ZAPI AC-1 Manual

COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA

Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - E-mail: [email protected]
AC1 INVERTER
OPERATING HANDBOOK
AND FUNCTION DESCRIPTION
INDEX
1
2
Page
Introduction .................................................................................................... 3
Specification .................................................................................................. 3
2.1 Technical specifications ........................................................................ 3
2.2 Control unit ............................................................................................ 4
2.2.a Microswitches ............................................................................... 4
2.2.b Accelerator unit ............................................................................. 4
2.2.c Other analog control unit ............................................................... 5
2.2.d Speed feedback............................................................................ 5
2.3
Protection features
2.4
2.5
2.6
Operational features .............................................................................. 7

Diagnosis .............................................................................................. 8
Thermal consideration ........................................................................... 8
2.7
General instructions and precautions
2.8
Susceptibility and electromagnetic emission
.......................................................................... 6
. ............................................ 8
................................. 9
2.9 Main contactor and emergency switch .................................................. 9

Installation .................................................................................................... 10
3.1 Connection cables .............................................................................. 10
3.2 Contactors ........................................................................................... 10
3.3 Fuses .................................................................................................. 10
3.4 Description of connectors - Standard version ..................................... 11
3.5 Description of connectors - MDI PRC Version ..................................... 13
3.6 Encoder installation ............................................................................. 15
3.7 Description of power connections ....................................................... 16
3.8 Mechanical drawing ............................................................................ 17
3.9 Connection drawing - Standard Version .............................................. 18
3.10 Connection drawing - MDI PRC Version ............................................. 19
Programming & Adjustments using Digital Console................................ 20
4.1 Adjustments via Console ..................................................................... 20
4.2 Description of Console & Connection ................................................. 20
4.3 Description of Standard Console Menu ............................................... 21
4.3.a Standard Version ........................................................................ 21
4.3.b MDI PRC Version ....................................................................... 22
4.4 Function configuration ......................................................................... 23
4.4.a Standard Version ........................................................................ 23
4.4.b MDI PRC Version ....................................................................... 28
4.5 Parameter regulation: Standard Version ............................................. 37
4.6 Parameter regulation: MDI PRC Version ............................................. 39
4.7 Programming console functions .......................................................... 43
4.8 Sequence for Ac Inverter Traction setting ............................................ 44
4.9 Tester: description of the function; Standard Version .......................... 45
4.10 Tester: description of the function; MDI PRC Version .......................... 48
2=CA
6
7
8
Other functions ............................................................................................ 51

5.1 Description of the Console Save function ............................................ 51
5.2 Description of Console Restore function. ............................................ 52
5.3 Description of Alarms menu ................................................................ 53
5.4 Description of Console Program Vacc function ................................... 54
Ac1 Inverter diagnostic ............................................................................... 55
6.1 Analysis of alarms displayed on console ............................................ 55
Recommended Spare parts for inverter .................................................... 60
Periodic Maintenance to be repeated at times indicated. ......................... 61
The informations included into the marked paragraphs by this symbol are
essential for the safety.
SIGNATURES TABLE
COMPANY DEPT. SERVICES
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publications N: ADTZP0BA
Edition: November 2000
2=CA
MANAGEMENT EXECUTIVE
1 INTRODUCTION
Within the ZAPIMOS family, the AC1 inverter is the model suitable for control of 700W to
2.5kW motors. It has been expressly designed for battery electric traction.
It is fit for electric transpallet, golf cars, utility cars.
2 SPECIFICATION
2.1 TECHNICAL SPECIFICATIONS
Inverter for AC asyncronous 3-phase motors
Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage: ................................................................................................ 24 - 36 - 48V
Maximum current (24V,36V): ........................................................ 250A (RMS) for 2'
Maximum current (48V): ............................................................... 180A (RMS) for 2'
Booster (all version) ............................10% of maximum current for some seconds;
Operating frequency: ........................................................................................ 8kHz
External temperature range: ................................................................ -30C 40C
Maximum inverter temperature (at full power): .................................................. 75C
BLOCK DIAGRAM
2=CA!
2.2 CONTROL UNIT

2.2.a Microswitches
- The microswitches must have a contact resistance lower than 0.1 and a leakage
current lower than 100A.
- When full load connected, the voltage between the key switch contacts must be lower
than 0.1V.
- The microswitches send a voltage signal to the microprocessor when a function
request (for ex.: running request) is made.
2.2.b Accelerator unit
The accelerator unit can consist of a potentiometer or an Hall effect device.
It should be in a 3-wire configuration.
CPOT (B10) signal ranges from 0 to 10V.
Potentiometer value should be in the 0.5 - 10 Kohm range; generally, the load should be
in the 1.5mA to 30 mA range. Faults can occur if it is outside this range.
The Procedure for automatic potentiometer signal aquisition is carried out using the
Console. This enables adjustment of the minimum and maximum useful signal level
(PROGRAM VACC function), 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 sequence of procedure is described in the programming console manual.
2=CA"
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical zero of the control lever. MI and MA indicate the point where
the direction switches close. 0 represents the mechanical zero of the rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
aquisition being made. The Right Hand Graph shows the same relationship after signal
aquisition of the potentiometer.
2.2.c Other analog control unit
Input A18 is an analog input, whose typical application is for proportional braking. It
should be in a 3 wire configuration. Potentiometer value should be in the 0.5-10KW
range. Generally, the load should be in the 1.5mA to 30 mA range.
The CPOTB (A18) signal range is from 0 to 10V.
2.2.d Speed feedback
The motor control is based upon the motor speed feedback. The speed trasducer is an
incremental encoder, with two phases shifted at 90. The encoder can be of different
types :
- power supply:
+5V or +12V
-
electric output:
open collector ( NPN or PNP), push-pull.
For more details about encoder installation see also chapter 3.6.
2=CA#
2.3 PROTECTION FEATURES

- Battery polarity inversion:
It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse
battery polarity and for safety reasons.
- Connection Errors:
All inputs are protected against connection errors.
- Thermal protection
If the chopper temperature exceeds 75C, the maximum current is reduced in
proportion to the thermal increase. The temperature can never exceeds 100C.
- External agents:
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP54.
- Protection against uncontrolled movements:
The main contactor will not close if:
- The Power unit is not functioning.
- The Logic is not functioning perfectly.
- the output voltage of the accelerator does not fall below the minimum voltage value
stored, with 1V added.
- Running microswitch in closed position.
- Low battery charge:
when the battery charge is low, the maximum current is reduced to the half of the
maximum current programmed.
- 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
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2.4 OPERATIONAL FEATURES

- Speed control.
- Optimum behaviour an a slope due to the speed feedback:
- the motor speed follows the accelerator, starting a regenerative braking if the
speed overtakes the speed set-point.
- the system can perform an electrical stop on a ramp (the machine is electrically
hold on a slope) for a programmable time (see also chapter 4)
- 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 analog 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.
- Self diagnosis with indication of the fault shown by a flashing led.
- 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.
2=CA%
2.5 DIAGNOSIS
The microprocessor continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points
1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor charging, phase's voltages, contactor drives, can-bus interface, if the switch
sequence for operation is correct and if the output of accelerator unit is correct.
2) Standby diagnosis at rest that checks: watchdog circuit, phase's voltages, contactor
driver, current sensor, can-bus interface.
3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current
sensors, can-bus interface.
4) Continuos diagnosis that check: temperature of the inverter, motor temperature.
Diagnosis is 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.
2.6 THERMAL CONSIDERATION
- 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.
2.7 GENERAL INSTRUCTIONS AND PRECAUTIONS
- Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER

because the ASYNCHRONOUS filter capacitors alter the SCR choppers' work. If it is
necessary to use two or more control units (traction + lift. for ex.), they must belong to
the ZAPIMOS family.
- Do not connect the inverter to a battery with a nominal value different from the value
indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it is
lower, the control unit does not "power up".
- During battery charge, disconnect ASYNCHRONOUS from the battery.
- Supply the ASYNCHRONOUS only with battery for traction; do not use a power
supply.
- When the chopper is installed, make tests with the wheels raised from the ground, in
order to avoid dangerous situations due to connection errors.
- After the chopper is switched off (key off), the filter capacitor remains charged for
some minutes; if you need to work on the inverter, discharge them using a
10 100 resistance connected from the +Batt to the -Batt.
2=CA&
2.8 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION

Electromagnetic susceptibility and emission 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. Therefore ZAPI declines any responsibility for
noncompliance if correct testing is not made (the irradiated emission directive is
EN50081-2).
2.9 MAIN CONTACTOR AND EMERGENCY SWITCH
- The connection of the battery line switches must be carried out following ZAPI instructions.
- If a mechanical battery line switch is installed, it is necessary that the key supply to
the inverter is open together with power battery line; 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.
2=CA'
3 INSTALLATION
Install the chopper with the base-plate on a flat metallic surface that is clean and
unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to
permit better heat dissipation.
Ensure that the wiring of the cable terminals and connectors is carried out correctly.
Fit transient suppression devices to the horn, solenoid valves, and contactors not connected to the chopper such as those for activating the pump motor or steering motor.
3.1 CONNECTION CABLES
For the auxiliary circuits, use cables of 0.5mm section.
For power connections to the motor and to the battery, use cables having section
of 16 mm (as a minimum).
For the optimum inverter performance, the cables to the battery should be run side by
side and be as short as possible.
3.2 CONTACTORS
The main contactor must be installed. Depending on the setting of a parameter (see
option menu):
- 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 cicle; this feature is useful to decrease the power dissipation of the contactor coil.
3.3 FUSES
- Use a 6.3A Fuse for protection of the auxiliary circuits.

- For protection of the power unit, refer to diagrams.. The Fuse value shown is the
maximum allowable. For special applications or requirements these values can be
reduced.
- For Safety reasons, we recommend the use of protected fuses in order to prevent the
spread of fused particles should the fuse blow.
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3.4 DESCRIPTION OF CONNECTORS - STANDARD VERSION
A1
NLC
Negative of main contactor coil.
A2
PLC , PEB
Positive of main contactor coil and electromechanical brake coil.
A3
NBRAKE
Output for driving the electromechanical brake coil; drives the load
to -Batt. Maximum current : 3A.
A4
NPC
Negative of pump contactor coil.
A5
PPC , PEV
Positive of pump contactor coil and lowering electrovalve coil.
A6
NEV
Negative of the lowering electrovalve coil.
A7
CAN-L
Low level CAN-BUS voltage I/O.
A8
NPOTB
-Batt.
A9
ENCODER
Incremental ENCODER (see chapter 3.6).
A10 ENCODER
A11 HM
Output for driving an hourmeter; when the hourmeter is active this

output provides a +Batt signal; 3A maximum current.
A12 -BATT
-Batt.
A13 SR1
Speed reduction 1 input. Active low (switch opened).
A14 SR2

2=CA
A15 SR3
A16 +12V
This output provides a +12V signal for thr MDI PRC, if present;
100mA maximum current.
A17 CAN-H
High level CAN-BUS voltage I/O.
A18 CPOTB
Brake potentiometer wiper.
A19 ENCODER
A20 ENCODER
B1
KEY
Connected to the power supply through a microswitch (KEY) with a

10A fuse in series.
B2
CM
Common of FW / BW / SR1 / SR2 / SR3 / TILLER / H&S / BELLY /

LIFTING / LOWERING microswitches.
B3
TILLER
Tiller request input. Must be connected to the tiller microswitch,

active high.
B4
H&S
Hard & Soft request input. Must be connected to the Hard & Soft
microswitch, active high.
B5
BACKWARD
Backward direction request input. Must be connected to the backward direction microswitch, active high.
B6
FORWARD
Forward direction request input. Must be connected to the forward

direction microswitch, active high.
B7
BELLY
Quick inversion function input; must be connected to the Belly

microswitch; it is active high.
B8
LOWERING
Lowering request input, active high.
B9
LIFTING
Lifting request input, active high.
B10 CPOT
Accelerator potentiometer wiper.
B11 NPOT
Negative of accelerator unit, tested for wire disconnection diagnosis.
B12 PPOT
Potentiometer positive: 10V output; keep load > 1K.
C1
PCLRXD
Positive serial reception.
C2
NCLRXD
Negative serial reception.
C3
PCLTXD
Positive serial transmission.
C4
NCLTXD
Negative serial transmission.
C5
GND
Negative console power supply.
C6
+12
Positive console power supply.
C7
FLASH
Must be connected to C8 for the Flash memory programming (if

used).
C8
FLASH

used).
2=CA
3.5 DESCRIPTION OF CONNECTORS - MDI PRC VERSION
A1
NLC
Negative of main contactor coil.
A2
PLC , PEB
Positive of main contactor coil and electromechanical brake coil.
A3
NBRAKE
Output for driving the electromechanical brake coil; drives the load
to -Batt. Maximum current : 3A.
A4
NPC
Negative of pump contactor coil.
A5
PPC , PEV
Positive of pump contactor coil the auxiliary output load.
A6
NEV
Negative of the auxiliary output.
A7
CAN-L
Low level CAN-BUS voltage I/O.
A8
NPOTB
-Batt.
A9
ENCODER
A10 ENCODER
A11 PEV (+B)
This output provides a +Batt for the electrovalves coils connected

to the MDI PRC; 3A maximum current.
A12 -BATT
-Batt.
A13 SR1
A14 LIFT AUX.
Auxiliary lifting request input, active high.

2=CA!
A15 LOW AUX.
Auxiliary lowering request input, active high.
A16 +12V
This output provides a +12V signal for thr MDI PRC; 100mA maximum current.
A17 CAN-H
High level CAN-BUS voltage I/O.
A18 CPOTB
Proprtional electrovalves potentiometer wiper.
A19 ENCODER
A20 ENCODER
B1
KEY
Connected to the power supply through a microswitch (KEY) with a

10A fuse in series.
B2
CM
Common of FW / BW / SR1 / LIFT AUX / LOW AUX / TILLER /

H&S / BELLY / LIFTING / LOWERING microswitches.
B3
TILLER
Tiller request input. Must be connected to the tiller microswitch,

active high.
B4
H&S
Hard & Soft request input. Must be connected to the Hard & Soft
microswitch, active high.
B5
BACKWARD
Backward direction request input. Must be connected to the backward direction microswitch, active high.
B6
FORWARD
Forward direction request input. Must be connected to the forward

direction microswitch, active high.
B7
BELLY
Quick inversion function input; must be connected to the Belly

microswitch; it is active high.
B8
LOWERING
Lowering request input, active high.
B9
LIFTING
Lifting request input, active high.
B10 CPOT
Accelerator potentiometer wiper.
B11 NPOT
Negative of accelerator unit, tested for wire disconnection diagnosis.
B12 PPOT
Potentiometer positive: 10V output; keep load > 1K.
C1
PCLRXD
Positive serial reception.
C2
NCLRXD
Negative serial reception.
C3
PCLTXD
Positive serial transmission.
C4
NCLTXD
Negative serial transmission.
C5
GND
Negative console power supply.
C6
+12
Positive console power supply.
C7
FLASH

used).
C8
FLASH

used).
2=CA"
3.6 ENCODER INSTALLATION

1) AC1 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.
A9
+5V/+12V
positive of encoder power supply.
A10
GND
negative of encoder power supply.
A19
phase A of encoder.
A20
phase B of encoder.
2) Connection of encoder with open collector output; +5V power supply.
3) Connection of encoder with open collector output: +12V power supply.
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.
2=CA#
3.7 DESCRIPTION OF POWER CONNECTIONS

View of the power bars:
-BATT
+BATT
U; V; W
2=CA$
Negative of the battery.

Positive of the battery.
Connection bars of the three motor phases; follow this sequence and the
indication on the motor.
3.8 MECHANICAL DRAWING
2=CA%
3.9 CONNECTION DRAWING - STANDARD VERSION
2=CA&
3.10 CONNECTION DRAWING - MDI PRC VERSION
2=CA'
4 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE

4.1 ADJUSTMENTS VIA CONSOLE
Adjustment of Parameters and changes to the inverters configuration are made using
the Digital Console. The Console is connected to the C connector of the inverter.
4.2 DESCRIPTION OF CONSOLE & CONNECTION
Digital consoles used to comunicate with AC inverter controllers must be fitted with
EPROM CK ULTRA, minimum "Release Number 3.02".
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4.3 DESCRIPTION OF STANDARD CONSOLE MENU

4.3.a Standard Version
2=CA
4.3.b MDI PRC Version
2=CA
4.4 FUNCTION CONFIGURATION

4.4.a Standard Version
SUBMENU "SET OPTIONS"

1
TILLER SWITCH
- HANDLE
input B3 is managed as a tiller input.
- SEAT
input B3 is managed as a seat input.
SET INPUT #1
- PRESENT:
input A13 is managed as a cutback speed input.
- OPTION #1:
input A13 is managed as an handbrake input.
SET INPUT #2
- PRESENT:
- OPTION #1:
input A14 is managed as an "Inching Forward" input.
SET INPUT #3
- PRESENT:
- OPTION #1:
input A15 is managed as an "Inching Backward" input.
SET INPUT #4
- BELLY:
input B7 is managed as a belly input.
- BRAKE:
input B7 is managed as a service brake input.
- EX. HYDRO:
input B7 is managed as a "Exclusive Hydro" input.
HOUR COUNTER
- RUNNING:
the counter registers travel time only.
- KEY ON:
the counter registers when the "key" switch is closed.
BATTERY CHECK
- ON:
the battery discharge level check is carried out; when the

battery level reaches 10%, an allarm is signalled and the
maximum current is reduced to the half of the programmed
value.
- OFF:
the battery discharge level check is carried out but no allarm

is signalled.
HYDRO KEY ON
- ON / OFF:
if this option is programmed ON the traction inverter manages

an hydraulic steering function when the "key" is switched ON
(only if the "aux output #1" option is programmed as "hydro
contactor" or as "exclusive hydro").
2=CA !
STOP ON RAMP
- ON:
the stop on ramp feature (truck electrically hold on a ramp) is

managed for a time established by "auxiliary time" parameter.
After this time, the behaviour depends on the "aux output #1"
option programmation (see also the following table).
- OFF:
the stop on ramp feature is not performed.
10
AUX OUTPUT #1
- BRAKE:
output A3 drives an electromagnetic brake coil (see also the

table below).
- HYDRO CONT.:
the inverter manages an hydraulic steering function when the

direction input or brake pedal input are active or a movement
of the truck is detected.
- EX. HYDRO:
output A3 drives an hydraulic steering function when the

exclusive hydro input is active.
11
PEDAL BRAKING
- ANALOG:
Option "Set input #4" programmed "Belly":

the mechanical brake pedal has a potentiometer installed.
When the accelerator is released and the pedal brake is
pushed the inverter performs an electrical braking whose
intensity is proportional to the brake pedal potentiometer. The
minimum intensity is established by the "Release braking"
parameter, when the brake pedal is slightly pressed (brake
potentiometer at the minimum). The maximum intensity is
established by the "Pedal braking" parameter when the brake
pedal is fully pressed (brake potentiometer at the maximum).
In the middle positions, the electrical braking intensity is a
linear function between minimum and maximum intensity.
Option "Set input #4" programmed "Brake":
the mechanical brake pedal has a switch and a potentiometer
installed. When the accelerator is released and the pedal
brake is pushed the inverter performs an electrical braking
whose intensity is proportional to the brake pedal
potentiometer. The minimum intensity is established by the
"Release braking" parameter, when the brake pedal is
slightly pressed (brake switch closed but brake potentiometer
at the minimum). The maximum intensity is established by the
"Pedal braking" parameter when the brake pedal is fully
pressed (brake potentiometer at the maximum). In the middle
positions, the electrical braking intensity is a linear function
between minimum and maximum intensity.
- DIGITAL:
The truck does not have a potentiometer installed on the

mechanical brake pedal, but only a microswitch; when the
accelerator pedal is released and the brake pedal is pushed
(brake switch closed), the inverter performs an electrical
braking following "Pedal braking" parameter.
2=CA "
- NONE:
12
Means that there aren't any switch or potentiometer installed

on the brake.
QUICK INVERSION
- NONE
The quick inversion function is not managed.
- TIMED
The quick inversion function is timed.
- BELLY
The quick inversion function is managed but not timed.
13
AUX VOLTAGE #1
- %
14
this parameter permits to program the supply voltage of the

main contactor coil and the electromechanical brake.
PERFORMANCE
- OPTION #1
Set of parameter which determines a "Low Performance".
- OPTION #2
Set of parameter which determines a "High Performance".
SOTTOMENU' "ADJUSTMENT"
1 SET POT BRK MIN:
records the minimum value of braking pedal potentiometer

when the braking pedal switch is closed; the procedure is
similar to the "Program Vacc" function (see chapter 5.4). This
procedure must be carried out only if the "Pedal braking"
option is programmed as "Analog".
2 SET POT BRK MAX:
records the maximum value of braking pedal potentiometer

when the braking pedal is fully pressed; the procedure is
similar to the "Program Vacc" function (see chapter 5.4). This
procedure must be carried out only if the "Pedal braking"
option is programmed as "Analog".
3 SET BATTERY TYPE: selects the nominal battery voltage;

4 ADJUST BATTERY:
fine adjustement of the battery voltage measured by the

controller.
5 THROTTLE 0 ZONE:
establishes a deadband in the accelerator input curve (see

also curve below).
6 THROTTLE X POINT: These parameter change the characteristic of the accelerator

input curve.
2=CA #
7 THROTTLE Y POINT: These parameter change the characteristic of the accelerator

input curve.
VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.
8 ADJUSTMENT #01:
adjust the upper level of the battery discharge table.
9 ADJUSTMENT #02:
adjust the lower level of the battery discharge table.
10 LOAD HM FROM MDI: for an explanation of this point see the MDI instrument
handbook
11 CHECK UP DONE:
for an explanation of this point see the MDI instrument

handbook
12 CHECK UP TYPE:

handbook
2=CA $
AUX
OUTPUT
BRAKE
BRAKE
HYDRO
CONT.
HYDRO
CONT.
EXCL.
HYDRO
EXCL.
HYDRO
STOP
ON
RAMP
A3
OUTPUT
BEHAVIOUR ON A SLOPE
ON
The truck is electrically hold on a

slope; when the time set by
"auxiliary time" parameter is elapsed
-Drives the coil of a electromagnetic
the brake is applied and the 3brake.
phase bridge is released. Do not
use this combination if the
negative brake is not installed.
OFF
The truck is not electrically hold on

a slope, but comes down very
slowly; when the time set by
-Drives the coil of a electromagnetic "auxiliary time" parameter is
brake.
elapsed, the brake is applied and
the 3-phase bridge is opened. Do
not use this combination if the
ON
-Drives the coil of a hydraulic

steering contactor.

"auxiliary time" parameter is
elapsed, the truck comes down very
slowly, till the flat is reached.
OFF

steering contactor.

slowly till the flat is reached.
ON

steering contactor.

OFF

steering contactor.

2=CA %
4.4.b MDI PRC Version

SUBMENU "SET OPTIONS"
1
TILLER SWITCH
- HANDLE
input B3 is managed as a tiller input.
- SEAT
input B3 is managed as a seat input.
SET INPUT #1
- PRESENT:
- OPTION #1:
input A13 is managed as an handbrake input.
SET INPUT #4
- BELLY:
input B7 is managed as a belly input.
- BRAKE:
input B7 is managed as a service brake input.
- EX. HYDRO:
input B7 is managed as a "Exclusive Hydro" input.
HOUR COUNTER
- RUNNING:
the counter registers travel time only.
- KEY ON:
the counter registers when the "key" switch is closed.
BATTERY CHECK
- ON:
the battery discharge level check is carried out; when the

battery level reaches 10%, an allarm is signalled and the
maximum current is reduced to the half of the programmed
value.
- OFF:
the battery discharge level check is carried out but no allarm

is signalled.
HYDRO KEY ON
- ON / OFF:
if this option is programmed ON the traction inverter manages

an hydraulic steering function when the "key" is switched ON
(only if the "aux output #1" option is programmed as "hydro
contactor" or as "exclusive hydro").
STOP ON RAMP
- ON:
the stop on ramp feature (truck electrically hold on a ramp) is

managed for a time established by "auxiliary time" parameter.
After this time, the behaviour depends on the "aux output #1"
option programmation (see also the following table).
- OFF:
the stop on ramp feature is not performed.
2=CA &
8 AUX OUTPUT #1
- BRAKE:
output A3 drives an electromagnetic brake coil (see also the

table below).
- HYDRO CONT.:
the inverter manages an hydraulic steering function when the

direction input or brake pedal input are active or a movement
of the truck is detected.
- EX. HYDRO:
output A3 drives an hydraulic steering function when the

exclusive hydro input is active.
9 PEDAL BRAKING
- ANALOG:
Option "Set input #4" programmed "Belly":

the mechanical brake pedal has a potentiometer installed.
When the accelerator is released and the pedal brake is
pushed the inverter performs an electrical braking whose
intensity is proportional to the brake pedal potentiometer. The
minimum intensity is established by the "Release braking"
parameter, when the brake pedal is slightly pressed (brake
potentiometer at the minimum). The maximum intensity is
established by the "Pedal braking" parameter when the brake
pedal is fully pressed (brake potentiometer at the maximum).
In the middle positions, the electrical braking intensity is a
linear function between minimum and maximum intensity.
Option "Set input #4" programmed "Brake":
the mechanical brake pedal has a switch and a potentiometer
installed. When the accelerator is released and the pedal
brake is pushed the inverter performs an electrical braking
whose intensity is proportional to the brake pedal
potentiometer. The minimum intensity is established by the
"Release braking" parameter, when the brake pedal is
slightly pressed (brake switch closed but brake potentiometer
at the minimum). The maximum intensity is established by the
"Pedal braking" parameter when the brake pedal is fully
pressed (brake potentiometer at the maximum). In the middle
positions, the electrical braking intensity is a linear function
between minimum and maximum intensity.
- DIGITAL:
The truck does not have a potentiometer installed on the

mechanical brake pedal, but only a microswitch; when the
accelerator pedal is released and the brake pedal is pushed
(brake switch closed), the inverter performs an electrical
braking following "Pedal braking" parameter.
- NONE:
Means that there aren't any switch or potentiometer installed

on the brake.
10
QUICK INVERSION
- NONE
The quick inversion function is not managed.
- TIMED
The quick inversion function is timed.
- BELLY
The quick inversion function is managed but not timed.

2=CA '
11
AUX VOLTAGE #1
- %
12
this parameter permits to program the supply voltage of the

main contactor coil and the electromechanical brake.
PERFORMANCE
- OPTION #1
Set of parameter which determines a "Low Performance".
- OPTION #2
Set of parameter which determines a "High Performance".
13
VALVE 1 TYPE
- OPTION #1
Electrovalve n1 is an On/Off valve.
- OPTION #2
Electrovalve n1 is a proportional valve.
14
VALVE 2 TYPE
- OPTION #1
Electrovalve n2 is an On/Off valve.
- OPTION #2
Electrovalve n2 is a proportional valve.
SOTTOMENU' "ADJUSTMENT"
1 MIN LIFT:
records the minimum value of the lifting proportional

potentiometer when the "Lift" switch is closed;
2 MAX LIFT:
records the maximum value of the lifting proportional

potentiometer.
3 MIN LOWER:
records the minimum value of the lowering proportional

potentiometer when the "Lower" switch is closed;
4 MAX LOWER:
records the maximum value of the lowering proportional

potentiometer.
3 SET BATTERY TYPE: selects the nominal battery voltage;

4 ADJUST BATTERY:
fine adjustement of the battery voltage measured by the

controller.
5 THROTTLE 0 ZONE:
establishes a deadband in the accelerator input curve (see

also curve below).
6 THROTTLE X POINT: These parameter change the characteristic of the accelerator

input curve.
2=CA!
7 THROTTLE Y POINT: These parameter change the characteristic of the accelerator

input curve.
VACC MIN and VACC MAX are values programmable by the "Program Vacc" function.
8 ADJUSTMENT #01:
adjust the upper level of the battery discharge table.
9 ADJUSTMENT #02:
adjust the lower level of the battery discharge table.
11 CHECK UP DONE:

handbook
12 CHECK UP TYPE:

handbook
2=CA!
AUX
OUTPUT
BRAKE
BRAKE
STOP
ON
RAMP
A3
OUTPUT
BEHAVIOUR ON A SLOPE
ON

"auxiliary time" parameter is elapsed
-Drives the coil of a electromagnetic
the brake is applied and the 3brake.
phase bridge is released. Do not
use this combination if the
OFF

slowly; when the time set by
-Drives the coil of a electromagnetic "auxiliary time" parameter is
brake.
elapsed, the brake is applied and
the 3-phase bridge is opened. Do
not use this combination if the
HYDRO
CONT.
ON

steering contactor.

HYDRO
CONT.
OFF

steering contactor.

EXCL.
HYDRO
ON

steering contactor.

EXCL.
HYDRO
OFF

steering contactor.

2=CA!
Flow chart showing how to make changes to OPTION Menu.

1) Opening Zapi Menu
2) Press Top Left & Right Buttons to enter
SET Menu.
3) The Display will show: SET MODEL
4) Press ROLL UP or ROLL DOWN button
until SET MODEL Menu appears.
5) SET OPTIONS appears on the display.
6) Press ENTER to go into the
SET MODEL Menu.
7) The display will shows the first OPTION.
until desired OPTION appears
9) Desired OPTION appears.
10) Press SET UP or SET DOWN button in
order to modify the changes.
11) New OPTION appears.
12) Press OUT to exit the Menu.
13) Confirmation request appears.
14) Press ENTER to accept the changes,
or press OUT if you do not accept
the changes.
15) SET OPTIONS Menu appears.
16) Press OUT again. Display now show the
Opening Zapi Menu.
2=CA!!
Flow chart showing how to make changes to ADJUSTMENT Menu

CONFIG Menu.
3) The display will show: SET MODEL
until ADJUSTMENTS Menu appears.
5) ADJUSTMENTS appears on the display.
6) Press ENTER to go into the ADJUSTMENTS
Menu.
7) The display will shows SET BATTERY TYPE.
8) Press ROLL UP or ROLL DOWN button until
the desired parameter is reached.
9) The desired parameter is appears.
10) Press SET UP or SET DOWN button to modify
the adjustment.
11) Press OUT.

12) Press ENTER to confirm.
13) Repeat the same from 5 to 12 points for the
other adjustment.
2=CA!"
Flow chart showing how to use the SET BATTERY TYPE adjustment
CONFIG Menu.
4) Press ROLL UP button until
ADJUSTMENTS. menu appears.
5) ADJUSTMENTS appears on the display.
6) Press ENTER to go into the ADJUSTMENTS
Menu.
7) The display will show: SET BATTERY TYPE.
8) Press SET UP to choose nominal value of
the battery.
9) New battery value appears.
10) Press OUT.
12) Press ENTER to accept the changes, or press
OUT if you do not accept the changes.
13) Press OUT. Display now shows the Opening
Zapi Menu.
2=CA!#
Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console.
CONFIG Menu.
4) Press ROLL UP button until
ADJUSTMENT Menu appears.
5) ADJUSTMENTS appears on the
display.
ADJUSTMENTS Menu.
7) The display will show the first
OPTION.
until desired OPTION appears
9) ADJUST BATTERY appears.
10) Press SET UP or SET DOWN button
in order to increase or decrease
respectively. Set the value read
by an external meter.
11) Battery value appears on the display.
12) Press OUT to exit the Menu.
14) Press ENTER to accept the changes,
or press OUT if you do not accept the
changes.
15) ADJUSTMENTS Menu appears.
16) Press OUT. Display now show the Opening Zapi Menu.
2=CA!$
4.5 PARAMETER REGULATION: STANDARD VERSION

The following parameters can be modified:
1
2
ACC DELAY:
RELEASE BRAKING:
INVERSION BRAKING:
PEDAL BRAKING:
SPEED LIMIT BRAKING:
BRAKE CUTBACK:
7
8
MAX SPEED FORWARD:

MAX SPEED BACKWARD:
9
10
11
12
13
CUTBACK SPEED 1:
CUTBACK SPEED 2:
CUTBACK SPEED 3:
H&S CUTBACK:
FREQUENCY CREEP:
14
15
16
17
MAXIMUM CURRENT:
BACKING SPEED:
BACKING TIME:
AUXILIARY TIME:
determines the acceleration ramp.

controls the deceleration ramp when the travel
request is released.
controls the deceleration ramp when the direction
switch is inverted during travel..
determines the deceleration ramp when the travel
request is released and the brake pedal switch is
closed.
deceleration ramp when the pedal position is
changed but not completely released.
determines the deceleration ramp when the speed
reduction input becomes active and the motor slow
down.
determines the maximum speed in forward direction.
determines the maximum speed in backward
direction.
speed reduction when the cutback switch 1 is active.
speed reduction when the Hard&Soft switch is active.
minimum speed when the forward or reverse switch
is closed, but the accelerator is on a minimum
position.
this changes the maximum current of the inverter.
determines the speed in inching function.
determines the time of the inching function.
determines the time that the truck is hold on the ramp
if the "stop on ramp" option is ON.
2=CA!%
The following table shows the different values at which the parameters can be set.
PROGRAMMED LEVEL
UNIT
ACCELERATION DELAY (*)
Sec.
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
RELEASE BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
INVERS BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
PEDAL BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
SPEED LIMIT BRAKING (**)
Sec.
8.9
8.3
7.7
7.1
6.6
6.0
5.5
4.9
4.4
3.8
BRAKE CUTBACK (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
MAX SPEED FW
Hz
65
80
95
110
125
140
155
170
185
200
MAX SPEED BW
Hz
65
80
95
110
125
140
155
170
185
200
CUTBACK SPEED 1
%Max Sp
10
15
20
25
37
50
62
75
87
100
CUTBACK SPEED 2
%Max Sp
10
15
20
25
37
50
62
75
87
100
CUTBACK SPEED 3
%Max Sp
10
15
20
25
37
50
62
75
87
100
H&S CUTBACK
%Max Sp
10
15
20
25
37
50
62
75
87
100
Hz
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.0
% IMAX
47
53
58
64
70
76
82
88
94
100
BACKING SPEED
Hz
10
12
14
16
18
BACKING TIME
Sec.
0.2
0.5
1.0
1.4
1.8
2.3
2.7
3.1
3.6
4.0
AUXILIARY TIME
Sec.
0.4
0.8
1.6
2.0
3.0
4.0
6.0
8.0
10.0
PARAMETER
FREQUENCY CREEP
MAXIMUM CURRENT
(*)
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp
calculated by the software; the real ramp could change as a function of motor control parameter setting and, obviously, as a function of the load.
(**) The braking feature is based upon deceleration ramps. The value shown in the
table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramps
2=CA!&
4.6 PARAMETER REGULATION: MDI PRC VERSION

The following parameters can be modified:
1
2
ACC DELAY:
RELEASE BRAKING:
INVERSION BRAKING:
PEDAL BRAKING:
SPEED LIMIT BRAKING:
BRAKE CUTBACK:
7
8
MAX SPEED FORWARD:

MAX SPEED BACKWARD:
9 CUTBACK SPEED 1:
10 H&S CUTBACK:
11 FREQUENCY CREEP:
12 MAXIMUM CURRENT:
13 BACKING SPEED:
14 BACKING TIME:
15 AUXILIARY TIME:
16 MIN VALVE 1:
17 MIN VALVE 2:
determines the acceleration ramp.

controls the deceleration ramp when the travel
request is released.
controls the deceleration ramp when the direction
switch is inverted during travel..
determines the deceleration ramp when the travel
request is released and the brake pedal switch is
closed.
deceleration ramp when the pedal position is
changed but not completely released.
determines the deceleration ramp when the speed
reduction input becomes active and the motor slow
down.
determines the maximum speed in forward direction.
determines the maximum speed in backward
direction.
speed reduction when the Hard&Soft switch is active.
minimum speed when the forward or reverse switch
is closed, but the accelerator is on a minimum
position.
this changes the maximum current of the inverter.
determines the speed when the "Backing function" is
active.
determines the during time when the "Backing
function" is active.
determines the time that the truck is hold on a slope
(only if the "Stop on ramp" option is ON).
this parameter determines the minimum voltage
applied on the electrovalve 1 when the position of the
potentiometer is at the minimum. This parameter is
not effective if the electrovalve 1 is programmed like a
On/Off valve (see the configuration chapter).
this parameter determines the minimum voltage
potentiometer is at the minimum. This parameter is
not effective if the electrovalve 2 is programmed like a
On/Off valve (see the configuration chapter).
2=CA!'
18 MAX VALVE 1:
19 MAX VALVE 2:
20 VALVE 3 VOLTAGE:
21 VALVE 4 VOLTAGE:
22 V1 OPENING RAMP
23 V2 OPENING RAMP
24 V1 CLOSING RAMP
25 V2 CLOSING RAMP
2=CA"
this parameter determines the maximum voltage

potentiometer is at the maximum. If the electrovalve 1
is programmed like a On/Off valve (see the
configuration chapter) this parameter determines the
voltage applied on the electrovalve coil.
this parameter determines the maximum voltage
potentiometer is at the maximum. If the electrovalve 2
is programmed like a On/Off valve (see the
configuration chapter) this parameter determines the
voltage applied on the electrovalve coil.
this parameter determines the voltage applied on the
electrovalve 3.
this parameter determines the voltage applied on the
electrovalve 4.
this parameter determines the ramp of voltage
applied on the electrovalve 1 in the opening transition
(if proportional); this is the time necessary to go from
the minimum to the maximum voltage. If the
electrovalve is programmed like an On/Off valve this
parameter is not effective.
applied on the electrovalve 2 in the opening
transition. (if proportional); this is the time necessary
to go from the minimum to the maximum voltage. If
the electrovalve is programmed like an On/Off valve
this parameter is not effective.
applied on the electrovalve 1 in the closing transition
the maximum to the minimum voltage. If the
applied on the electrovalve 2 in the closing transition
the maximum to the minimum voltage. If the
The following table shows the different values at which the parameters can be set.
PROGRAMMED LEVEL
UNIT
ACCELERATION DELAY (*)
Sec.
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
RELEASE BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
INVERS BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
PEDAL BRAKING (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
SPEED LIMIT BRAKING (**)
Sec.
8.9
8.3
7.7
7.1
6.6
6.0
5.5
4.9
4.4
3.8
BRAKE CUTBACK (**)
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
MAX SPEED FW
Hz
65
80
95
110
125
140
155
170
185
200
MAX SPEED BW
Hz
65
80
95
110
125
140
155
170
185
200
CUTBACK SPEED 1
%Max Sp
10
15
20
25
37
50
62
75
87
100
H&S CUTBACK
%Max Sp
10
15
20
25
37
50
62
75
87
100
Hz
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.0
% IMAX
47
53
58
64
70
76
82
88
94
100
BACKING SPEED
Hz
10
12
14
16
18
BACKING TIME
Sec.
0.2
0.5
1.0
1.4
1.8
2.3
2.7
3.1
3.6
4.0
AUXILIARY TIME
Sec.
0.4
0.8
1.6
2.0
3.0
4.0
6.0
8.0
10.0
PARAMETER
FREQUENCY CREEP
MAXIMUM CURRENT
MIN VALVE 1
This parameter can be adjusted from 1 to 255 with regolation of 1digit
MIN VALVE 2
MAX VALVE 1
MAX VALVE 2
VALVE 3 VOLTAGE
%V
10
20
30
40
50
60
70
80
90
100
VALVE 4 VOLTAGE
%V
10
20
30
40
50
60
70
80
90
100
V1 OPENING RAMP
Sec.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
V2 OPENING RAMP
Sec.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
V1 CLOSING RAMP
Sec.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
V2 CLOSING RAMP
Sec.
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
(*)
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the ideal ramp
(**) The braking feature is based upon deceleration ramps. The value shown in the
table is the time to decrease the speed from 100 Hz to 0 Hz. This is the ideal ramps
2=CA"
1) Opening Zapi Display.

2) Press ENTER to go into the General
Menu.
3) The Display will show :
Parameter Change facility.
5) The Display will show the first
parameter.
6) Press either ROLL UP and ROLL DOWN
to display the next parameter.
7) The names of the Parameters appear
on the Display.
8) When the desired Parameter appears, the
Display will show a Level Number that will
be between 0 and 9. Press either PARAM
(Top Right) or SET (Bottom Right)buttons
to change the Level value.
9) The Display will show the New Level.
10) When you are satisfied with the results of
the changes you have made, Press OUT.
11) The Display asks ARE YOU SURE"?
12) Press ENTER to accept the changes, or
press OUT if you do not wish to accept the
changes and wish to make further
modifications to the parameters.
2=CA"
4.7 PROGRAMMING CONSOLE FUNCTIONS

- Functional configuration (see 4.1 , 4.2 , 4.3 , 4.4)
- Parameter programming (see 4.5 , 4.6)
- Tester: the user can verify the state of the following parameters:
STANDARD Version
battery voltage (V)
motor voltage (%)
voltage booster (%)
frequency (Hz)
encoder (Hz)
slip value (Hz)
cos fi
current rms (A)
battery current (A)
battery charge (A)
temperature (C)
accelerator (V)
brake pedal pot (%)
lifting switch (ON/OFF)
descent switch (ON/OFF)
forward switch (ON/OFF)
backward switch (ON/OFF)
seat switch (ON/OFF)
Hard&Soft (ON/OFF)
quick inversion(ON/OFF)
cutback switch (ON/OFF)
cutback switch 2 (ON/OFF)
cutback switch 3 (ON/OFF)
MDI PRC Version

battery voltage (V)
motor voltage (%)
voltage booster (%)
frequency (Hz)
encoder (Hz)
slip value (Hz)
cos fi
current rms (A)
battery current (A)
battery charge (A)
temperature (C)
accelerator (V)
lifting control (V)
lifting switch (ON/OFF)
descent switch (ON/OFF)
forward switch (ON/OFF)
backward switch (ON/OFF)
seat switch (ON/OFF)
Hard&Soft (ON/OFF)
quick inversion(ON/OFF)
cutback switch (ON/OFF)
digital input #1 (ON/OFF)
digital input #2 (ON/OFF)
- Save function (for storing data)

- Restore function (for loading parameters on another chopper)
- Display of the last 5 alarms including hour-meter value and temperature at the moment of the alarm.
- Accelerator range programming: records the minimum and maximum useful accelerator stroke values for both direction of running.
- See the console manual for a detailed description of function and parameters.
2=CA"!
4.8 SEQUENCE FOR AC INVERTER TRACTION SETTING

When the "Key Switch" is closed, if no alarms or errors are present, the Console Display
will be showing the Standard Zapi Opening Display.
If the chopper is not configured to your requirements, follow the sequence detailed on
Chapter 5.2 . Remember to re-cycle the Key Switch if you make any changes to the
choppers configuration. Otherwise follow the sequence detailed below :
1) Select the Options required. See Chapter 4.1 4.4.
2) Select and set the Battery Voltage. See Chapter 4.4.
3) Confirm correct installation of all wires. Use the Consoles TESTER function to
assist.
4) Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC. Procedure is detailed on Chapter 5.4.
5) Set the "MAXIMUM CURRENT Current, using the table on Chapter 4.5 , 4.6.
6) Set the Acceleration Delay requirements for the machine. Test the parameters in
both directions.
7) Set the FREQUENCY CREEP level starting from level 0.6 Hz. The machine should
just move when the accelerator microswitch is closed. Increase the Level accordingly.
8) Set the Speed Reductions as required. Make adjustments to CUTBACK SPEED
Check the performance with the accelerator pedal totally depressed. If the machine
is a forklift, check the performance with and without load.
9) RELEASE BRAKING. Operate the machine at full speed. Release the accelerator
pedal. Adjust the level to your requirements. If the machine is a forklift, check the
performance with and without load.
10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst traveling
INVERT the Direction Switch. Set a soft Level of Inversion Braking. When satisfactory, operate the machine at Full Speed and repeat. If the machine is a Forklift, repeat the tests and make adjustments with and without load. The unladen full speed
condition should be the most representative condition.
11) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the accelerator pedal and press the Pedal Brake. Set braking level to your requirements.
12) Set MAX SPEED FORW.
13) Set MAX SPEED BACK (Reverse).
14) Make the choice for the truck behaviour on a slope (see chapter 4.4). If the "Stop on
ramp" option is ON, set the desired value of "auxiliary time" parameter.
2=CA""
4.9 TESTER: DESCRIPTION OF THE FUNCTION; STANDARD VERSION

The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage,
current and temperature. The following definition listing shows the relative measurements :
1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key
switch.
2) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is
expressed as a percentage of the full voltage (which depends of the battery voltage).
3) VOLTAGE BOOSTER: this is the booster of the voltage supplied to the motor in
load condition; it is expressed in a percentage of the full voltage.
4) FREQUENCY: this is the frequency of the voltage and current supplied to the motor.
5) ENCODER: this is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
6) SLIP VALUE: this is the difference of speed between the rotating field and the shaft
of the motor, expressed in the same unit of the frequency.
7) COS FI: this is the cos (real time calculated) of the motor.
8) CURRENT RMS: Root Mean Square value of the motor current.
9) BATTERY CURRENT: this is the battery current (not measured but calculated).
10) BATTERY CHARGE: the percentage Charge level of the battery.
11) TEMPERATURE: the temperature measured on the aluminum heat sink holding the
MOSFET devices.
12) ACCELERATOR: the voltage of the accelerator potentiometer's wiper (CPOT). The
voltage level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
13) BRAKE PEDAL POT: the voltage of the brake pedal potentiometer's wiper
(CPOTB). The voltage level is shown on the Left Hand Side of the Console Display
and the value in percentage is shown on the Right Hand Side.
14) LIFTING SWITCH: the level of the "Lifting switch" digital entry.
ON / +VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
15) DESCENT SWITCH: the level of the "Descent switch" digital entry.
16) FORWARD SWITCH: the level of the Forward direction digital entry FW.
17) BACKWARD SWITCH: the level of the Reverse direction digital entry BW.
2=CA"#
18) SEAT SWITCH: the level of the Seat Microswitch digital entry.
or:
TILLER SWITCH: the level of the Tiller Microswitch digital entry. ("Tiller switch"
option set as "Handle").
19) H&S CUTBACK: the level of the Hard&Soft Microswitch digital entry.
20) QUICK INVERSION: the level of the Quick Inversion Microswitch digital entry. ("Set
Input #4" option set as "Belly").
or:
BRAKE SWITCH: the level of the Brake Pedal Microswitch digital entry. ("Set Input
#4" option set as "Brake").
or:
EXCLUSIVE HYDRO: the level of the Exclusive Hydro Microswitch digital entry.
("Set Input #4" option set as "Ex.Hydro").
21) CUTBACK SWITCH 1: the level of the Speed Reduction Microswitch 1. ("Set Input
#1" option set as "Present").
ON / GND = active entry of open switch.
OFF / +VB = non active entry of closed switch.
or:
HAND BRAKE: the level of theHand Brake. ("Set Input #1" option set as "Option
#1").
or:
2=CA"$
INCHING FORW: the level of the Inching Microswitch - Forward direction. ("Set Input
#2" option set as "Option #1").
or:
INCHING BACK: the level of the Inching Microswitch - Backward direction. ("Set
Input #3" option set as "Option #1").
2=CA"%
4.10 TESTER: DESCRIPTION OF THE FUNCTION; MDI PRC VERSION

The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage,
current and temperature. The following definition listing shows the relative measurements :
1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key
switch.
2) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is
expressed as a percentage of the full voltage (which depends of the battery voltage).
3) VOLTAGE BOOSTER: this is the booster of the voltage supplied to the motor in
load condition; it is expressed in a percentage of the full voltage.
4) FREQUENCY: this is the frequency of the voltage and current supplied to the motor.
5) ENCODER: this is the speed of the motor, expressed in the same unit of the frequency; this information comes from the speed sensor.
6) SLIP VALUE: this is the difference of speed between the rotating field and the shaft
of the motor, expressed in the same unit of the frequency.
7) COS FI: this is the cos (real time calculated) of the motor.
8) CURRENT RMS: Root Mean Square value of the motor current.
9) BATTERY CURRENT: this is the battery current (not measured but calculated).
10) BATTERY CHARGE: the percentage Charge level of the battery.
11) TEMPERATURE: the temperature measured on the aluminum heat sink holding the
MOSFET devices.
12) ACCELERATOR: the voltage of the accelerator potentiometer's wiper (CPOT). The
13) LIFTING CONTROL: the voltage of the lifting potentiometer's wiper (CPOTB). The
14) LIFTING SWITCH: the level of the "Lifting switch" digital entry.
15) DESCENT SWITCH: the level of the "Descent switch" digital entry.
16) FORWARD SWITCH: the level of the Forward direction digital entry FW.
17) BACKWARD SWITCH: the level of the Reverse direction digital entry BW.
2=CA"&
18) SEAT SWITCH: the level of the Seat Microswitch digital entry.
or:
TILLER SWITCH: the level of the Tiller Microswitch digital entry. ("Tiller switch"
option set as "Handle").
19) H&S CUTBACK: the level of the Hard&Soft Microswitch digital entry.
20) QUICK INVERSION: the level of the Quick Inversion Microswitch digital entry. ("Set
Input #4" option set as "Belly").
or:
BRAKE SWITCH: the level of the Brake Pedal Microswitch digital entry. ("Set Input
#4" option set as "Brake").
or:
EXCLUSIVE HYDRO: the level of the Exclusive Hydro Microswitch digital entry.
("Set Input #4" option set as "Ex.Hydro").
or:
HAND BRAKE: the level of theHand Brake. ("Set Input #1" option set as "Option
#1").
22) DIGITAL INPUT #1: the level of the Auxiliary Lifting digital entry.
23) DIGITAL INPUT #2: the level of the Auxiliary Lowering digital entry.
2=CA"'
Flow Chart showing how to use the TESTER function of the Digital Console.
2) Press ENTER to go into the General menu.
TESTER MENU appear on the display.
5) The Display shows :
6) Press ENTER to go into the TESTER function.
7) The first variable to be tested is shown on the Display.
8) Press either ROLL UP or ROLL DOWN buttons until your
desired variable for measurement appears on the Display.
9) When you have finished, Press OUT.

10) The Display shows :
11) Press OUT again and return to Opening Zapi Display.
Remember it is not possible to make any changes using TESTER. All you can do is
measure as if you were using a pre-connected multimeter.
2=CA#
5 OTHER FUNCTIONS
5.1 DESCRIPTION OF THE CONSOLE SAVE FUNCTION

The SAVE function allows the operator to transmit the Parameter values and Configuration data of the chopper 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 chopper using the RESTORE function.
The data that is available via the SAVE function is as follows:
- 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.
SAVE PARAM. appears on the display
6) Press ENTER to go into the SAVE function.
7) If this facility has been used before the type
of chopper data stored appears on the top Main with
a 2 digit reference.
8) Keep pressing either ROLL UP or ROLL DOWN keys until
the second Main indicates a FREE storage facility.
9) Press ENTER to commence SAVE routine.

10) You can see the items that are being stored whilst
the SAVE routine is happening.
11) When finished, the Console shows :
13) Press OUT to return to the Opening Zapi Display.
2=CA#
5.2 DESCRIPTION OF CONSOLE RESTORE FUNCTION.

The RESTORE PARAM function allows transfer of the Consoles stored data into the
memory of the chopper. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM. function.
The data that is available via the RESTORE PARAM. function is as follows :
- 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 chopper memory
will be writtten over and replace with data being restored.
Flow Chart showing how tto use the RESTORE function of the Digital Console.
RESTORE PARAM. appears on the display.
6) Press ENTER to go into the RESTORE PARAM. function.
7) The Display shows the type of Model stored,
with a Code Number.
8) Keep pressing either ROLL UP and ROLL DOWN buttons
until the desired model appears on the Display.
9) Press ENTER to commence the Restore operation.

10) The Display will ask ARE YOU SURE.
Press ENTER for YES, or OUT for No.
11) You can see the items that are being stored in
the chopper memory whilst the RESTORE
routine is happening.
12) When finished the Console displays :
13) Press OUT to return to the Opening Zapi Display .
2=CA#
5.3 DESCRIPTION OF ALARMS MENU

The microprocessor in the chopper remembers the last five Alarms that have occurred.
Items remembered relative to each Alarm are : the code of the alarm, the number of
times the particular Alarm occurred, the Hour Meter count, and the chopper temperature.
This function permits a deeper diagnosis of problems as the recent history can now be
accessed.
Flow Chart showing how to use the ALARMS function via the Digital Console.
PARAMETER CHANGE appears on the display.
5) The Display will show:
6) Press ENTER to go into the ALARMS function.
7) The Display will show the most recent Alarm.
8) Each press of the ROLL UP button brings up following
Alarms. Pressing ROLL DOWN returns to the most recent.
9) If an Alarm has not occurred, the Display will show:
ALARM NULL.
10) When you have finished looking at the Alarms, press
OUT to exit the ALARMS menu.
11) The Display will ask CLEAR LOGBOOK ?
12) Press ENTER for yes, or OUT for NO.
13) Press OUT to return to the Opening Zapi Display.
2=CA#!
5.4 DESCRIPTION OF CONSOLE PROGRAM VACC FUNCTION

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.
Flow Chart showing how to use the PROGRAM VACC function of the Digital Console.
2) Press ENTER to go into the General Menu.
PROGRAM VACC appears on the display.
5) Tthe Display will show :
6) Press ENTER to go into the PROGRAM VACC routine.
7) The Display will show the minimum and maximum
values of potentiometer wiper output.
Both directions can be shown.
8) Press ENTER to clear these values.
Display will show 0.0.
9) Select Forward Direction, close any interlock
switches that may be in the system.
10) Slowly depress the accelerator pedal (or tiller butterfly) to
its maximum value. The new minimum and maximum
voltages will be displayed on the Console plus an
arrow indicating the direction.
11) Select the Reverse Direction and repeat Item 10.
12) When finished , press OUT.
13) The Display will ask : ARE YOU SURE ?.
14) Press ENTER for yes, or OUT for NO.
15) Press OUT again to return to the Opening Zapi Menu.
2=CA#"
6 AC1 INVERTER DIAGNOSTIC

The alarms are signalled by a diagnostic LED.
1 blink:
logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3",
"CHECK UP NEEDED").
2 blinks:
running request on start-up or error in seat sequence or double direction request ("INCORRECT START", "HANDBRAKE", "FORW + BACK").
3 blinks:
phase voltage or capacitor charge failure

("CAPACITOR CHARGE", "VMN LOW", "VMN HIGH").
4 blinks:
failure in accelerator ("VACC NOT OK", "PEDAL WIRE KO").
5 blinks:
failure of current sensor

("STBY I HIGH").
6 blinks:
failure of contactor driver

("COIL SHORTED", "DRIVER SHORTED", "CONTACTOR
DRIVER", "AUX OUTPUT KO", "CONTACTOR OPEN",
"PEV NOT OK", "MDI COIL SHORTED", "MDI NEG EVP",
"MDI PEV", "MDI VALVE DRIVER", "MDI DRIVER
SHORTED").
7 blinks:
excessive temperature ("HIGH TEMPERATURE", "THERMIC SENSOR KO").
8 blinks:
failure detection from can-bus ("CAN-BUS KO").
long blink:
discharge battery ("LOW BATTERY")

6.1 ANALYSIS OF ALARMS DISPLAYED ON CONSOLE
1. WATCH DOG
The test is made in both running and standby. It is a self-diagnosing test within the
logic. If an alarm should occur, replace the logic.
2. EEPROM KO
Fault in the area of memory in which the adjustment parameters are stored; this
alarm inhibits machine operation. If the defect persists when the key is switched OFF
and ON again, replace the logic. If the alarm disappears, remember that the parameters stored previously have been cancelled and replaced by the default values.
3. LOGIC FAILURE #1
This alarm signals that an undervoltage / overvoltage protection operation has
occured. Two possible reasons:
a. A real undervoltage / overvoltage situation happened.
b. Fault in the hardware section of the logic board which manages the overvoltage
protection. Replace the logic card.
2=CA##
4. LOGIC FAILURE #2
Fault in the hardware section of the logic board which manages the phase' s voltage
feedback. Replace the logic board.
5. LOGIC FAILURE #3
Fault in the hardware section of the logic board which manages the hardware current
protection. Replace the logic board.
6. CHECK UP NEEDED
This is a warning. It is an information for the user that the programmed time for maintenance is elapsed.
7. INCORRECT START
This alarm signals an incorrect starting sequence. Possible causes:
a. running microswitch failure;
b. error in sequence made by the operator;
c. incorrect wiring;
d. if the default persists, replace the logic.
8. FORW + BACK
The test is carried out continuously. An alarm is signalled when a double running
request is made simultaneously. Possible causes:
a. defective wiring;
b. running microswitch failure;
c. incorrect operation;
d. if the defect persists, replace the logic.
9. HANDBRAKE
The truck does not start because the handbrake switch is opened. Possible causes:
a.
defective wiring;
b.
failure of the microswitch;
c.
incorrect operation of the operator;
If the defect persist , replace the logic.
10. CAPACITOR CHARGE
Follows the charging capacitor system:
When the key is switched ON, the inverter tries to charge the capacitor through a
power resistance, and check if the capacitor are charged within a timeout. If this is
not true: an alarm is signalled; the main contactor is not closed.
2=CA#$
Possible reasons:
a) the charging resistance is opened; if it is opened.
b) The charging circuit has a failure.
c) There is a problem on the power modules.
11. VMN LOW, VMN HIGH
The test is carried out during initial diagnosis and in standby.
Possible causes:
a. problem with the motor connections or the motor power circuit; check if the 3
phases are correctly connected; check if there's a dispersion of the motor towards
ground;
b. inverter failure, replace it.
12. VACC NOT OK
The test is made in standby. This alarm indicates that the accelerator voltage is 1V
greater than the minimum value programmed by the PROGRAM VACC function.
Possible causes:
a. the potentiometer is not correctly calibrated;
b. the potentiometer is defective.
13. PEDAL WIRE KO
This alarm is signalled if a fault is detected in the accelerator unit wiring (NPOT or
PPOT cable is interrupted).
14. PROG LIFT LEVER
This alarm is signalled if a fault is detected in the program of the lifting / lowering
potentiometer (MDI PRC version only).
15. STBY I HIGH
Test carried out in standby. Check if the current is 0. If not verified, an alarm is signalled which inhibits machine operations. Possible causes:
a. current sensor failure;
b. logic failure: first replace the logic; if the defect persists, replace the power unit.
16. MAIN CONTACTOR ALARMS
COIL SHORTED:
When the key is switched ON the P checks the MC driver FF SR. If it does not react
in a correct way to the P stimulus, the alarm is signalled. Replace the logic board.
The FF SR makes an hardware control of the current in the MC coil. If this is too
high, it opens the MC and the alarm is signalled.
Check if there are external shortcircuit and if the ohmic value of the MC is correct;
otherwise replace the logic.
DRIVER SHORTED:
When the key is switched ON, the P checks that the MC coil driver is not shorted; if
it is, this allarm is signalled; replace the logic board.
CONTACTOR DRIVER:
When the initial diagnosis is finished, the traction logic closes the MC and checks
the voltage on the Drain of the driver. If this is not low , an alarm is signalled.
Replace the logic.
2=CA#%
CONTACTOR OPEN:
The main contactor coil has been driven by the logic board, but the contactor does
not close. Two possible reasons:
a) the wires to the coil are interrupted or not well connected.
b) the contact of the contactor is not properly working.
17. AUX OUTPUT KO
The P checks the driver of the electromechanical brake. If the status of the driver
output does not correspond to the signal coming from the P, the allarm is signalled.
Replace the logic.
18. PEV NOT OK
The voltage of the "HM" output (Standard version) or the "PEV" output (MDI PRC
version) is not correct.
Possible cause:
a) output transistor is damaged.
b) defect in the logic
19. MDI COIL SHORTED
This failure is detected by MDI PRC and the information is sent to AC1 by Can-Bus
link. It means MDI PRC has detected a short-circuit on a coil of one of the On/Off
valves. Possible reasons:
a) the coil is really shorted or there is a wrong connection.
b) problem in MDI PRC hardware.
20. MDI VALVE DRIVER
link. It means that one of the On/Off valves driver is open.
21. MDI DRIVER SHORTED
link. It means that one of the On/Off valves driver is shorted. Possible reasons:
a) wrong external connection, check the wiring.
b) problem in MDI PRC hardware.
22. MDI NEG EVP
link. It means there is a problem on one of the two drivers of proportional valves.
23. MDI PEV
link. It means MDI PRC has detected a wrong value of the electrovalves positive.
Possible reasons:
a) wrong connection.
b) problem on AC1 PEV output.
c) problem in MDI PRC hardware.
2=CA#&
24. HIGH TEMPERATURE

Chopper temperature is greater than 75C. The maximum current is reduced proportionally to the temperature increase. The chopper stops at 100C.
If the alarm is signalled when the chopper is cold:
a) check the wiring of the thermal sensor;
b) thermal sensor failure;
c) logic failure.
25. THERMIC SENSOR KO
The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range.
When this alarm is signalled, check the connection of the sensors.
26. CAN BUS KO
The diagnosis of the CAN-BUS line is present only if the inverter uses this link (depends on the software version). It is signalled if the inverter does not receive any
message from the CAN-BUS line. First of all, check the wiring. If it is ok, the problem
is on the logic board, which must be replaced.
27. BATTERY LOW
If the "battery check" option is ON, a battery discarge algorithm is carried out. When
the charge level is 10% , this allarm is signalled and the current is reduced to the half
of the programmed level.
2=CA#'
7 RECOMMENDED SPARE PARTS FOR INVERTER
2=CA$
Part Number
Description
C29522
SW 180 48V
Single Pole Contactor
C29508
SW 180 24V
Single Pole Contactor
8 PERIODIC MAINTENANCE TO BE REPEATED

AT TIMES INDICATED.
Check the wear and condition of the Contactors moving and fixed contacts.
Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that
there is no electrical resistance between the contacts by measuring the volt drop between the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the chopper, and cables to the motor. Ensure the
insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller . Are the return springs ok. Do the
potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be free to
move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement parts used
should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the diagrams
included in this Manual. Any variations or special requirements should be made after
consulting a Zapi Agent. The supplier is not responsible for any problem that arises
from wiring methods that differ from information included in this Manual.
During periodic checks, if a technician finds any situation that could cause damage or
compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
2=CA$

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COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI

42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA

Operational features .............................................................................. 7

General instructions and precautions

Susceptibility and electromagnetic emission

2.9 Main contactor and emergency switch .................................................. 9

Other functions ............................................................................................ 51

2.2 CONTROL UNIT

open collector ( NPN or PNP), push-pull.

2.3 PROTECTION FEATURES

2.4 OPERATIONAL FEATURES

- Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER

2.8 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION

- Use a 6.3A Fuse for protection of the auxiliary circuits.

3.4 DESCRIPTION OF CONNECTORS - STANDARD VERSION

Negative of main contactor coil.

Positive of main contactor coil and electromechanical brake coil.

Negative of pump contactor coil.

Positive of pump contactor coil and lowering electrovalve coil.

Negative of the lowering electrovalve coil.

Low level CAN-BUS voltage I/O.

Incremental ENCODER (see chapter 3.6).

Incremental ENCODER (see chapter 3.6).

Output for driving an hourmeter; when the hourmeter is active this

Speed reduction 1 input. Active low (switch opened).

Speed reduction 2 input. Active low (switch opened).

Speed reduction 3 input. Active low (switch opened).

High level CAN-BUS voltage I/O.

Brake potentiometer wiper.

Incremental ENCODER (see chapter 3.6).

Incremental ENCODER (see chapter 3.6).

Connected to the power supply through a microswitch (KEY) with a

Common of FW / BW / SR1 / SR2 / SR3 / TILLER / H&S / BELLY /

Tiller request input. Must be connected to the tiller microswitch,

Forward direction request input. Must be connected to the forward

Quick inversion function input; must be connected to the Belly

Lowering request input, active high.

Lifting request input, active high.

Accelerator potentiometer wiper.

Negative of accelerator unit, tested for wire disconnection diagnosis.

Potentiometer positive: 10V output; keep load > 1K.

Positive serial reception.

Negative serial reception.

Positive serial transmission.

Negative serial transmission.

Negative console power supply.

Positive console power supply.

Must be connected to C8 for the Flash memory programming (if

Must be connected to C7 for the Flash memory programming (if

3.5 DESCRIPTION OF CONNECTORS - MDI PRC VERSION

Negative of main contactor coil.

Positive of main contactor coil and electromechanical brake coil.

Negative of pump contactor coil.

Positive of pump contactor coil the auxiliary output load.

Negative of the auxiliary output.

Low level CAN-BUS voltage I/O.

Incremental ENCODER (see chapter 3.6).

Incremental ENCODER (see chapter 3.6).

A11 PEV (+B)