LOGIC FAILURE 2 Cause Fault in the hardware section of the logic board which manages the phase s voltage feedback Troubleshooting This type of fault is not related to external components so when it happens it is necessary to replace the Controller 15 LOGIC FAILURE 3 Cause Hardware problem in the logic card circuit for high current overload protection Troubleshooting This type of fault is not related to external components so when it is present it is necessary to replace the controller 16 STBY HIGH Cause The current transducer or the current feedback circuit is damaged in the controller Troubleshooting This type of fault is not related to external components so when it is present it is necessary to replace the controller 17 WRONG BATTERY Cause At start up the controller checks the battery voltage and verify it i
97. us of the Battery and the common ground point pointed by the arrow in the image must dimensioned taking into account thermal and voltage drop problems E Can advantages The complexity of today systems needs more and more data signal and information must flow from a node to another CAN is the solution to different problems that arise from this complexity simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability fewer connections analysis of problems improved easy connection with a pc to read the data flowing through the cable 4 2 4 Wirings I O connections After crimping the cable verify that all strands are entrapped in the wire barrel Verify that all the crimped contacts are completely inserted on the connector cavities AN A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire for information about the mating connector pin assignment see the paragraph description of the connectors AFCZPOBB COMBIACX amp ACEN User Manual Page 15 81 4 2 5 Connection of the encoder Page 16 81 1 COMBIACX ACEX card is fit for different types of encoder To control an AC motor with the Zapi inverter it is necessary to install an incremental encoder with 2 phases shifted o
98. ximum current 24V 1 coocoooocccocccoconcncccnonananancnnnncnonannns 280A for 2 Dc chopper Maximum current GOIN 240A for 2 Chopper Eet E AN GE 16kHz External temperature working range 40 C 40 C Maximum heatsink temperature start of the thermal cutback 85 C Note 1 The DC chopper specifications are related to COMBIACX only AFCZPOBB COMBIACX amp ACEX User Manual 2 3 Block diagrams 2 3 1 Traction control CAN H BATT KEY SR POTENTIOMETER HH gui al EE TA AC MICROSWITCHES CH lt de lt N MOTOR PROGRAMMING Vv CONSOLE KEY HA OO 2 3 2 Pump control lt MC i S Scere Il POTENTIOME TER gt ai ICROSWITCH gt Y Ej z We AFCZPOBB COMBIACX amp ACEX User Manual Page 7 81 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 3 1 Digital inputs COMBIACX ACEX digital inputs work in the voltage range Batt Batt Related command devices microswitches must be connected to BATT typically to key voltage Pull down resistance to Batt is built in Functional devices like FW BACK LIFT DESCENT HORN H amp S TILLER BELLY switches are Normally Open so related function becomes active when the microswitch closes Safety devices like CUTBACK switches are Normally Closed so related function becomes active when the micro
99. xternal connector D1 D2 D3 D4 D5 D6 ENCA PENC PTHERM ENCB NENC NTHERM 6 1 5 CNE internal connector Accelerator potentiometer wiper input High level CAN BUS voltage I O Input of the switch DIO The input is activated when it is connected to Batt With the logic hardware properly configured it can be used to supply the EB and MC positive voltage The default function is the controller TILLER input Input of the switch DI7 The input is activated when it is connected to Batt The default function is the controller H amp S Hard amp Soft request input closing this input truck performances are modified Potentiometers positive supply Hardware has to be configured to output 12V or 5 V Lift Lower potentiometer wiper input Low level CAN BUS voltage I O Traction motor encoder phase A Encoder Positive Supply Hardware has to be configured to output 12V or 5 V Traction motor thermal sensor input The internal pull up is a fixed 2mA Max 5V source current Traction motor encoder phase B Negative of the Encoder Negative reference GND for the motor thermal sensor The connector used is a 8 way STRIP E1 E2 E3 E4 E5 E6 E7 E8 NCLRXD PCLTXD NCLTXD GND 12 FLASH BOOT GND Not used Internally disconnected Negative serial reception pin Positive serial transmission pin Negative serial transmission pin Serial communication negative reference 12V serial co

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