Combiac0 & Ace0: User Manual
Combiac0 & Ace0: User Manual
Combiac0 & Ace0: User Manual
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: zapi@zapispa.it – web: www.zapispa.it
EN
User Manual
COMBIAC0
&
ACE0
Copyright © 1975-2008 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.
NOTES LEGEND
APPROVAL SIGNS
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
PP
MANAGER VISA
The Procedure for automatic potentiometer signal acquisition is carried out using
the Hand Set. This enables adjustment of the minimum and maximum useful
signal level, in either direction.
4 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:
CA0Z2A ZP1.00
That means:
CA0Z= COMBIAC0 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
U 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.
U 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 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:
- The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would
be to use a cable with a shield connected to the frame of the truck.
Sometimes it is sufficient a simple double wire cable or a duplex cable not
shielded.
- In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and
that could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.
Module
Module
1
2
Module
3
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.
U Correct Layout:
Module
Module
1
2
Module
3
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)
U Correct Layout:
Page - 14/77 AF6ZP0AD - COMBIAC0 & ACE0 - User Manual
Module
Module
1
2
Module
3
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.
4 Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
- lower costs (less and smaller cables )
- improved reliability (fewer connections)
- analysis of problems improved (easy connection with a pc to read the data
flowing through the cable)
U A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire
- for information about the mating connector pin assignment see the paragraph
“description of the connectors”
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.
U 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).
- The connection of the battery line switches must be carried out following
ZAPI instructions.
- If a 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.
- 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.
4.4 EMC
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:
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
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
“electrostatic charge”; ESD happen when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
- this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus) which
are spread everywhere on the truck and which carry critical informations.
- in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
There are different solutions for EMC issues, depending on level of emissions/
immunity required, the type of controller, materials and position of the wires and
electronic components.
5.1 Diagnosis
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) 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.
2) Standby Diagnosis that checks: watch-dog, phase’s voltages, pump motor
output, Contactor Drivers, Current Sensors, can-bus interface.
3) Driving diagnosis that checks: Watchdog, Current sensors, Contactor(s), can-
bus interface.
4) 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.
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
This internal connector is used for software download via JTAG interface. The
connector is also used by Zapi technicians to realize the software debug.
U; V; W Connection bars of the three motor phases; follow this sequence and the
indication on the motor.
CA0Z2A ZP1.00
Opening Zapi Display 24V 200A 00000
CONFIG MENU
The Display will show : SET MODEL SET MODEL
CONFIG MENU
The Display will show : SET OPTIONS SET OPTIONS
' % '
Press ENTER to go in the SET OPTIONS MENU ' ' '
HOURCOUNTER
The Display will show the first OPTION RUNNING
HOURCOUNTER
The Display will show the new option KEYON
CONFIG MENU
The Display will show : SET OPTIONS SET OPTIONS
Press OUT again. Display now will show the ' ' '
opening Zapi menu. ' % '
2) HOUR COUNTER
This option specifies the hour counter mode. It can be set one of two:
- RUNNING: The counter registers travel time only
- KEY ON: The counter registers when the "key" switch is closed
(controller supplied)
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 released 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.
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.
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.
CA0Z2A ZP1.00
1) Opening Zapi Menu 24V 200A 00000
CONFIG MENU
3) The Display will show: SET MODEL SET MODEL
CONFIG MENU
5) ADJUSTMENTS appears on the display ADJUSTMENTS
BATTERY TYPE
7) The display will show: SET BATTERY TYPE 24V
TROTTLE 0 ZONE
9) The desired parameter appears 3%
TROTTLE 0 ZONE
7%
' % '
12) Press ENTER to confirm ' ' '
13) Repeat the same from 5 to 12 points for the
other adjustments
2) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
3) THROTTLE 0 ZONE
Establishes a deadband in the accelerator input curve.
4) THROTTLE X POINT
5) THROTTLE Y POINT
This parameter, together with the THROTTLE X POINT, changes the
characteristic of the accelerator input curve (see also paragraph 13.5): when
the accelerator is de-pressed to X point per cent, the corresponding truck
speed is Y point per cent of the Maximum truck speed. The relationship
between the accelerator position and the truck speed is linear between the
THROTTLE 0 ZONE and the X point and also between the X point and the
maximum accelerator position but with two different slope.
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.
CA0Z2A ZP1.00
1) Opening Zapi Menu 24V 200A 00000
' % '
2) Press ENTER to go into the General Menu ' ' '
MAIN MENU
3) The Display will show: PARAMETER CHANGE PARAMETER CHANGE
ACC DELAY
5) The Display will show the first parameter LEVEL = 5
RELEASE BRAKING
9) The Display will show the new level. LEVEL = 2
10) When you are satisfied with the result of the ' ' '
changes you have made, press OUT. ' % '
12) Press ENTER to accept the changes, or press ' ' '
OUT to discard them. ' % '
MAIN MENU
13) The Display will show PARAMETER CHANGE
1) ACCELER. DELAY
Seconds. It determines the acceleration ramp. The parameter sets the time
needed to speed up the traction motor from 0Hz to 100Hz.
2) RELEASE BRAKING
Seconds. It controls the deceleration ramp when the travel request is
released. The parameter sets the time needed to decelerate the traction
motor from 100Hz to 0Hz.
3) TILLER BRAKING
AF6ZP0AD - COMBIAC0 & ACE0 - User Manual Page - 41/77
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 0Hz
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 0Hz.
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 0Hz.
6) PEDAL BRAKING
Seconds. This parameter determines the deceleration ramp when the travel
request is released and the brake pedal switch is closed. It sets the time
needed to decelerate the traction motor from 100Hz to 0Hz.
28) COMPENSATION
From 0% to 100% This parameter sets the voltage compensation (∆V)
applied to the motor when the proportional lifting function is active. The value
of this ∆V 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.
4 Note: the below set-up description is for skilled persons only: if you aren’t, please
keep your hands off. To enter this Zapi hidden menu a special procedure is
required. Ask for this procedure, directly to a Zapi technician.
In the SPECIAL ADJUSTMENTS functions list, there are factory adjusted
parameters only.
1) 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.
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 used one of three:
- 0: the dither signal frequency is 62.5 Hz
- 1: the dither signal frequency is 83 Hz
- 2: the dither signal frequency is 125 Hz.
1) BATTERY VOLTAGE
Voltage value with 1 decimal digit. Battery voltage value measured at the key
on.
2) 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.
3) 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.
4) VOLTAGE BOOSTER
Percentage value. It is the booster contribute to the voltage really supplied to
the motor expressed in per cent of the actual battery voltage. (Note: when
DC_LINK COMPENSATION is set ON, the VOLTAGE BOOSTER reading
will not match perfectly the booster setting because this latest one is
calculated respect to the nominal battery voltage; VOLTAGE BOOSTER is
expressed respect to the actual battery voltage).
5) FREQUENCY
Hz value. This is the frequency of the sine waves the inverter is supplying.
6) ENCODER
Hz value. This is the speed of the motor measured with the encoder and
expressed in the same unit of the FREQUENCY reading.
7) SLIP VALUE
Hz value. This is the slip between the frequency and the speed of the motor
(SLIP VALUE = FREQUENCY-ENCODER).
8) CURRENT RMS
Ampere value. Root Mean Square value of the line current in the motor.
9) 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.
14) ACCELERATOR
From 0.0V to 5.0V. The voltage 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.
CA0Z2A ZP1.00
Opening Zapi Display 24V 200A 00000
' % '
Press ENTER to go into the General menu ' ' '
MAIN MENU
The Display will show : PARAMETER CHANGE
MAIN MENU
The Display will show : SAVE PARAMETERS
' % '
Press ENTER to go into the SAVE function ' ' '
SELECT: MOD. 01
FREE
' % '
Press ENTER to commence SAVE routine ' ' '
You can see the items that are being stored whilst READING …
the SAVE routine is happening ACCEL. DELAY (ECC.)
SELECT: MOD. 01
When finished, the Console shows : FREE
CA0Z2A ZP1.00
Opening Zapi Display 24V 200A 00000
' % '
Press ENTER to go into the General menu ' ' '
MAIN MENU
The Display will show : PARAMETER CHANGE
MAIN MENU
The Display will show : RESTORE PARAM.
The Display shows the type of Model stored, with a SELECT : MOD. 00
Code Number ACE0 ZAPI V1
SELECT : MOD. 00
ACE0 ZAPI V1
' % '
Press ENTER to commence the Restore operation ' ' '
You can see the items that are being stored in the
STORING
chopper memory whilst the RESTORE routine is ACCELER. DELAY
happening
MAIN MENU
When finished, the Console shows : RESTORE PARAM.
4 NOTE: in reality the SAVE and RESTORE function requires the Windows PC-
Console.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the
point where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
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.
CA0Z2A ZP1.00
Opening Zapi Display 24V 200A 00000
' % '
Press ENTER to go into the General menu ' ' '
MAIN MENU
The Display will show : PARAMETER CHANGE
MAIN MENU
The Display will show : PROGRAM VACC
' % '
Press ENTER for yes, or OUT for NO ' % '
MAIN MENU
When finished, the Console shows : PROGRAM VACC
THROTTLE X POINT & THROTTLE Y POINT: the speed of the truck grows up
with a fixed slope (linear relationship) from the THROTTLE 0 ZONE up to
THROTTLE X POINT. This slope is defined by the matching between the X point
percentage of the MAX VACC setting with the Y point percentage of the full truck
speed.
From the X point up to the MAX VACC point, the slope of the relationship
between the truck speed and the accelerator position is different (see figure
below) to match the full speed in the truck with the MAX VACC voltage in the
accelerator position.
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 charge
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.
4 NOTE: if the same alarm is continuously happening, the controller does not use
new memory of the logbook, but only updates the last memory cell increasing the
related counter (point 2) of previous list). Nevertheless, the hourmeter indicated
in this memory refers to the first time the alarm occurred. In this way, comparing
this hourmeter with the controller hourmeter, it is possible to determine:
- When this alarm occurred the first time.
- How many hours are elapsed from the first occurrence to now.
- How many times it has occurred in said period.
Key-off
valve, pump, traction
shorted - Key-off signal is low at Key-on start-up Key re-cycle
stopped, Lc opened
MDI CAN 76
Evp1 not ok - Evp driver is failed shorted (always ON) valve, pump, traction start-up, stby valve or pump
MDI CAN 48 mismatch between the valve set-point and stopped, Lc opened, or traction
its feedback Eb applied request
Evp2 not ok - Evp2 driver is failed shorted (always ON) valve, pump, traction start-up, stby valve or pump
MDI CAN 47 mismatch between the valve set-point and stopped, Lc opened, or traction
its feedback Eb applied request
Pump Vmn Pump motor output is too low, with respect valve, pump, traction start-up, stby, valve or pump
Low - MDI to pwm applied stopped, Lc opened, during pump or traction
CAN 28 Eb applied function request
Pump Vmn Pump motor output is too high, with respect valve, pump, traction during pump valve or pump
High - MDI to pwm applied stopped, Lc opened, function or traction
CAN 29 Eb applied request
Wrong Zero - The outputs of the amplifiers (used to valve, pump, traction init valve or pump
MDI CAN measure the motor voltage) are cheked this stopped, Lc opened, or traction
code alarm alarm occurs when voltage signals >3V or Eb applied request
53 <2V at the init
Evp1 coil The Evp1 coil is not connected between valve, pump, traction start-up, stby, valve or pump
open - MDI Paux and NEVP1 output, and the parameter stopped, Lc opened, traction or traction
CAN 50 EVP TYPE in the set-option menu is set Eb applied request
Analog or Digital
Evp2 coil The Evp2 coil is not connected between valve, pump, traction start-up, stby, valve or pump
open - MDI Paux and NEVP2 output, and the parameter stopped, Lc opened, traction or traction
CAN 51 EVP TYPE in the set-option menu is set Eb applied request
Analog or Digital
Aux Batt. When the positive of the AUX OUTPUT is valve, pump, traction start-up, stby
Short - MDI driven by the tiller, the positive is high and stopped, Lc opened,
CAN code the tiller is released. Eb applied
alarm 74
Emergency - The PAUX connector (A3) is not connected valve, pump, traction continuous
MDI CAN to the battery or the voltage is different. stopped, Lc opened,
code alarm Eb applied
80
Flash The software is corrupted or the flash on the valve, pump, traction continuous
Checksum - inverter is damaged. stopped, Lc opened,
MDI CAN 08 Eb applied
Phase KO - One of the motor phases is open valve, pump, traction continuous
MDI CAN 27 stopped, Lc opened,
Eb applied
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
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
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) If the 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
controller
5) “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.
6) “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 –BATT.
7) “CONTACTOR DRIVER”
Cause:
The LC coil driver is not able to drive the load. The device itself or its driving
circuit is damaged.
Troubleshooting:
This type of fault is not related to external components; replace the controller.
8) “CONTACTOR OPEN”
Cause:
The main contactor coil has been driven by the controller, but the contactor
does not close.
Troubleshooting:
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.
9) “CONTACTOR CLOSED”
Cause:
Before driving the LC coil, the controller checks if the contactor is stuck. The
controller drives the bridge for some tens milliseconds, trying to discharge the
capacitors bank. If they don’t discharge the fault condition is entered.
Troubleshooting:
It is suggested to verify the power contacts of LC; to replace the LC is
necessary.
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.
32) “EMERGENCY”
Cause:
The voltage on A3 is different than +Vbatt.
Troubleshooting:
- If A3 is correctly connected to +Vbatt.
Machine status
Restart
Error code Description Effect when the test is
procedure
done
Slip profile - Error on the parameters of the slip Traction is stopped start-up, stand-by, Traction
MDI CAN 99 profile setting. traction request
Forward+back The travel demands are active in both Traction is stopped start-up, stand-by, Traction
ward - MDI directions at the same time traction request
CAN 80
Incorrect start - Incorrect starting sequence Traction is stopped start-up, stand-by, Traction
MDI CAN 79 traction request
Vacc not ok - The acceleretor value is higher than Traction is stopped start-up, stand-by, Traction
MDI CAN 78 the minimum value recorded, and the traction request
direction/enable switches are opened.
Th. Protection -The controller has reached the Traction controller continuous
MDI CAN 62 thermal cutback temperature 85°C reduces the maximum
current linearly from
Imax (85°C) down to
0A (105°C)
Battery low - Battery is <= 10% when the The maximum current continuous
MDI CAN 65 parameter BATTERY CHECK is set is reduced to half and
>0 speed is reduced (if
CHECK OPTION = 1)
Eeprom ko - Error is detected in eeprom or in Controller works using continuous
MDI CAN 71 eeprom management Deafult parameters
Motor Traction motor temperature sensor is The maximum current continuous
temperature - opened (if digital) or has overtaken is reduced to half and
MDI CAN 65 the threshold of 150°C (if analog) speed is reduced
Thermic sens The output of the controller thermal The maximum current continuous
ko - MDI CAN sensor is out of range. is reduced to half and
61 speed is reduced
Check up Maintenance time is reached
needed
Data Maximum current adjustment Traction is stopped stand-by Traction
acquisition procedure is in progress (NOTE: this request
procedure has to be done only by
Zapi test department)
Pedal wire ko Accelerator poti negative (Npot) Traction is stopped start-up, stand-by, Traction
MDI CAN 86 voltage is out of range (less than 0,3V traction request
or >2V)
Tiller open - The truck is in stby with tiller switch LC opens standby Valve or pump
MDI CAN 51 opened for more than 30s or traction
request
Current gain - The Maximum current gain Controller works, but start-up, stanby
MDI CAN 92 parameters are the default values, with low maximum
which means the maximum current current
adjustment procedure has not been
carried out yet
Waiting for A Canbus network node is in alarm continuous
node - MDI condition. uC is waiting for it to
CAN 68 resolve its error condition.
Deadman With the parameter "Positive EB" at LC opens standby Valve or pump
absent - MDI level 2 in the "HW setting" menu and or traction
CAN 98 "Deadman" input open the alarm request
appears
Evp2 not ok - MDI Evp2 driver open (not able to close, Evp stopped during Evp valve evp request
CAN 47 so not able to drive the valve) function
Pump I NO zero - Pump chopper current sensor Pump motor stopped start-up, stby pump request
MDI CAN 56 feedback is out of permitted stby
range
Pump I=0 ever - Pump current feedback is always Pump motor stopped pump function pump request
MDI CAN 52 0A even when pump motor is
running
lift+lower - 49 lift+lower request Pump motor stopped continuous hydraulic request
Cont. Drv. Ev1 - MDI Driver of Ev1 is open, not able to Ev1 stopped during Ev1 valve Ev1 request
CAN 75 close function
Cont. Drv. Ev2 - MDI Driver of Ev2 is open, not able to Ev2 stopped during Ev2 valve Ev2 request
CAN 75 close function
Cont. Drv. Ev3 - MDI Driver of Ev3 is open, not able to Ev3 stopped during Ev3 valve Ev3 request
CAN 75 close function
Cont. Drv. Ev4 - MDI Driver of Ev4 is open, not able to Ev4 stopped during Ev4 valve Ev4 request
CAN 75 close function
Cont. Drv. Ev5 - MDI Driver of Ev5 is open, not able to Ev5 stopped during Ev5 valve Ev5 request
CAN 75 close function
Pump Vacc not OK - The pump accelerator value is Pump stopped Continuous Pump request
MDI CAN 89 higher than the minimum value
recorded, and the lift/lower
switches are open
Sens. Mot. Temp. The motor temperature sensor is Performance highly Continuous Key-on recycle
KO - MDI CAN 67 damaged reduced
2) “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.
3) “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 controller.
5) “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.
7) “EEPROM KO”
Cause:
It’s due to a HW or SW defect of the non-volatile embedded memory
supporting the controller parameters. This alarm does not inhibit the machine
operations, but the truck will work with the default values.
Troubleshooting:
Try to execute a CLEAR EEPROM operation (refer to Console manual).
Switch the key off and on to check the result. If the alarm occurs
permanently, it is necessary to replace the controller. If the alarm disappears,
the previously stored parameters will have been replaced by the default
parameters.
8) “MOTOR TEMPERATURE”
Cause:
This warning occurs when the temperature sensor is opened (if digital) or has
overtaken the threshold of 150°C (if analog).
Troubleshooting:
Check the thermal sensor inside the motor (use the MOTOR
TEMPERATURE reading in the TESTER menu); check the sensor ohmic
value and the sensor wiring. If the sensor is OK, improve the air cooling of
the motor. If the warning is present when the motor is cool, then the problem
is inside the controller.
AMPSEAL CONNECTOR
C12532
35 pins Female
SW 180 24V
C29508
Single Pole Contactor
SW 180 48V
C29522
Single Pole Contactor