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COMBIAC0 & ACE0

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1. 60 12 4 Warnings OVEIVIBW EE 68 12 5 Analysis and troubleshooting of warnings ccceceeeeeeeeeeeeeeeeeeeeeeeeteaaeeeeeeeeeeeeeaaa 70 13 RECOMMENDED SPARE PANI vsisi ile jej 76 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT FF PROJECT MANAGER FG TECHNICAL ELECTRONIC pp MANAGER VISA SALES MANAGER VISA MC Publication N AF6ZPOAA Edition August 2007 Page 4 76 AF6ZPOAA COMBIACO amp ACEO User Manual 1 INTRODUCTION The COMBI ACO ACEO 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 700W to 2 5 Kw AC motors Pump controller for series wounded DC motors up to 5 KW only for Combi ACO Drivers for ON OFF electrovalves and for two proportional valves electro distributor Can bus interface Interface for canbus tiller Zapi patented sensorless and sense coil control 128 Kbytes Flash memory embedded Software downloadable via Serial link or JTAG internal connectors or Canbus external connector ESD protection on CAN BUS inputs CANL and CANH AF6ZPOAA COMBIACO 8 ACEO User Manual Page 5 76 2 SPECIFICATION 2 1 Technical specifications Combi ACO ACEO Inverter for traction AC asynchronous 3 phase motors plus chopper for DC series pump motors
2. 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 Material overview Before to start it is necessary to have the reguired 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 CONTACOTOR 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
3. BRAKING L 2 ARE YOU SURE YES ENTER NO OUT MAIN PARAMETER GHANGE MENU Seconds It determines the acceleration ramp The parameter sets the time needed to speed up the traction motor from OHz to 100Hz 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 TILLER BRAKING AF6ZPOAA COMBIACO amp ACEO User Manual Page 41 76 Page 42 76 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 decelerate the traction motor from 100Hz to OHz 6 PEDAL BRAKING Seconds This parameter determines the deceleration ramp when the travel reguest 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 tim
4. 60 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 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 2 VMN LOW Cause 1 start up test Before switching the LC on the software checks the power bridge it turns on alternatingly 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 voltage 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 Ifthe alarm occurs during motor ru
5. In the SPECIAL ADJUSTMENTS functions list there are factory adjusted parameters only 1 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 2 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 3 SET CURRENT Factory adjusted This is the traction motor maximum current 4 SET TEMPERATURE Set the temperature offset to have the correct value reading This is a fine calibration of the controller temperature sensor 5 ADJUSTMENT 03 Factory adjusted value This is the gain of the Current Sensing Amplifier of pump motor 6 SET CURRENT PUMP Factory adjusted This is the pump motor maximum current 7 HIGH ADDRESS To be used to have access to special memory address NOTE only Zapi technicians should change this value 8 DITHER AMPLITUDE It is the dither signal amplitude The dither 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 9 DITHER FREQUENCY It is the dither signal frequency It can be us
6. Regenerative braking functions Digital control based upon microcontroller ee A e ET PE EEA 24 36 48V Inverter maximum current 24V 36V 200A RMS for 2 Inverter maximum current 36V 48V 175A RMS for 2 Continuous output current 24V 36V 70A RMS for 2 Continuous output current 36V 48V 60A RMS for 2 Inverter operating freguencoy s si kann 8kHz Dc chopper Maximum current 24V 36V 1 aesesseesssseeeeereesesserrrressenne 270A for 2 Dc chopper Maximum current 36V A0 220A for 2 Chopper Operating frequency 1 ecccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeeseaeeerens 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 relative to Combi ACO 2 2 Block diagrams 2 2 1 Traction control Page 6 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 2 2 2 Pump control AF6ZPOAA COMBIACO amp ACEO User Manual Page 7 76 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 3 1 Digital inputs COMBI ACO ACEO digital inputs work in the voltage range Batt Bati Related command devices microswitches must be connected to B typ
7. 10 3 1 ACEO COMBIACO Menu gt 4 HEADIN MAIN MENU PARAMETER CHANGE CONFIG MENU gt AY ACCELERATION DELAY RELEASE BRAKING TILLER BRAKING NVERS BRAKING DECEL BRAKING PEDAL BRAKING SPEED LIMIT BRK MAX SPEED FORW MAX SPEED BACK HYDRO SPEED FINE HYDRO COMPENS CUTBACK SPEED 1 H amp S CUTBACK FREOUENCY CREEP MAXIMUM CURRENT ACC SMOOTH NV SMOOTH STOP SMOOTH BRK SMOOTH STOP BRK SMOOTH AUXILIARY TIME HYDRO TIME PUMP IMAX PU ACCELER DEL PU DECELER DEL SPEED LIMIT CREEP SPEED COMPENSATION MIN EVP MAX EVP MIN EVP2 EVP2 OPEN DELAY CLOSE DELAY gt OPEN DELAY2 CLOSE DELAY2 Sec Sec Sec Sec Sec Sec Z z Z IA z z Z Hz 2 SS N NYT 0 ON oa lt q o o OODONNNNENNNUGL ooo ano o o lt lt TESTER BATTERY VOLTAGE V BATTERY CURRENT A ANY MOTOR VOLTAGE z VOLTAGE BOOSTER Z FREQUENCY Hz NCODER Hz SLIP VALUE Hz CURRENT RMS A BATTERY CHARGE TEMPERATURE KS MOTOR TEMPERAT ie A PUMP CURRENT A PUMP VMN z ACCELERATOR V LIFTING CONTROL v DIO TILLER SW ON OFF DIH DESCENT ON OFF DI2 CUTBACK ON OFF DI3 FORWARD ON OFF 314 REV ON O DI5 HORN ON OFF DI6 BELLY ON OFF DI7 ON OFF O18 LIFT ON OFF wh DIS H amp S ON OFF V DITO ON OFF Dm ON OFF DI12 ON OFF SAVE SET POINT EVP PARAMETER SET POINT EVP2 z OUTPUT EV1 ON OFF ANY OUTPUT EV2 ON OF
8. 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 freguency 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 the 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 Page 64 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 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 cont
9. Contents INTRODUCTION ssssisessiessssecsuaasscsinasdacsssavinianesdsieassinrsdassnniecnesnssisnumas taessansasaesasncieazersaanandannions 5 SPECIFICATION sisissessesscsssiesascedivntanesssacasadsassasadansetansidad sacstendaniactiaateinadaanctesandadaaessanaaaiunceanas 6 2 1 Technical specifications Combi ACO ACEO e 6 2 2 oe e el ogee een ee tere eee cee meen oven ere Re Meee aT ee enn ere EME net 6 2 2 1 raction NU EE 6 2222 Pump CONO cinadan a aa aa eb Pra dalje 7 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 8 3 1 Ree EE 8 3 1 1 DIO DI10 technical details 24 V system 8 3 1 2 DIO DI10 technical details 48 V system 8 3 1 3 Microswitches rane oe vede ee o ae ano anat kao ad 8 32 Analogue E 8 3 3 Other analogue control unit E 9 3 4 Analogue motor thermal sensor input 9 3 5 Speed feedback 10 INSTALLATION HINT S sivina nanja jaka aa kolka alna aknah 11 4 1 Material OVervieW a o o a SEE EEE Ennan ane nenna 11 4 1 1 Connection E 11 ee 11 a EE 12 4 2 Installation of the bhariware ueEEEEREEEEEREEREEEERRREEEEEEEEEEREEREEEEGEEEEEESEREEEEEREEEEEEEEEENEEER 12 4 2 1 Positioning and cooling of the controller 12 4 2 2 Wirings power EE cxcctchcmitnctanderataataninientycenmucntatuntaslenduchwecthetanausceenstaes 13 4 2 3 Wirings CAN conn
10. S GH i g ma ot on m E je Ag S Za R 5 zd o 8 z amp 5 8 4 8 EN S a F7 z ei a K OD lt z a R A PL S S FE 2a 5 2 se z ES 2 4 o lt 808 L0 Die ER vle k sle 216 5 ut Th gt B Le l INS dg Wi usi San V Ss D ees BI x e ON ko hte v8 E Se EN vzve 7 de bal ke m L s O a Late W I BN e in NI ial vi o D EK s E Zo pe S pes iM ccd a S e A a H v76 lt H ti W LJ Er o bal Ur ze 100 Moi T v val K e a HS L gt BEN v E2 e 4 ra to OR Hp E s 5 if Tay vun m VOL end j H ar ra ma E JJ wei a a vE lt a I Z s cu S H a Pa We a ga 3 is uer S mas g g E Sp sl z u S ud a ma 1 zi s 2 z a SEH R Ki ER ae z 22 8 a Hu a zi aoe 2 tl ki gs BEE es Su of oo Haz 25 b 22 542 gt Z RES 254 a D a m E G z Connection drawing CombiACO AF6ZPOAA COMBIACO amp ACEO User Manual Page 29 76 9 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure To move the truck needs a minimum UO outfit t
11. in order to verify if a positive is connected to the Smart driver output CNA 2 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 48V controller overvoltage threshold is 65V 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 relais or contactor switching solenoids energizing deenergizing B 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 controller Troubleshooting of fault displayed during motor driving in this case it can be an undervoltage or a overvoltage condition A Ifthe 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 Ifthe alarm happens during release b
12. x ca st o V 5 HHHH H 4 U A AF6ZPOAA COMBIACO amp ACEO User Manual Page 27 76 I LW R I l EE BS m ui NON ods bd RN NACOONS HLIM SITA SE TIVJSAWYV ONIMYAC ob NN4 0300 a SERGE 5 SLONGOYd Idvz JO SulVydiu FHL OL ZMIVIJA IVHl SI 3SN G4aMOTIV A JHL V dOJ 1439X343 OIIHIHOME ods idvZ V Sl 3 Ya SIHL S x gt a NOD 3H NI AND D z D dil dv im BD Q i St OMVDEHSVI Lu AJHID dl TOW TA me S S T WN H Q im i S s D PU om 4 S Om 9 s O 97 h D EE lt x gl e DG a a9 S Valin D JTOSNOI N ij et to NO ire e L H kW i i SBD ER e 5 4 z s VeA AVEA ili eo Ll M E S 3 S S B ER RY OS 4 z H rb E Bo za 4 if H mp 3 ar T T T eP aT RS o uod am e i S a W TN DCH ke oo Nel V sei TNE a z JE YIWLNOW NON S Ng D i e ON5 f s l H Wi A C 10d gl ec yc S g S z S si S S 8 S le E s l so z NE A S E bee 5 f Z 3 JE S z 9 5 BE EO BE Azi V asn Ka Z inna 0 O n EE IH 0 fig O Oy O O E 8 Bf a ni S Ze i 8 Se Bf Ki 2 OI m s EEN e 4 O si SODA z gie C s a s o c T m R o VA O 10 N N S 8 ra 1 9 S D E 2 D da 8 3 e g a eo 7 Zen Do 5 d Es
13. A 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 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 4 3 2 Safety Features A ZAPI controllers are designed according to the prEN954 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 instal
14. 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 16 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 17 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 18 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 37 76 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 Page 38 76 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 Opening Zapi Menu Press Top Left
15. 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 EVP1 NOT Ok 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 EVP1 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 EVP2 NOT OK AF6ZPOAA COMBIACO 8 ACEO User Manual Page 65 76 Page 66 76 Cause A The EVP2 driver is shorted B The microcontroller detects a mismatch between the valve set point and the diver voltage measured on the EVP2 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 26 PUMP VMN LOW Cause The pump motor output is lower than expected considering the pwm applied Troubleshooting A Ifthe 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
16. Positive EB at LC opens Hevel 2 in the HW setting menu and Deadman input open the alarm appears start up stanby continuous standby Valve or pump r traction Page 68 76 AF6ZPOAA COMBIACO 8 ACEO User Manual Machine status Error code Description Effect when the test isi done Restart procedure Current Sensor Pump motor stopped sart up stby runipump request Low Valve Coil Shorted Greg on On off valves coil 1On off valves stopped start up stby Ivahye on off request during valve function EV1 5 driver On off valves stopped start up stby shorted valve on off request On off valves stopped start up stby valve on off request iOn off valves stopped istart up stby valve on off request On off valves stopped istart up stby valve on off request Evp Driver Ko Evp driver open not able to close Evp stopped during Evp iso not able to drive the valve function i valve evp request Evp2 Driver Ko Evp2 driver open not able to close Evp stopped iduring Evp iso not able to drive the valve ifunction valve evp request Pump NO zero Pump chopper current sensor Pump motor stopped istart up stby pump request feedback is out of permitted stby pump request Pump I lt 0 ever Pump current feedback is always Pump motor stopped pump function IDA even when pump motor is ram warning ichecksum ram failed continuous eep warning jchecksum eeprom failed ti tinit
17. 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 acguisition when the accelerator is released Troubleshooting Check the mechanical calibration and the functionality of the potentiometer HIGH TEMPERATURE 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 0 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 6 BATTERY LOW Cause It occurs when the battery charge is calculated being less than or egual 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 su
18. 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 ACEO COMBI ACO controller is divided into 2 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 Page 58 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 12 2 Alarms overview Machine status when the test is done Restart procedure Capacitor Power capacitors voltage does not increase Valve pump traction stopped Le start up Valve or pump or charge opened Eb applied traction reguest Vmn low Motor output voltage lower than expected Valve pump traction stopped Le start up trac
19. re cycle valve or pump or traction irequest iyalve or pump or traction reguest iKey re cycle valve or pump por traction irequest ivalve or pump tor traction I ireguest ivalve or pump or traction reguest The outputs of the amplifiers used to ivalve pump traction measure the motor voltage are cheked this stopped Lc opened alarm occurs when voltage signals gt 3V or Eb applied lt 2V at the init iThe Evp1 coil is not connected between iPaux and NEVP1 output and the parameter EVP TYPE in the set option menu is set valve pump traction istart up stby Analog or Digital i stopped Lc opened itraction Eb applied valve or pump or traction request valve pump traction start up stby stopped Lc opened itraction Eb applied iThe Evp2 coil is not connected between Paus and NEVP2 output and the parameter EVP TYPE in the set option menu is set Analog or Digital valve or pump or traction request 12 3 Analysis and troubleshooting 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 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 Page
20. 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 3 EVP TYPE Analog digital defines the type of the EVP1 electrovalve current controlled Analog the related output manages a proportional valve current controlled Digital the related output manages an on off valve 4 EVP2 TYPE Analog digital defines the type of the EVP2 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 inhibits the Lifting function Level 2 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 truck speed down to 24 of the full truck speed and it inhibits the Lifting function 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 re
21. the percentage of voltage applied to EVP2 valve 31 OUTPUT EV1 On Off determines if the valve EV1 or EV5 are open or closed 32 OUTPUT EV2 On off determines if the valve EV2 is open or closed 33 OUTPUT EV3 On off determines if the valve EV3 is open or closed 34 OUTPUT EV4 On off determines if the valve EV4 is open or closed AF6ZPOAA COMBIACO 8 ACEO User Manual 11 OTHER FUNCTIONS 11 1 Description of console SAVE function 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 CAOZ2A ZP1 00 Opening Zapi Display 24V 200A 00000 Press ENTER to go into the General menu z sa MAIN MENU The Display will show PARAMETER CHANGE Press ROLL UP or ROLL DOWN button until SAVE poo PARAM appears on the display RSR The Display will show MAIN MENU SAVE PARAMETERS Press ENTER to go into the SAVE function O z O If this feature has been used before the type of controller data stored appears on the
22. the right side top and left side top buttons Then roll until the SET OPTION item appears Page 34 76 on the 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 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 AF6ZPOAA CAOZ2A ZP1 00 24V 200A 00000 CONFIG MENU SET MODEL CONFIG MENU SET OPTIONS OMO a dd HOURCOUNTER RUNNING HOURCOUNTER KEYON ood OMO ARE YOU SURE YES ENTER NO OUT CONFIG MENU SET OPTIONS COMBIACO amp ACEO User Manual 1 TILLER SWITCH This option handles the input CNA 1 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 CNA 1 is managed as tiller input no delay when released SEAT CNA 1 is managed as seat input with a delay when released gt debouncing function 2 HOUR COUNTER This option
23. 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 30 LIFT LOWER Cause This alarm occurs when both forks movement requests Lift Lower are active at the same time Troubleshooting Check the wiring of the Lift and lower 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 31 CONT DRV EV1 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 32 CONT DRV EV2 Cause Page 74 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 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 33 CONT DRV EV3 Cause The EV3 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 34 CONT DRV EV4 Cause The EV4 valve driver is not able to drive the load cannot close Troubleshooti
24. to Set Option menu 36 EVP CLOSE DELAY2 In seconds It defines the closing ramp of the EVP2 electrovalve when related output is set as Analog refer to Set Option menu AF6ZPOAA COMBIACO 8 ACEO User Manual iii potite2tstatstet7 s 9 ACCELERATION DELAY From 0 to 10 sec resolution of 0 1 RELEASE BRAKING From 0 to 10 sec resolution of 0 1 TILLER BRAKING From 0 to 10 sec resolution of 0 1 INVERSION BRAKING From 0 to 10 sec resolution of 0 1 DECEL BRAKING s From 0 to 10 sec resolution of 0 1 PEDAL BRAKING From 0 to 10 sec resolution of 0 1 pro nar mne Ose romani zone 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 resolution of 0 1 From 0 to 100 resolution of 0 1 From 0 to 100 resolution of 0 1 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 45 76 10 4 4 Zapi menu SPECIAL ADJUSTMENTS functions list EY Page 46 76 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
25. 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 AF6ZPOAA COMBIACO amp ACEO User Manual Page 11 76 4 1 3 Fuses Use a 6 3 10A Fuse for protection of the auxiliary circuits For protection of the power unit use a 150A fuse in the Battery Positive connection For special applications or reguirements 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 a2 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 Page 12 76 CONTROLLER WITH BASE PLATE Inst
26. 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 Page 15 76 4 2 5 Connection of the encoder 1 COMBI ACO ACEO card is fit for different types of encoder To control AC motor with Zapi inverter it is necessary to install an incremental encoder with 2 phases shifted of 90 The encoder power supply can be 5 or 12V It can have different electronic output AMPSEAL CONNECTOR A25 5V 12V positive of encoder power supply A5 GND negative of encoder power supply A14 A phase A of encoder A13 B phase B of encoder 2 Connection of encoder with open collector output 5V power supply Ps Seel SS a Connection of encoder with open collector output 12V power supply ae A 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 Page 16 76 AF6ZPOAA COMBIACO 8 ACEO 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 LE J The connection of the battery line switches
27. 4 76 AF6ZPOAA COMBIACO amp ACEO User Manual Module 1 Module 2 Module 3 Note Module 1 power lt 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 minus 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 EY Can advantages 4 2 4 Wirings A AF6ZP0AA COMBIACO amp ACEO User Manual 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 UO 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 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
28. CO 8 ACEO User Manual 6 1 2 CND internal connector The connector used is a 8 Vie STRIP D1 D2 D3 D4 D5 D6 D7 D8 Not used NCLRXD PCLTXD NCLTXD GND 12 FLASH BOOT GND Internally disconnected Negative serial reception pin Positive serial transmission pin Negative serial transmission pin Serial communication negative reference 12V serial communication supply To connect this pin to GND D8 for software download via serial communication Serial communication negative reference This internal connector is used for software download with Zapi Flasher or for the communication with Zapi Handset or with lap top for controller setting an diagnosis 6 1 3 CNE internal connector The connector used is a 16 Vie STRIP E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 TMS 5 TDO GND CPUCLOCK GND TDI RESET TRST BRK OUT TCLK GND BRK IN Not used Not used Not used JTAG interface test mode selection microcontroller input 5V JTAG interface supply JTAG data output microcontroller output JTAG interface negative reference CPU clock signal for JTAG interface JTAG interface negative reference JTAG data input microcontroller input Logic reset signal Test System reset microcontroller input Debug System Break Out microcontroller output Debug System JTAG clock microcontroller input JTAG interface negative reference Debug System Break In micro
29. EH PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary output coil connected to CAN 4 ON the PWM reduces the voltage on the main contactor coil down to the value programmed with PWM CHOP START and PWM CHOP WORK parameters AF6ZPOAA COMBIACO 8 ACEO 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 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 Opening Zapi Menu Press ENTER to go into the General Menu The Display will show PARAMETER CHANGE Press ENTER to go into the Parameter Change menu The Display will show the first parameter Press either ROLL UP and ROLL DOWN to display the next parameter The names of the Parameters appear on the Display When the desired Parameter appears it s possible to change the Level by pressing either SET UP or SET DOWN buttons The Display will show the new level When you are satisfied with the result of the changes you have made press OUT The Display asks ARE YOU SURE Press ENTER to accept the changes or press OUT to discard them The Display will show ACCELER DELAY CAOZ2A ZP1 00 24V 200A 00000 MAIN OMO Iess MENU PARAMETER GHANGE OMO D H H RELEASE LEVE BRAKING LS RELEASE LEVE om e E OMO
30. F OUTPUT EV3 ON OFF RESTORE OUTPUT Eva ON OFF PARAMETER ALARMS gt as c lt 7 N 76 AY gt PROGRAM VACC E VACC SETTING MIN MAX ANY AF6ZPOAA COMBIACO amp ACEO User Manual V ANG SET MODEL E A ANY SET OPTIONS y A AY ILLER SWITCH HOUR COUNTER EVP TYPE EVP2 TYPE BATTERY CHECK STOP ON RAMP AUX OUTPUT 1 QUICK INVERSION SET MOT TEMP EV1 5 Ev2 EV3 EV4 DIAG PEDAL WIRE KO INVERSION MODE HYDRO FUNCTION MC FUNCTION AUX OUT FUNCT HANDLE SEAT RUNNING KEY ON ANALOG DIGITAL NONE ANALOG DIGITAL NONE LEVELO LEVEL1 LEVEL2 ON OFF BRAKE HYDRO CONT EX HYDRO BELLY TIMED NONE ANALOG DIGITAL NONE PRESENT ABSENT PRESENT ABSENT PRESENT ABSENT PRESENT ABSENT PRESENT ABSENT ON OFF KEY ON RUNNING PRESENT ABSENT gt RESENT ABSENT DJUSTMENTS PP A gt SET BATTERY TYPE ADJUST BATTERY THROTTLE O ZO THROTTLE X POINT THROTTLE Y POINT BAT MIN ADJ BAT MAX ADJ LOAD HM FROM MDI CHECK UP DONE CHECK UP TYPE MIN LIFT MAX LIFT MIN LOWER MAX LOWER PWM CHOP START PWM CHOP WARM PWM ON MAIN CONT PWM ON AUX OUT 24V 36V 48V N ah E 9 0 9 ON OFF ON OFF OPTIONJO 1 42 jo V wi a ON OFF ON OFF V Page 33 76 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
31. Pump motor stopped continuous hydraulic request close function close function close function close function close function AF6ZPOAA COMBIACO 8 ACEO User Manual Page 69 76 12 5 Analysis and troubleshooting of warnings Page 70 76 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 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
32. RIVER KO Cause The EVP valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 25 EVP2 DRIVER KO Cause The EVP2 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller AF6ZPOAA COMBIACO 8 ACEO User Manual Page 73 76 26 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 27 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 28 RAM WARNING Cause Checksum of the ram failed Troubleshooting This fault is not related to external components 29 EEP WARNING Cause Eeprom checksum failed Troubleshooting Try to execute a CLEAR EEPROM operation refer
33. TLE 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 6 BAT MIN ADJ Adjust the lower level of the battery charge table Level 0 to 9 7 BAT MAX ADJ Adjust the upper level of the battery charge table Level 0 to 9 8 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 9 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 10 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 shown 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 11 MIN LIFT This parameter stores the minimum voltage of lifting potentiometer output connected to CNA 30 The min value acquisition is done closing the Lift SW and bringing the potenti
34. V Azam ELECTRONIC OLEODYNAMIC INDUSTRIAL EGUIPMENTS 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 COMBIACO amp ACEO Copyright 1975 2007 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 MAP isa 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 A 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 76 AF6ZPOAA COMBIACO 8 ACEO User Manual
35. When it is not connected to a battery key voltage or it is connected to GND the Lowering request is not active 18 DI2 CUTBACK SWITCH ON OFF This is the level of the digital input CNA 11 in AmpSaab connector CNA 6 in AmpSeal connector ON GND When it is not closed to a battery key voltage or connected to GND the SR 1 request is active OFF VB When it is closed to a battery key voltage the SR 1 request is not active 19 DI3 FORWARD SWITCH ON OFF This is the level of the digital input CNA 18 in AmpSaab connector CNA 32 in AmpSeal connector 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 Page 48 76 AF6ZPOAA COMBIACO 8 ACEO User Manual connected to GND the Forward Travel demand is not active 20 DI4 REV SWITCH ON OFF This is the level of the digital input CNA 19 in AmpSaab connector CNA 31 in Ampseal connector 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 21 DI5 HORN SWITCH ON OFF This is the level of the digital input 5 CNA 20 in AmpSaab connector CNA419 in AmpSeal connector ON VB When it is closed to a battery key voltage the di
36. all the controller with the base plate on a flat metallic surface that is clean and unpainted suggested characteristics are RR 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 should 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 i
37. ameter determines the minimum voltage applied on the EVP1 when the position of the potentiometer is at the minimum This parameter is not effective if the EVP1 is programmed like a On Off valve AF6ZPOAA COMBIACO 8 ACEO User Manual Page 43 76 Page 44 76 30 MAX EVP 0 to 100 This parameter determines the maximum voltage applied on the EVP1 when the position of the potentiometer is at the maximum If the EVP1 is programmed like a On Off valve this parameter determines the fixed voltage applied on the electrovalve coil 31 MIN EVP2 0 to 100 This parameter determines the minimum voltage applied on the EVP2 when the position of the potentiometer is at the minimum This parameter is not effective if the EVP2 is programmed like a On Off valve 32 MAX EVP2 0 to 100 This parameter determines the maximum voltage applied on the EVP2 when the position of the potentiometer is at the maximum If the EVP2 is programmed like a On Off valve this parameter determines the fixed voltage applied on the electrovalve coil 33 EVP OPEN DELAY In seconds It defines the opening ramp of the EVP1 electrovalve when related output is set as Analog refer to Set Option menu 34 EVP CLOSE DELAY In seconds It defines the closing ramp of the EVP1 electrovalve when related output is set as Analog refer to Set Option menu 35 EVP OPEN DELAY2 In seconds It defines the opening ramp of the EVP2 electrovalve when related output is set as Analog refer
38. amp Right Buttons to enter CONFIG MENU The Display will show SET MODEL Press ROLL UP button until ADJUSTMENTS MENU appears ADJUSTMENTS appears on the display Press ENTER to go into the ADJUSTMENTS MENU The display will show SET BATTERY TYPE Press ROLL UP or ROLL DOWN button until the desired parameter is reached The desired parameter appears Press SET UP or SET DOWN button to modify the adjustment Press OUT Press ENTER to confirm Repeat the same from 5 to 12 points for the other adjustments SET BATTERY TYPE Selects the nominal battery voltage ADJUST BATTERY CAOZ2A ZP1 00 24V 200A 00000 CONFIG MENU SET MODEL CONFIG MENU ADJUSTMENTS BATTERY TYPE 24V TROTTLE O ZONE 3 Fine adjustment of the battery voltage measured by the controller THROTTLE 0 ZONE Establishes a deadband in the accelerator input curve THROTTLE X POINT AF6ZPOAA COMBIACO 8 ACEO User Manual 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 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slopes 5 THROTTLE Y POINT This parameter together with the THROT
39. anddens 30 9 1 Sequence for Ac Inverter traction setting 31 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 3 76 10 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE ennneeeee 32 de fN WE TER 32 10 2 Description of console hand set amp connection 32 10 3 Description of the console menu 33 10 3 1 ACE0 COMBIACO Menu E 33 TOA Function configuration EE 34 10 4 1 Config menu SET OPTIONS functions list 34 10 4 2 Config menu ADJUSTMENTS functions list 38 10 4 3 Main menu PARAMETER CHANGE functions list 41 10 4 4 Zapi menu SPECIAL ADJUSTMENTS functions list 46 10 4 5 Main menu TESTER functions list 47 11 OTHER en te TE 51 11 1 Description of console SAVE function eaannnnna 51 11 2 Description of console RESTORE function 52 11 3 Description of console PROGRAM VACO function 53 11 4 Description of the throttle regulation nn 55 11 5 Description of the battery charge detection setting 56 12 AGE0 COMBI ACO ALARMS UIEST egrstereesstsergsessgerkusegebeg Geesse n REE Ea SES 58 FAN NR GE We E 58 12 2 ee EO ae 59 12 3 Analysis and troubleshooting of microcontroller alarms
40. ay will show Press ROLL UP or ROLL DOWN button until moo RESTORE PARAM appears on the display NOG MAIN MENU The Display will show RESTORE PARAM Press ENTER to go into the RESTORE PARAM oma function ooa The Display shows the type of Model stored with a SELECT MOD OO Code Number ACEDO ZAPI V1 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display SELECT MOD OO ACEO ZAPI V1 OMO Press ENTER to commence the Restore operation EH The Display will ask ARE YOU SURE EEN AF6ZPOAA COMBIACO 8 ACEO User Manual 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 happening STORING AGCELER DELAY MAIN MENU RESTORE PARAM When finished the Console shows Press OUT to return to the Opening Zapi Display EY NOTE in reality the SAVE and RESTORE function requires the Windows PC Console 11 3 Description of console PROGRAM VACC function 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 poin
41. ayed 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 CA0Z2A ZP1 00 24V 200A 00000 MAIN OMO ood MENU PARAMETER GHANGE MAIN MENU PROGRAM VAGG MIN VACC MAX 0 6 T 4 4 oo oO ogo ARE YO YES ENTE E GO MAIN E O E O MENU PROGRAM VAGG AF6ZPOAA COMBIACO 8 ACEO User Manual 11 4 Description 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 freguency 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 percen
42. booster setting because this latest one is calculated respect to the nominal battery voltage VOLTAGE BOOSTER is expressed respect to the actual battery voltage FREQUENCY Hz value This is the frequency of the sine waves the inverter is supplying ENCODER Hz value This is the speed of the motor measured with the encoder and expressed in the same unit of the FREQUENCY reading SLIP VALUE Hz value This is the slip between the frequency and the speed of the motor SLIP VALUE FREQUENCY ENCODER CURRENT RMS Ampere value Root Mean Square value of the line current in the motor BATTERY CHARGE Percentage value It supplies the residual charge of the battery as a percentage of the full charge level 10 TEMPERATURE C value This is the temperature of the inverter base plate This temperature is used for the HIGH TEMPERATURE alarm detection 11 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 KTY84 130 This temperature is used only to raise a warning in the hand set AF6ZPOAA COMBIACO amp ACEO User Manual Page 47 76 when the motor temperature overtakes the MOTOR OVERTEMP setting 12 PUMP CURRENT Ampere It is the continuous current in the pump motor 13 PUMP VMN It is the voltage applied to the pump motor Expressed in percentage of the maximum voltage 14 ACCELERATOR From 0 0V to 5 0V The vol
43. ck 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 26 DI10 SWITCH ON OFF This is the level of the digital input CNA 36 in AmpSaab connector CNA 17 in AmpSeal connector for the lifting request AF6ZPOAA COMBIACO 8 ACEO User Manual Page 49 76 ON VB When is closed to a battery key voltage the Lifting request is Active OFF GND When is not connected to a battery key voltage or it is connected to GND the Lifting request is not active 27 DI11 SWITCH ON OFF This is the level of the CNA 37 digital input only in AmpSaab connector ON GND When CNA 37 is not closed to a battery key voltage or connected to GND the Lift Stop is active OFF VB When CNA 37 is closed to a battery key voltage the Lift Stop is not active 28 DI12 SWITCH ON OFF This is the level of the digital input 12 CNA 38 only in AmpSaab connector ON VB When it is closed to a battery key voltage the digital input 12 is active OFF GND When it is not closed to a battery key voltage or it is connected to GND the digital input 12 is not active 29 SET POINT EVP This parameter shows the setpoint of EVP valve 30 SET POINT EVP2 Show
44. cond proportional electrovalve driver driving to Batt Negative of the lower proportional electrovalve driver driving to Batt Encoder Positive Supply 412 45 Vdc Negative of the protected horn electrovalve driver driving to Batt Low level CAN BUS voltage I O High level CAN BUS voltage I O Input of the switch DI9 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 Lift Lower potentiometer wiper input With the logic hardware properly configured it can be used as potentiometer negative reference Using this input as NPOT the diagnosis PEDAL WIRE KO is implemented 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 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 Output of the ON OFF electrovalve EV3 1 5 A maximum continuous current driving to Batt Output of the ON OFF electrovalve EV4 1 5A maximum continuous current driving to Batt Input of the switch DI7 The input is activated when it is connected to Batt It doesn t have a default function AF6ZPOAA COMBIA
45. connected between the output and PAUX positive Troubleshooting A It is suggested to check the harness in order to verify if EVP1 coil is AF6ZPOAA COMBIACO 8 ACEO User Manual 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 30 EVP2 COIL OPEN Cause This fault appears when the EVP2 output is used parameter EVP2 TYPE in SET OPTION menu is set ANALOG or DIGITAL but no load is connected between the output and PAUX positive Troubleshooting A It is suggested to check the harness in order to verify if EVP2 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 67 76 12 4 Warnings overview i Machine status Error code Description Effect when the test is Restart procedure Error on the parameters of the slip Traction is stopped iprofile setting Forward back iThe travel demands are active in bothiTraction is stopped i tart up stand by ward idirections at the same time traction Incorrect start Incorrect starting sequence Traction is stopped istart up stand by itraction iThe acceleretor value is h
46. controller input Internally disconnected Internally disconnected Internally disconnected This internal connector is used for software download via JTAG interface The connector is also used by Zapi technicians to realize the software debug AF6ZPOAA COMBIACO 8 ACEO User Manual Page 25 76 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 U V W Connection bars of the three motor phases follow this sequence and the indication on the motor Page 26 76 AF6ZPOAA COMBIACO amp ACEO User Manual 8 DRAWINGS 8 1 Mechanical drawing ff X A gen a a j oy hoot A i II II Il Hil A amp Il a SE dil 11 7 iii dt da d S o e 3 3 G Z m S U D G 15011 Z S 640 5 138 0 1 ES te li o 5 ej o O m 2 4 m 2 x D 9 BE ek o gt gc gt We Z co Db SI el Sot S Hi v H o X 56H 3 Q7 oun KC S IC j D oO a m Kat imi k gt Iw gt Z oO IL o ke ea
47. e needed to decelerate the traction motor from 100Hz to OHz 8 MAX SPEED FWD Percentage It determines the maximum speed in forward direction 9 MAX SPEED BWD Percentage It determines the maximum speed in backward direction 10 HYD SPEED FINE Percentage Fine adjustment of the pump motor steering function speed 11 HYDRO COMPENSATION Percentage Adjustment of the compensation function when the pump motor steering function is active 12 CUTBACK SPEED 1 Typically from 10 to 100 It determines the percentage of the max speed applied when the cutback switch 1 CNA 6 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 CNA 29 connector is active When set to 100 the speed reduction is ineffective 14 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 15 MAXIMUM CURRENT Maximum level of the current percentage of the maximum current of the controller AF6ZPOAA COMBIACO 8 ACEO User Manual 16 ACCELERATION SMOOTH It gives a parabolic form to the acceleration ramp 17 INVERSION SMOOTH It gives a parabolic form to the acceleration ramp after a direction inversion 18 STOP SMOOTH Hz It sets the level of freguency where the smooth effect of the acceleration parab
48. ections and possible interferences 13 4 2 4 Wirings VO connections ach vee vrabec area arab banalen ka ua ea akad alne ten 15 4 2 5 Connection of HEEN 16 4 2 6 Main contactor and key Conpnechon 17 4 2 7 Insulation of truck ANE ui onda teak aa ee kale ere anale bebe 17 4 3 Protection and safety TEE esrumgbzersrgeratAASebeRESEeSESRSEEA AER vdani ukane aaa 18 4 3 1 Protection PSU EE 18 4 3 2 Safety OURS nl ra alone kane 19 44 EE 19 4 5 Various suggestions a asencdsnccentanceatadonsetanantteraaaaaas vamatiuteeacadatianwnqedeiecenteatare sce area 21 OPERATIONAL FEATURES sassssccssiccssscssnncaiaisasseseindandactseaanadensnasanaiaraoassnadadassicsasadananastaasena 22 5 1 Bre 3 gle cl yee eer Seren ey eer eee eee eer ee er eT ee ee 22 DESCRIPTION OF THE CONNECTORS isi sisisesssnadcdassiaccanesnanssancdatcsioanncassstadaaanesnanssnnasanaiaas 23 6 1 Connectors of the l0giC a A a NE a Na a 23 NN WR ec E EE EE 23 6 1 2 CND internal DEE i deaccrhemctratanndrnenctarectaniasunatlvndatlonSedleetatnamanenoblaneianeniaie 25 6 1 3 CNE VMI e EE 25 DESCRIPTION OF POWER CONNECTIONS e nana nnnnnnnnnnnnnnnnnannnnanannnnnnnna 26 IK e 27 8 1 Mechanical drawing je PN a va ea a nam 27 8 2 Connection drawing Eege able Aender obre bedi 28 8 3 Connection drawing COMDIACO veccccccscicasssscccnccatedendusaseceeis banana a pnih ka a kakih 29 ONE SHOT INSTALLATION PROCEDURE sissssisssdasssessesesinadssastsnnctesnesascesadaaenoiadsnenas
49. ed 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 10 4 5 Main menu TESTER functions list 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 2 3 4 5 6 7 8 9 BATTERY VOLTAGE Voltage value with 1 decimal digit Battery voltage value measured at the key on BATTERY CURRENT Battery current in Ampere This value is not directly measured by the controller but is software computed through the instantaneous values of battery voltage and percentage of charge MOTOR VOLTAGE Percentage value It is the voltage generated by the inverter expressed in percent of the actual battery voltage 100 means the sine wave width is close to the actual battery voltage 0 means the sine wave width is null 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
50. ent resistance providing the sensor characteristic to Zapi the correct table can be loaded in the controller software 1 DIGITAL A digital on off sensor for the motor temperature monitoring is connected to CNA 22 input 2 NONE No temperature sensor is connected 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 EV2 PRESENT ABSENT If set PRESENT the diagnosis EV2 DRIVER SHORTED relative to the load connected to CNA 11 is activated When set ABSENT the diagnosis is not implemented 12 EV3 PRESENT ABSENT If set PRESENT the diagnosis EV3 DRIVER SHORTED relative to the load connected to CNA 33 is activated When set ABSENT the diagnosis is not implemented 13 EV4 PRESENT ABSENT If set PRESENT the diagnosis EV4 DRIVER SHORTED relative to the load connected to CNA 34 is activated When set ABSENT the diagnosis is not implemented 14 DIAG PEDAL WIRE KO PRESENT ABSENT If set PRESENT the diagnosis PEDAL WIRE KO relative to the connection of the two supply ends 12V CNA 25 NPOT CNA 30 of the potentiometer in the accelerator is activated When set ABSENT the diagnosis is not implemented 15 INVERSION MODE ON OFF This parameter sets the logic of the Quick
51. equest Pos EB Output of built in Smart Driver which supplies Eb coil Valve pump traction stopped Lc start up Valve or pump or shorted positive is high batt when the tiller switch is opened opened Eb applied traction request Logic Failure Overvoltage Undervoltage condition has been detected Valve pump traction stopped Lc start up Valve or pump or 1 opened Eb applied traction request Logic Failure Motor voltage feedback circuits are damaged Valve pump traction stopped Le stby immediately Valve or pump or 2 opened Eb applied after Lc closing traction request Logic failure Failure in the high current HW protection circuit valve pump traction stopped Le start up stby Valve or pump or 3 opened Eb applied traction request Stby i high In stby condition no current applied to the traction motor Valve pump traction stopped Le start up stby Valve or pump or the current feedbacks are aout of permitted stby range opened Eb applied traction request Wrong Set The battery voltage is too low or too high lt 0 8 Vbatt OR Valve pump traction stopped Lc start up stand by Valve or pump or Battery gt 1 2 Vbatt opened Eb applied only immediately traction request after Lc closing Analog input Problem on the A D conversion of uC Valve pump traction stopped Le traction Valve or pump or opened Eb applied traction request Encoder Error Problem on the encoder Valve pump traction stopped Le traction Val
52. er CONTACTOR OPEN Cause The main contactor coil has been driven by the controller but the contactor does not close Troubleshooting A The wires to the LC coil are interrupted or not connected so check the coil related harness B It could be also a problem of the contact in the LC that is not working does not pull in try replacing the LC 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 10 AUX DRIVER SHORTED 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 DRIVER OPEN Cause 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 H8S switch are open Troubleshooting A Itis suggested to check the harness
53. ergy 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 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 19 76 Page 20 76 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
54. errite 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 good grounding can divert the discharge current trough a safe path the AF6ZPOAA COMBIACO 8 ACEO User Manual frame of a truck can works like a local earth ground absorbing excess charge So it 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 COMBI ACO ACEO modules The filter capacitors contained in the COMBI ACO ACEO 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 COMBI ACO ACEO 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 v
55. gital input 5 reguest is active OFF GND When it is not closed to a battery key voltage or connected to GND the digital input 5 request is not active 22 DI6 BELLY SWITCH ON OFF This is the level of the digital input CNA 33 in AmpSaab connector CNA 7 in AmpSeal connector 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 Belly request is not active 23 DI7 SWITCH ON OFF This is the level of the digital input 7 CNA 34 in AmpSaab connector CNA 35 in AmpSeal connector ON VB When it is closed to a battery key voltage the voltage the digital input 7 request is active OFF GND When it is not closed to a battery key voltage or connected to GND the voltage the digital input 7 request is not active 24 DI8 LIFT SWITCH Only for AmpSaab version ON OFF This is the level of the digital input 8 CNA 35 in AmpSaab connector ON VB When it is closed to a battery key voltage the digital input 8 is active OFF GND When it is not closed to a battery key voltage or it is connected to GND the digital input 8 is not active 25 DI9 H amp S CUTBACK ON OFF This is the level of the digital input CNA 6 in AmpSaab connector CNA 29 in AmpSeal connector for the Hard amp Soft request With the H amp S service is possible to turn the tru
56. harge percentage in a table and with comparison is found a new charge percentage 4 Thresholds value can be changed with parameters Bat Max Adj and Bat Min Adj 5 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 battery charge value is updated otherwise the Battery charge is not updated AF6ZPOAA COMBIACO 8 ACEO User Manual Page 57 76 12 ACEO COMBI ACO 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
57. hat it is mandatory this minimum outfit is listed in the Steps from 1 to 8 below Page 30 76 Step1 Step2 Step3 Step4 Step5 Step6 Step7 Steps Connect a potentiometer in the range 0 5 to 10Kohms to modify the wished speed between 12 CNA 25 and GND CNA 5 The potentiometer wiper is connected to CPOTTR CAN 15 Connect two travel demand switches The FWD travel demand must be connected between a battery key voltage and CNA 32 The REV travel demand must be connected between a battery key voltage and CNA 31 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 CNA 1 and a key voltage It becomes active enabling the motion when closed to a key voltage Connect the encoder in the motor shaft between CNA 25 VDD CNA 5 GND CNA 14 CHA CNA 13 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 CNA 10 This is the input for the controller supply Connect the Main Contactor Coil to CNA 10 and CNA 12 The contactor must connect the battery positive to the BATT power terminal of the ACEO COMBI ACO Connect the motors and the minus battery to the corresponding power terminals of the ACEO COMBI ACO Connect the Electromechanical Brake coil between CNA 2 and CNA 4 when the tiller switch ope
58. he acquisition is done 12 PEDAL WIRE KO Cause The SW continuously checks for the connection of the two supply ends of the AF6ZPOAA COMBIACO amp ACEO User Manual Page 71 76 Page 72 76 potentiometer in the accelerator The test consists of reading the voltage drop on a sense diode connected between NPOT CNA 30 and GND and cascaded with the potentiometer if the potentiometer gets disconnected on PPOT CNA 25 or NPOT no current flows in this sense diode and the voltage on the NPOT connection collapses down When the NPOT voltage is less than 0 3V this alarm occurs This alarm occurs also when the NPOT voltage is higher than 2Vdc to detect also the condition of a broken sense diode Troubleshooting Check the voltage on NPOT and the potentiometer connections 13 TILLER OPEN Cause Warning when the tiller is released after a fixed period of time of standby 30 seconds the main contactor open Troubleshooting At the next travel request the warning disappear 14 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 15 WAITING FOR NODE Cause The controller receives from the CAN the message that another controller in the net is in fault c
59. hort 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 21 EV3 DRIVER SHORTED Cause Electrovalve EV3 driver is shorted Troubleshooting Check if there is a short or a low impedance between the negative of this coil and DATT 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 22 EV4 DRIVER SHORTED Cause Electrovalve EV4 driver is shorted Troubleshooting Check if there is a short or a low impedance between the negative of this coil and DATT This warning occurs also if the external load is not present and the parameter EV4 in the Set Options menu is set PRESENT in this case the warning disappears setting the EV4 parameter ABSENT Otherwise the driver circuit is damaged and the controller must be replaced 23 VALVE CONT DRIVER Cause One or more on off valve drivers is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 24 EVP D
60. ia the charger AF6ZPOAA COMBIACO amp ACEO User Manual Page 21 76 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 upon 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 D
61. ically 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 microswitches 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 48 V system Switching threshold 4 3V 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 100HA 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 Analogue 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 CNA 25 Potentiometer output signal must be inp
62. igher than Traction is stopped istart up stand by ithe minimum value recorded and the ttraction idirection enable switches are opened The controller has reached the Traction controller thermal cutback temperature 85 C reduces the maximum current linearly from Imax 85 C down to OA 105 C continuous Battery is lt 10 when the iThe maximum current icontinuous parameter BATTERY CHECK is set is reduced to half and gt 0 ispeed is reduced if CHECK OPTION 1 Error is detected in eeprom or in iController works using ieeprom management i Deafult parameters Traction motor temperature sensor is The maximum current opened if digital or has overtaken e reduced to half and ithe threshold of 150 C if analog ispeed is reduced continuous continuous The maximum current continuous is reduced to half and speed is reduced The output of the controller thermal sensor is out of range Traction is stopped stand by Traction request Traction is stopped start up stand by traction he truck is in stby with tiller switch opened for more than 30s LC opens Valve or pump r traction The Maximum current gain Controller works but i parameters are the default values with low maximum which means the maximum current current adjustment procedure has not been carried out yet 1A Canbus network node is in alarm icondition UC is waiting for it to resolve its error condition With the parameter
63. 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 easier 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 reguired 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 f
64. irect communication between traction AC inverter and pump DC chopper 5 1 Diagnosis Page 22 76 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 that 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 6 DESCRIPTION OF THE CONNECTORS zi Connectors of the logic 6 1 1 CNA external connector The connector used is an AMPSEAL plug 35 pins A1 A2 A3 Ad A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 DIO PEB PAUX NEB NENC DI2 DIG EV5 EV1 KEY EV2 NMC ENC B ENC A CPOTTR DI10 DI8 Input of the switch DIO The input is activated when it is c
65. lation 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 a4 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 offer 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 en
66. lded Ina 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 13 76 A Wrong Layout Module 1 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 A Correct Layout Module Module 1 2 Module 3 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the BATT 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 Correct Layout Page 1
67. leased but the tiller is not released ON The stop on ramp feature truck electrically hold on a ramp is managed 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 7 AUX OUTPUT 1 This option handles the digital output CNA 4 It can be used one of four BRAKE it drives an electromechanical Brake _HYDROCONT it drives the contactor for a hydraulic steering function when the direction input or a movement of the truck is detected AF6ZPOAA COMBIACO 8 ACEO User Manual Page 35 76 Page 36 76 EX HYDRO it drives the contactor for a hydraulic steering function when the exclusive hydro input is active FREE it is not used 8 QUICK INVERSION It can be set NONE The quick inversion function is not managed no effect when CNA 7 switches over TIMED The quick inversion function is timed BELLY The quick inversion function is managed but not timed 9 SET MOTOR TEMPERATURE It can be set ANALOG An analogue sensor for the control of the motor temperature is connected to CNA 22 Typically the temperature sensor is a PTC positive thermal coeffici
68. lerator potentiometer wiper Input of the switch DI10 The input is activated when it is connected to Batt It doesn t have a default function Input of the switch DI8 The input is activated when it is connected to Batt The default function is the AF6ZPOAA COMBIACO 8 ACEO User Manual Page 23 76 Page 24 76 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 DI11 DIS DI1 DI12 THMOT EVP2 LOWER EVP PENC HORN OUT CANL CANH DI9 CPOTL NPOT DI4 DI3 EV3 EV4 DI7 controller LIFT enable input Input of the switch DI11 The input is activated when the external switch is closed to Batt In the Sense Coil version this input is connected to the AC motor sense coil 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 DI1 The input is activated when it is connected to Batt The default function is the controller DESCENT enable input Input of the switch DI12 The input is activated when the external switch is closed to Batt It doesn t have a default function In the Sense Coil version this input is connected to the AC motor sense coil Traction motor thermal sensor input The internal pull up is a fixed 2mA Max 5V source current Output of the se
69. 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 disconnected pe 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 AF6ZPOAA COMBIACO amp ACEO User Manual Page 17 76 a3 Protection and safety features 4 3 1 Protection features Page 18 76 The COMBI ACO ACEO 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 ax
70. nd 13 2 paragraphs Remember to re cycle the Key Switch if you make any changes to the chopper s configuration Step1 Step2 Step3 Step4 Step5 Step6 Step7 Step8 Step9 Step10 Step11 Step12 Step13 Step14 Fill your setting with the Options you need Select the Battery Voltage Check the correct installation of all wires Use the Console s TESTER function to assist Perform the accelerator signal acguisition procedure using the Console PROGRAM VACC Procedure is detailed on paragraph 13 3 Set the MAXIMUM CURRENT Current parameter Set the ACCELERATION DELAY requirements for the machine Test the parameters in both directions Set the FREQUENCY CREEP level starting from 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 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 RELEASE BRAKING Operate the machine at full speed Release the accelerator Adjust the level to your requirement If the machine is a forklift check the performance with and without load 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 i
71. ng The device or its driving circuit is damaged replace the controller 35 CONT DRV EV5 Cause The EV5 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller AF6ZPOAA COMBIACO 8 ACEO User Manual Page 75 76 13 RECOMMENDED SPARE PARTS po E C12532 AMPSEAL CONNECTOR 35 pins Female CE Na aaa SW 180 24V 929508 Single Pole Contactor EE SW 180 48V 929922 Single Pole Contactor Page 76 76 AF6ZPOAA COMBIACO 8 ACEO User Manual
72. nning check Motor connections If motor phases 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 3 VMN HIGH Cause 1 Before switching the LC on the software checks the power bridge it turns on alternatingly 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 If the motor connection are OK the problem is inside the controller B Ifthe problem 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 61 76 Page 62 76 4 5 6 7 8 9 controller POWER MOS SHORTED Cause Before switching the LC on the software checks the power bridge i
73. ns the electromechanical brake gets de energized braking the truck The Steps from 1 to 8 describe the installation operations that is mandatory to do in order your truck moves Obviously the ACE0 COMBI ACO may execute a wider set of optional services as 1 to handle some speed reductions requests 2 to handle an analogue 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 guick inversion 7 to handle a proportional input for the forks lifting lowering 8 to handle a second proportional electrovalve 9 to handle a number of on off E valves 10 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 AF6ZPOAA COMBIACO 8 ACEO User Manual 9 1 Seguence for Ac Inverter traction setting This section of the manual describes the basic ACEO COMBI ACO set up procedure using the hand set 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 a
74. nside the controller compartment AF6ZPOAA COMBIACO 8 ACEO User Manual 4 2 2 Wirings power cables The power cables length must be as short as possible to minimize power losses They must be tightened on controller power posts with a Torque of 13 15 Nm The COMBI AC 1 module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact the nearest Zapi Service Centre A 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 E 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 It 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 oe CAN Controller Transceiver 12042 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 shie
75. olic form ends 19 BRK SMOOTH It gives a parabolic form to the deceleration ramp 20 STOP BRK SMOOTH Hz It sets the level of freguency where the smooth effect of the deceleration parabolic form ends 21 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 22 HYDRO TIME Sec It determines the time duration the pump motor is driven after the hydraulic request is released 23 PUMP IMAX Level 0 to 9 Set the maximum current for the pump motor 24 PUMP ACCELERATION DELAY In seconds Set the acceleration ramp for the pump motor 25 PUMP DECELERATION DELAY In seconds Set the deceleration ramp for the pump motor 26 SPEED LIMIT Percentage It limits the maximum speed of the lifting function Percentage of the maximum voltage applied to the pump motor 27 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 28 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 29 MIN EVP 0 to 100 This par
76. ometer in its min output position 12 MAX LIFT This parameter stores the maximum voltage of lifting potentiometer output connected to CNA 30 The max value acquisition is done closing the Lift SW and bringing the potentiometer in its max output position 13 MIN LOWER This parameter stores the minimum voltage of lowering potentiometer output connected to CNA 30 The min value acquisition is done closing the DESCENT SW DI1 and bringing the potentiometer in its min output position AF6ZPOAA COMBIACO 8 ACEO User Manual Page 39 76 Page 40 76 14 MAX LOWER This parameter stores the maximum voltage of lifting potentiometer output connected to CNA 30 The min value acquisition is done closing the DESCENT SW DI1 and bringing the potentiometer in its min output position 15 PWM CHOP START This parameter stores the PWM value applied to MC coil and AUX COIL for the first second of the output activation It is expressed in percentage of battery voltage 16 PWM CHOP WORK This parameter stores the PWM value applied to MC coil and AUX COIL after the first second of the output activation It is expressed in percentage of battery voltage koji PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil connected to CNA 12 ON the PWM reduces the voltage on the main contactor coil down to the value programmed with PWM CHOP START and PWM CHOP WORK parameters S
77. ondition as a consequence the ACEO COMBIACO controller itself cannot enter an operative status but has to WAIT for the other controller coming out from the fault status 16 DEAD MAN ABSENT Cause This warning presents only in trucks with Dead Man switch appears when the Dead Man switch is open Troubleshooting At the next travel request with dead man switch close the warning disappears 17 CURRENT SENSOR LOW Cause The pump chopper current sensor feedback is too low below 0 5V Troubleshooting This type of fault is not related to external components replace the controller 18 VALVE COIL SHORTED Cause This alarm occurs when there is a short circuit on an on off valve coil Troubleshooting A lf the fault is present at start up it is very likely that the hw overcurrent protection circuit is damaged it is necessary to replace the controller B Ifthe fault is present when the controller drives the outputs the problem is located in the harness and in the coils AF6ZPOAA COMBIACO 8 ACEO User Manual 19 EV1 5 DRIVER SHORTED Cause Electrovalve EV1 or EV2 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 20 EV2 DRIVER SHORTED Cause Electrovalve EV2 driver is shorted Troubleshooting Check if there is a s
78. onnected to Batt With the logic hardware properly configured it can be used to supply the EB and MC positive The default function is the controller TILLER input Positive of the electromechanical brake coil Positive supply for electrovalves EV1 EV2 EV3 EV4 EV5 LOWER EVP1 EVP2 HORN OUT and with the logic hardware properly configured it can be used to supply the EB This input has to be supplied with positive taken after main contactor Electro mechanic brake coil driver output PWM controlled 2 5A maximum continuous current driving to Batt Negative of the Encoder Input of the switch DI2 The input is activated when the external switch is opened The default function is the controller CUTBACK input opening the switch truck speed is reduced Input of the switch DI6 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 Output of the ON OFF electrovalve EV5 1 5A maximum continuous current driving to Batt Output of the ON OFF electrovalve EV1 1 5A maximum continuous current driving to Batt Input of the key switch signal Output of the ON OFF electrovalve EV2 1 5A maximum continuous current driving to Batt Main contactor coil driver output PWM controlled 2 5A maximum continuous current driving to Batt Traction motor encoder phase B Traction motor encoder phase A Acce
79. pporting 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 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 SENSOR KO Cause 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 t
80. raking 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 63 76 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 SET BATTERY Cause At start up the controller checks the battery voltage and verify it is 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
81. roller 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 It is suggested to check the harness in order to verify if the Smart driver output CNA 2 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 This fault is displayed when the controller detects a low 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
82. s a Forklift repeat the tests and make adjustments with and without load The unloaded full speed condition should be the most representative condition Set the parameter MAX SPEED FORW Set the parameter MAX SPEED BACK Reverse Test the truck on the maximum ramp specification at full load 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 31 76 10 PROGRAMMING 8 ADJUSTMENTS USING DIGITAL CONSOLE 10 1 Adjustments via console Adjustment of Parameters and changes to the inverter s configuration are made using the Digital Console The Console is connected to the CND internal connector of the inverter 10 2 Description of console hand set amp connection INVERTER Cc CONNECTOR N SS CONSOLE CONNECTOR al DISPLAY 1 PARAM IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE 2 TESTE SES MAX SP SPEED I ea S PI SPEED II 3 SAVE S P SPEED II BYPASS FIELD WEAK 4 RESTORE IMOT O V POT h TEMP V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 ACCELERATOR 7 MOTOR DATA 4 3 5 Tt Ne ROLL ENTER SET BUTTONS S ROLL OUT SET lise D Gi ZAPI Page 32 76 AF6ZPOAA COMBIACO 8 ACEO User Manual 10 3 Description of the console menu
83. t turns on alternatingly 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 COIL SHORTED Cause This alarm occurs when there is a short circuit of one of the coils connected to outputs of the Combiac1 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 DRIVER SHORTED Cause The driver of the main contactor coil is shorted Troubleshooting A Check if there is a short or a low impedance pull down between NMCC CAN 17 in AmpSaab CAN 12 in AmpSeal and DATT B The driver circuit is damaged in the controller which has to be replaced 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 controll
84. t 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 A IZ E 7 V Z p J E N V V i P J Z V j j o V This function looks for and 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 53 76 Page 54 76 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 displ
85. tage 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 D dF gt AF6ZPOAA COMBIACO 8 ACEO User Manual Page 55 76 11 5 Description of the battery charge detection setting Page 56 76 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 24V NOMINAL BATTERY VOLTAGE DOLI A AF6ZPOAA COMBIACO 8 ACEO User Manual The Battery Charge detection follows this algorithm 1 Battery voltages is read when the Battery current is zero that is when the output power stage is not driven 2 Vbatt is the mean of the least samples measured by the microcontroller converter the samples are took on key input 3 Vbatt is compared with a threshold value function of the actual c
86. tage on the wiper of the accelerator CPOT on CNA 24 in AmpSaab version CNA 15 in AmpSeal version 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 LIFTING CONTROL From 0 0 to 5 0V The voltage on the wiper of the accelerator CPOTLIFT on CNA 25 AmpSaab connector CNA 30 AmpSeal connector 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 16 DIO TILLER SWITCH ON OFF This is the level of the digital input CNA 6 in AmpSaab connector CNA 29 in AmpSeal connector 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 17 DI1 DESCENT SWITCH ON OFF This is the level of the digital input CNA 5 in AmpSaab connector CNA 20 in AmpSeal connector for the Lowering request ON VB When it is closed to a battery key voltage the Lowering request is Active OFF GND
87. 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 27 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 28 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 29 EVP1 COIL OPEN Cause This fault appears when the LOWER EVP1 output is used parameter EVP TYPE in SET OPTION menu is set ANALOG or DIGITAL but no load is
88. tion Valve or pump or opened Eb applied traction request Vmn high Motor output voltage higher than expected Valve pump traction stopped Lc start up traction Valve or pump or opened Eb applied traction request Power mos Short circuit on the power mosfets Valve pump traction stopped Le start up Valve or pump or shorted opened Eb applied traction request Coil shorted Shortcircuit on LC or EB coil Valve pump traction stopped Le stby traction Valve or pump or opened Eb applied traction request Driver shorted Driver of Lc coil is shorted so it is not able to open the LC Valve pump traction stopped Le start up Valve or pump or opened Eb applied traction request Contactor Driver of Lc coil is damaged not able to close Valve pump traction stopped Le stby traction Valve or pump or Driver opened Eb applied traction request Contactor The Lc coil has been driven but LC does not close Valve pump traction stopped Le stby traction Valve or pump or Open opened Eb applied traction request Contactor LC contact is stuck Valve pump traction stopped Le start up Valve or pump or closed opened Eb applied traction request Aux driv Shrt When the mos of EB is shorted Valve pump traction stopped Le start up stby marcia Valve or pump or opened Eb applied traction request Aux driver Driver of EB coil is damaged not able to close Valve pump traction stopped Le stby traction Valve or pump or open opened Eb applied traction r
89. 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 MOD O1 FREE Press ENTER to commence SAVE routine 5 m i You can see the items that are being stored whilst READING the SAVE routine is happening ACCEL DELAY ECC SELECT MOD O1 When finished the Console shows CREE Press OUT to return to the Opening Zapi Display s AF6ZPOAA COMBIACO amp ACEO User Manual Page 51 76 EY NOTE in reality the SAVE and RESTORE function requires the Windows PC Console 11 2Description of console RESTORE function Page 52 76 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 f ae CAOZ2A ZP1 00 Opening Zapi Display 24V 200A 00000 OMO Press ENTER to go into the General menu Bm BE MAIN MENU PARAMETER GHANGE The Displ
90. uld be in the 1 5mA to 30 mA range The CPOTL CNA 30 signal range is from 0 to 10V Use CNA 25 positive and CNA 5 negative to supply it 3 4 Analogue motor thermal sensor input Input CNA 22 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 AF6ZPOAA COMBIACO 8 ACEO User Manual Page 9 76 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 COMBI ACO ACEO could also be used without encoder 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 CAOZ2A ZP1 00 That means CA0Z COMBIACO 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 76 AF6ZPOAA COMBIACO 8 ACEO User Manual
91. ut to CPOT1 CNA 15 signal range is from 0 to 10V If the pedal wire disconnection diagnosis is implemented PEDAL WIRE KO warning the negative supply of the potentiometer has to be taken from NPOT CNA 30 otherwise has to be taken from CNA 5 GND Potentiometer value should be in the 0 5 10K range generally the load should be in the 1 5mA to 30mA range Faults can occur if it is outside this range Page 8 76 AF6ZPOAA COMBIACO 8 ACEO User Manual The standard connection for the potentiometer is the one in the Left side 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 Travel demand switches The Procedure for automatic potentiometer signal acguisition 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 CNA 30 can be used as analogue input the PEDAL WIRE KO warning is lost 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 10K range Generally the load sho
92. ve or pump or opened Eb applied traction request Tiller error Input mismatch between hard amp soft switch input and tiller Valve pump traction stopped Lc start up stby Valve or pump or input opened Eb applied traction traction request Watchdog One of two or both Watchdog circuit outputs becomes Valve pump traction stopped Le start up stby Key re cycle high due to an HW or SW problem opened Eb applied traction AF6ZPOAA COMBIACO 8 ACEO User Manual Page 59 76 Error code Smart driver Smart driver is open not able to provide EB positive Key off signal is low at Key on Evp driver is failed shorted always ON mismatch between the valve set point and tits feedback iEvp2 driver is failed shorted always ON imismatch between the valve set point and tits feedback to pwm applied to pwm applied Description Pump motor output is too low with respect Pump motor output is too high with respect Effect valve pump traction stopped Lc opened ivalve pump traction istopped Lc opened ivalve pump traction istopped Lc opened IER applied ivalve pump traction istopped Lc opened IER applied ivalve pump traction istopped Lc opened IER applied ivalve pump traction istopped Lc opened Eb applied Machine status when the test is done start up stby istart up stby start up stby during pump function during pump function Restart procedure Key

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