ZAPI AC-X Manual PDF
ZAPI AC-X Manual PDF
ZAPI AC-X Manual PDF
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
AC-X
Copyright © 1975-2005 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
PROJECT MANAGER MI
TECHNICAL ELECTRONIC
PP
MANAGER VISA
Figure 2–1
3.1 Microswitches
- The microswitches must have a contact resistance lower than 0.1Ω and a
leakage current lower than 100µA.
- When full load connected, the voltage between the key switch contacts must
be lower than 0.1V.
- The microswitches (if not otherwise noted) must connect or break a battery
voltage to the inputs pins.
The standard connection for the potentiometer is the one in the Left side of
Figure 3–1 (potentiometer on one end at rest) in combination with a couple of
Travel demand switches. On request it is also possible the handling in the Right
side of Figure 3–1 (potentiometer in the middle at rest) in combination with at
least one Travel Demand switch. We strongly advice against the adoption of the
Right side configuration without travel demand switch at all, because of a safety
issue.
Figure 3–1
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 (see paragraph 13.3 PROGRAM VACC function), in either direction.
The wished resolution must be specified when ordering the controller. The
suggested resolution is from 32pulses/rev up to 64pulses/rev.
For more details about encoder installation see also chapter 8.4.
4 Note: The encoder resolution and the motor poles pair (the controller can
handle), is specified in the home page display of the handset showing
something like:
ACXT2AE4 ZP1.04
That means:
ACXT = AC-X traction controller
2= poles pair number
A= 32 pulses/rev encoder
E= premium version
4= KTY84 motor thermal sensor
The encoder resolution is given by the letter after the poles pair number
in the following list:
A= 32 pulses/rev
K= 48 pulses/rev
B= 64 pulses/rev
The AC-X premium version is specified by the letter E after the encoder
resolution.
The final number specifies the thermal sensor.
3= KTY83 – 122
4= KTY84 - 130
Figure 5–1
One of the reason for the adoption of this Passive Emergency cell is to comply
with the EN1175-5.9.5: “A separate device indipendent of the speed control
device (accelerator) shall automatically prevent operation of the travel circuit
when the operator leaves the truck, e.g. seat switch, pedestrian tiller switch”. To
be sure this separate device really prevent operation of the travel circuit, it is
necessary a redundant device (togheter with the Elaboration Unit) reads this
6.1 Diagnosis
The microprocessor continuously monitors the inverter and carries out a
diagnostic procedure on the main functions. The diagnosis is made in 4 points:
- 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.
- Standby diagnosis at rest that checks: phase's voltages, contactor driver,
current sensor, can-bus interface.
- Diagnosis during operation that checks: contactor driver, current sensors,
encoder, can-bus interface.
- Continuous 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.
Figure 7–1
8.2 Contactors
Usually a main contactor is adopted to connect and cut off the battery to the
controller. Depending on the setting of a parameter (see paragraph 12.4.1.10
option AUX VOLTAGE #1):
- the output which drives the main contactor coil is on/off (the coil is driven with
the full battery voltage).
- the output which drives the main contactor coil is switched at high frequency
(1 KHz) with a programmable duty cycle; this feature is useful to decrease
the power dissipation of the contactor coil.
The EN1175 states the main Contactor is not mandatory (under proper
conditions); anyway it is useful 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.
8.3 Fuses
- Use a 6.3-10A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, use a 80-100A fuse in the Battery Positive
connection. 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.
1) AC-X 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 is +5V. It can have different
electronic output.
B2 +5V positive of encoder power supply.
B6 GND negative of encoder power supply.
B1 A phase A of encoder.
B5 B phase B of encoder.
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 letter
after the poles pair number in the software release name (see 3.5).
Figure 9–1
Figure 9–2
Figure 9–3
Figure 9–4
-B Negative of the battery.
+B Positive of the battery.
U; V; W Connection bars of the three motor phases; follow this
sequence and the indication on the motor.
Figure 10–1
Figure 10–2
Figure 10–3
Figure 10–4
Figure 12–1
Figure 12–2
Figure 12–3
Figure 12–4
The configurations have different list of settings (the Base version has a reduced
settings list). In the next we refer to a complete settings that is the sum of the
settings list of the configurations. When the setting refers to only one
configuration, it will be specified in the description.
ACX ZP 0.14
Opening Zapi Display 24V 100A 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. ' % '
Figure 12–5
1) TILLER SWITCH
This option handles the input CNA#3. This input opens when the operator
leaves the truck (released). It is connected to a key voltage when the
operator is present. There are two levels:
- HANDLE: CNA#3 is managed as tiller input (no delay when
released).
- SEAT: CNA#3 is managed as seat input (with a delay when
released).
3) SET INPUT #2
(Only Premium version without MDI PRC).
This option handles the digital input CND#9. It can be used one of two:
- PRESENT: CND#9 is managed as a cutback speed input (SR#2)
- OPTION #1: CND#9 is managed as an inching forward input
The input CND#9 can only be used as Aux Lifting request when the MDI-
PRC is PRESENT.
This input must be connected to a Key voltage.
The SR#2 becomes active when CND#9 is opened.
The inching forward becomes active when the CND#9 is closed to a key
voltage.
4) SET INPUT #3
(Only Premium version without MDI PRC).
This option handles the digital input CND#12. It can be used one of two:
- PRESENT: CND#12 is managed as a cutback speed input (SR#3)
- OPTION #1: CND#12 is managed as an inching backward input
The input CND#12 can only be used as Aux Lowering request when MDI
PRC is present.
This input must be connected to a Key voltage.
The SR#3 becomes active when CND#12 is opened.
The inching forward becomes active when the CND#12 is closed to a key
voltage.
5) SET INPUT #4
This option handles the digital input CNA#8. It can be used one of three:
- BELLY: CNA#8 is managed as a Belly Switch input.
- BRAKE: CNA#8 is managed as service brake input. This
information can be used also to recognise when the
operator is driving with a pressed pedal braking.
- EX.HYDRO: CNA#8 is managed as Exclusive Hydro (actually not
implemented).
This input must be connected to a Key voltage.
The Belly switch active level is specified on the QUICK INV LOGIC below.
The service brake or the exclusive hydro becomes active when CNA#8 is
opened.
6) 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
8) HYDRO KEY ON
- ON/OFF: (function not implemented yet) 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).
9) STOP ON RAMP
(Only for the encoder versions).
It is possible to keep the truck on a ramp with a released travel demand.
- 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”, if the electromechanical brake is applied, 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
programmation and see also 13.4).
17) MDI-PRC
(Premium version only). This option specifies:
- PRESENT: The MDI-PRC is connected to the AC-X via the CAN Bus:
the handling of the Hydraulics is specified on the TRUCK
TYPE setting below.
- ABSENT: The MDI-PRC is not connected to the AC-X: some
options disappear from the function list.
ACX ZP 0.14
1) Opening Zapi Menu 24V 100A 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 is appears 3%
TROTTLE 0 ZONE
7%
' % '
12) Press ENTER to confirm ' ' '
13) Repeat the same from 5 to 12 points for the
other adjustment
Figure 12–6
1) MIN LIFT
(Only with MDI-PRC or in premium version when CND#15 is used for lifting).
By entering this setting, the SW records the actual value of the CND#15
potentiometer. The MIN LIFT setting must be Entered with the potentiometer
in a position is a little bit ahead the main Lifting switch (CND#10) turns
closed.
AENZP0CB – AC-X - User Manual Page - 45/90
2) MAX LIFT
(Only with MDI-PRC or in premium version when CND#15 is used for lifting).
By entering this setting, the SW records the actual value of the CND#15
potentiometer. The MAX LIFT setting must be Entered after the Lifting control
Lever is pushed against the maximum limiting position.
3) MIN LOWER
(Only with MDI-PRC or in premium version when CND#15 is used for lifting).
By entering this setting, the SW records the actual value of the potentiometer
on CND#15. The MIN LOWER setting must be Entered with the CND#15
potentiometer in a position is a little bit ahead the Main Lowering switch
(CND#11) turns closed.
4) MAX LOWER
(Only with MDI-PRC or in premium version when CND#15 is used for lifting).
By entering this setting, the SW records the actual value of the potentiometer
on CND#15. The MAX LOWER setting must be Entered after the Lowering
control Lever moving the CND#15 potentiometer is pushed against the
maximum limiting position.
8) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
9) THROTTLE 0 ZONE
Establishes a deadband in the accelerator input curve (see also paragraph
13.5).
17) OPTION 05
(MDI-PRC version only). This setting, together with the four settings below,
specifies an offset for the MDI-PRC HourMeter. The MDI-PRC HourMeter will
be the sum of the Controller HourMeter plus this offset. This offset value is 5
Digits with:
- OPTION 05 is the MSDigit
- OPTION 01 is the LSDigit
It is possible to change this offset only when the controller HourMeter is less
than 10 Hours. (It is used when the controller is replaced with a new one to
keep updated the Total Hours measurement of the truck. It is just enough to
set the OPTION 01 to OPTION 05 with the Final HourMeters of the replaced
Controller).
18) OPTION 04
(MDI-PRC version only). See OPTION 05.
19) OPTION 03
(MDI-PRC version only). See OPTION 05.
21) OPTION 01
(MDI-PRC version only). See OPTION 05.
ACX ZP 0.14
1) Opening Zapi Menu 24V 100A 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
Figure 12–7
2) RELEASE BRAKING
Level 0 to 9. It controls the deceleration ramp when the travel request is
released. At Level 9 the truck brakes abruptly.
3) INVERS. BRAKING
Level 0 to 9. It controls the deceleration ramp when the direction switch is
inverted during travel. At Level 9 the truck brakes abruptly.
4) PEDAL BRAKING
Level 0 to 9. It controls the deceleration ramp when the travel request is
released and the brake pedal switch is pressed to its maximum. At Level 9
the truck brakes abruptly.
6) BRAKE CUTBACK
Level 0 to 9. It controls the deceleration ramp when a speed reduction input
becomes active and the motor slows down. At Level 9 the truck decelerate
abruptly.
9) CUTBACK SPEED
(Only if used with encoder, because this cutback speed input is used for the
thermal sensor in the sensorless version)
Typically from 10% to 100%. It determines the percentage of the max speed
applied when the cutback switch 1 (SR#1 on CNA#7) is active. When set to
100% the speed reduction is ineffective.
Below is the list of all the settings used to specify the above three parameters.
Are also listed the settings for the sensorless function.
1) ENCODER
ON/OFF. It choose the type of the motor control used. It’s possible to choose
between encoder version (set ON) and sensorless version (set OFF). After
any change of this parameter, is necessary to recycle the key. At new key on
AC-X provides a CLEAR EEPROM and the controller restarts with default
parameters of the configuration required.
2) CONTACTOR CLOSED
ON/OFF. This parameter enables the CONTACTOR CLOSED diagnosis.
3) MONITOR
Not used in the encoder version.
5) SLIP CONTROL
On/Off. Set it On to enable the control law with the encoder getting the slip
limited under its maximum (see the control law description at the beginning of
this topic). When it is set Off the slip is not more limited and the frequency is
only proportional to the accelerator position. Used, when set Off, for
troubleshooting.
6) DC LINK COMPENSATION
On/Off. When it is set On the SW calculates the voltage quantities for the
booster and minimum voltage settings as a function of the nominal battery
voltage (e.g. BOOST AT LO FREQ=20% and nominal batt=24Vdc, means
20%*nominal batt=4.8V). When it is set Off the SW calculates the voltage
quantities for the booster and minimum voltage settings as a function of the
actual battery voltage (e.g. BOOST AT LO FREQ=20% means 20%*actual
battery voltage).
21) OPTION 06
(Factory adjusted). Level 0 to 9. This parameters (togheter with the OPTION
07 and OPTION 08) handles the ramp on the phase voltage to pursuit the
booster setting or the maximum current limitation (what occurs first). In
particular OPTION 06 defines the phase voltage ramp when the current is
higher than 1.2*Imax. By increasing this setting, the voltage ramp gets faster.
22) OPTION 07
(Factory adjusted). Level 0 to 9. This parameters (togheter with the OPTION
06 and OPTION 08) handles the ramp on the phase voltage to pursuit the
booster setting or the maximum current limitation (what occurs first). In
particular OPTION 07 defines the phase voltage ramp when the current is
inside the range Imax to 1.2*Imax. By increasing this setting, the voltage
ramp gets faster.
23) OPTION 08
(Factory adjusted). Level 0 to 9. This parameters (togheter with the OPTION
06 and OPTION 07) handles the ramp on the phase voltage to pursuit the
booster setting or the maximum current limitation (what occurs first). In
particular OPTION 08 defines the phase voltage ramp when the current is
less than Imax. By increasing this setting, the voltage ramp gets faster.
1) ENCODER
ON/OFF. It choose the type of the motor control used. It’s possible to choose
between encoder version (set ON) and sensorless version (set OFF). After
any change of this parameter, is necessary to recycle the key. At new key on
AC-X provides a CLEAR EEPROM and the controller restarts with default
parameters of the configuration required.
2) CONTACTOR CLOSED
ON/OFF. This parameter enables the CONTACTOR CLOSED diagnosis.
3) COMPENSATION
On/Off. This must be set On in order the three waves shape are perfectly
sinusoidal.
4) MINIMUM VOLTAGE
(Factory adjusted). A Percentage of the Battery Voltage. This setting
increases the phase voltage (and current) when low frequency during
5) MONITOR
(On/Off). This is a predisposition to enable a monitoring function of the motor
speed when either the frequency is low (control blind area) or an untuning
condition is detected between frequency and speed. The aim is to get the
control tuned (frequency and speed matched) togheter with the de-
enegization of the Electromechanical Brake. It is not handled yet.
1) ADJUSTMENT #01
(Factory adjusted). % value. This is the Gain of the first Current Sensing
Amplifier.
NOTE: keep your hand off this setting.
2) ADJUSTMENT#02
(Factory adjusted). % value. This is the Gain of the second Current Sensing
Amplifier.
NOTE: keep your hand off this setting.
3) MOTOR RESIST
(Sensorless configuration only). The Sensorless control estimates the
electromotive force in the motor (EMF) by knowing the drop in the motor
resistances. For this reason it is necessary to know the delta wound motor
resistance. This setting is the autoacquired value in milliohms of the delta
wound resistance. To autoacquire this value, roll this setting down to zero or
do a CLEAR EEPROM operation (see also the set-up procedure 11.1).
4) IOM
(Sensorless configuration only, Factory adjusted). Ampere value. This is the
magnetization current supporting the MAX FLUX in a lightened motor.
5) MAX FLUX
(Sensorless configuration only, Factory adjusted). Units value. This is the
maximum flux at the knee of the saturation curve of the motor. It is expressed
in mWb.
6) SET TEMPERATURE
(Factory adjusted) Set the temperature offset to have the correct value read.
NOTE: keep your hand off this setting.
8) AUX FUNCTION #2
Management of debug test point.
9) HIGH ADDRESS
Used to have access to special memory address.
NOTE: keep your hand off this setting.
1) BATTERY VOLTAGE
Voltage value with 1 decimal digit. Battery voltage value measured at the key
input CNA#1.
2) MOTOR VOLTAGE
Percentage value. It is the voltage generated by the inverter expressed in per
cent 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.
3) VOLTAGE BOOSTER
(Only with encoder)
Percentage value. It is the booster contribute to the voltage really supplied to
the motor expressed in per cent of the actual battery voltage. (Note: when
DC_LINK COMPENSATION is set ON, the VOLTAGE BOOSTER reading
will not match perfectly the booster setting because this latest one is
calculated respect to the nominal battery voltage; VOLTAGE BOOSTER is
expressed respect to the actual battery voltage).
4) FLUX MILLIWB
(Sensorless only). Units value. It is the estimated flux in the motor.
6) FREQUENCY
Hz value with two decimal digit. This is the frequency of the sine waves the
inverter is supplying.
7) ENCODER
Hz value with two decimal digit. This is the speed of the motor measured with
the encoder and expressed in the same unit of the FREQUENCY reading.
8) SLIP VALUE
Hz value with two decimal digit. This is the slip between the frequency and
the speed of the motor (SLIP VALUE = FREQUENCY-ENCODER).
11) TEMPERATURE
°C value. This is the temperature of the inverter base plate. This temperature
is used for the HIGH TEMPERATURE alarm detection (see 14.1.7.1).
13) ACCELERATOR
From 0.0V to 5.0V. The voltage on the wiper of the accelerator (CPOT on
CNA#11) 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.
ACX ZP 0.14
Opening Zapi Display 24V 100A 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
NOTE: in reality the SAVE and RESTORE function requires the Windows PC-
Console.
ACX ZP 0.14
Opening Zapi Display 24V 150A 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 ACX ZAPI V1
SELECT : MOD. 00
ACX 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
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.
Figure 13–1
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.
ACX ZP 0.14
Opening Zapi Display 24V 100A 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
BRAKE OFF -Drives the coil of a "The truck is not electrically hold on a
electromagnetic slope, but comes down very slowly; when
brake. the time set by ""auxiliary time""
parameter is elapsed, the brake is applied
and the 3-phase bridge is opened. Do not
use this combination if the negative brake
is not installed."
HYDRO OFF -Drives the coil of a The truck is not electrically hold on a
CONT. hydraulic steering slope, but comes down very slowly till the
contactor. flat is reached.
EXCL. OFF -Drives the coil of a The truck is not electrically hold on a
HYDRO hydraulic steering slope, but comes down very slowly till the
contactor. flat is reached.
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 13–
2 below) to match the full speed in the truck with the MAX VACC voltage in the
accelerator position.
Figure 13–2
Figure 13–3
2) EEPROM KO
MDI-PRC Code = 13
- Cause: It occurs due to a HW or SW defect of the non-volatile
embedded memory supporting the controller regulations.
- Remedy: Try to execute a CLEAR EEPROM operation. This consists of
Entering the ALARMS item in the MAIN MENU’. Push at the
same time the two right side buttons to enter the hidden ZAPI
MENU’. Roll up and Down until the CLEAR EEPROM appears
on the hand set display. Push Twice the Enter Button. Switch
the key off and on to check the result. If the alarm occurs
permanently, it is necessary to substituite the controller.
3) LOGIC FAILURE #1
MDI-PRC Code = 19
- Cause: It occurs when the battery voltage overtakes 45V (when the
battery is 24V) or 47.5V (when the battery is 36V). It also
occurs when the supply voltage inside the logic falls less than
11Vdc.
4) LOGIC FAILURE #2
MDI-PRC Code = 18
- Cause: It occurs when the circuit, to compensate for the dead times of
the sine waves, is failed.
- Remedy: It is necessary to substituite the Controller.
5) LOGIC FAILURE #3
MDI-PRC Code = 17
- Cause: It occurs when the circuit to limitate via HW the current peak in
the controller is active.
- Remedy: It is probably a power failure or a logic failure. If it occurs
permanently it is necessary to substituite the Controller.
6) CHECK UP NEEDED
MDI-PRC Code = 99
- Cause: This is just a warning to call for the time programmed
maintanance.
- Remedy: It is just enough to turn the CHECK UP DONE option to level
ON (see 12.4.2.15) after the maintanance is executed.
2) FORW+BACK
MDI-PRC Code = 80
- Cause: This alarm occurs when both the travel demands (Fwd and
Bwd) are active at the same time.
- Remedy: Check the wiring of the Fwd and Bwd travel demand inputs (use
the readings in the TESTER to facilitate the troubleshooting).
A failure in the logic is possible too. When you have verified the
travel demand switches are fine working and the wiring is right,
it is necessary to substituite the controller.
4) CURRENT GAIN
MDI-PRC Code = 94
- Cause: This alarm occurs the first time the controller is switched on
when the not volatile memory (EEPROM) with the set-up
parameters is not initialized yet. Then it is necessary to acquire
the gains of the current sensing circuit.
- Remedy: The current sensing set-up must be factory adjusted and so
this alarm never should happen when the controller is on the
field. So ask for the assistance of a Zapi technicians when this
alarm occurs.
5) MOS SHORTED
MDI-PRC Code = 89
- Cause: This alarm can detect a short circuit on power mosfet at startup.
Before to switch on the main contactor, the sw turns on
sequencely the Bottom and the Top side power mosfets, to
check the phase voltage.
Normally without driven mosfet the phase voltage is to Vbatt/2.
If the software checks that it remains fixed to +Vbatt or to GND
it means that there are mosfet shorted, and this alarm occurs.
- Remedy: Two possible reason:
- An external shortcircuit exist between +BATT and phase
voltage. Check harness and motor.
- A power or logic failure occurred on the controller.
2) WRONG ACQUISITION
MDI-PRC Code =31
- Cause: (Sensorless configuration only). It occurs when the automatic
acquisition of the Motor Resistance fails. See 11.
- Remedy: Check the Motor connections, the Motor Phases continuity and
the Power Battery Positive arrives to +B of the ACx
3) VMN HIGH
MDI-PRC Code = 31
- Cause: Before to switch the main contactor on, the SW turns on
sequencely the Bottom side Power Mosfets and expects the
phase V voltage falls to GND value. If the phase V remains
high level this alarm occurs.
- Remedy: Two possibilities:
- At least a motor phase is not connected to the controller or
broken.
- A Power Failure (e.g. a Bottom side Power Mosfet opened)
or a Logic Failure occured in the controller.
In this case it is necessary to substituite the controller
4) VMN LOW
MDI-PRC Code = 30
- Cause: Before to switch the main contactor on, the SW turns on
sequencely the Top side Power Mosfets and expects the phase
V voltage increases toward the rail capacitor value. If the phase
V does not increases this alarm occurs.
This alarm may occur also when the initial diagnosis is
overcome, and so the Main Contactor is expected to be
closed.Then, when the operator asks the truck moving but the
+Batt terminal of the controller is lower voltage than the Battery
voltage, this alarm occurs (Main Contactor has lost the
contactation although it is closed).
2) PEDAL WIRE KO
MDI-PRC Code = 86
- Cause: The SW continuously checks for the connection of the two
supply ends of the potentiometer in the accelerator. The test
consists of reading the voltage drop on a sense diode,
connected between NPOT (CNA#12) and GND and cascaded
with the potentiometer: if the potentiometer gets disconnected
on PPOT or NPOT, no current flow in this sense diode and the
voltage on the NPOT connection collapses down.
When the NPOT voltage is less than 0.3V this alarm occurs.
This alarm occurs also when the NPOT voltage is higher than
2Vdc (to detect also the condition of a broken sense diode).
- Remedy: Check the voltage on NPOT (CNA#12) and the potentiometer
connections.
3) INPUT ERROR #1
MDI-PRC Code = 91
- Cause: This alarm occurs when the PLD device has a failure. The PLD
device is used for both, the Passive Emergency Cell (see 5.1)
and a Multiplexer on the Main Lifting/Lowering requests. This
Multiplexer exits the Lifting and the Not Lifting level on two
distinct addresses. When the Lifting and the Not Lifting outputs
have the same Logic Level the PLD device has failed and this
alarm occurs.
- Remedy: It is necessary to substituite the controller.
4) WRONG ZERO
MDI-PRC Code = 92
- Cause: (Sensorless configuration only). This diagnosis is executed
every time the controller turns from resting to move. Then,
before to turn the truck moving, the outputs of the amplifiers
(used to measure the Motor Currents and Voltages) are
checked to be near null. This alarm occurs when the Current
5) MISMATCHED RM
MDI-PRC Code = 70
- - Cause: (Sensorless configuration only). Each time the travel demands
are at rest longer than 5sec, the SW compares the Actual Motor
Resistance with the Value was acquired at the installation (see
11.1 Step6) by iniecting a DC current in the motor. If the Actual
Value and the Acquired Value are different more than 20% this
alarm occurs.
- - Remedy: Check the Motor connections are tightened, the thermal sensor
in the motor is right working, the Motor Phases continuity.
It is mandatory to do a new Motor Resistance acquisition
after the cause of the problem was fixed.
6) OVERLOAD
MDI-PRC Code = 97
- Cause: This is just a warning occuring when the circuit to limit the
current via HW (under a limiting value is about 20% higher than
the nominal Current Limitation), operates several times in a
short interval. The OVERLOAD condition de-energizes the
Electromechanical Brake. The controller exits by itself from this
condition when the circuit to limit the Current via Hardware
stops to operate.
- Remedy: Normally this is a temporary warning due to a sudden
application of too much load or gradient in the truck.
7) EVP NOT OK
MDI-PRC Code = 88
- Cause: The voltage of the CND#7 that provide positive for proportional
valves is checked by the software.
If this voltage is not correct this alarm is signalled.
- Remedy: Two possible reason:
- Check if there is the positive on CND#7 and if something in
the harness is not correct.
- The problem could be on the power Mosfet or on the logic
board of the AC-X.
2) STBY I HIGH
MDI-PRC Code = 53
- Cause: This diagnosis is executed only when the main contactor is
opened and asked to be closed (e.g. at key on or when the
main contactor is opened and a new motion request turns
active). Then the outputs of the Current amplifiers must be in a
narrow window close to 2.5Vdc (from 2.26V to 2.74V).
Otherwise this STBY I HIGH alarm occurs.
- Remedy: If the alarm occurs permanently, it is necessary to substituite
the controller.
2) CONTACTOR OPEN
MDI-PRC Code = 38
- Cause: The main contactor coil has been driven by the logic board, but
the contactor doesn’t close.
- Remedy: Check the coils wires of the Main Contactor. They could be
interrupted. The contact of the contactor does not work properly
(doesn’t pull in).
3) CONTACTOR CLOSED
MDI-PRC Code = 37
- Cause: Before driving the LC coil, the controller checks if the LC
contact is stuck. The controller drives the bridge for a while,
trying to discharge the capacitor bank. If they don't discharge,
the fault condition is entered.
- Remedy: Check if contact is really stuck.
4) AUX OUTPUT KO
MDI-PRC Code = 16
- Cause: This alarm occurs when the feedforward PWM generated by the
controller to supply the Electromechanical Brake and the actual
feedback voltage on the Electromechanical Brake are not
matched in between. The diagnosis is made only when the
Tiller Switch is active.
Then:
a) When the feedforward PWM is less than 10% of the battery
voltage, the Actual voltage on the Electromechanical Brake
is expected low. If it is higher than 14V it means the
Electromechanical Brake never Brakes the truck (probably
the Driver of the Elecromechanical Brake is short circuited)
and this alarm occurs.
b) When the feedforward PWM is higher than 70% of the
battery voltage, the Actual voltage on the
Electromechanical Brake is expected high. If it is lower than
14V it means the Electromechanical Brake always gets the
truck Braked (probably the Driver of the Elecromechanical
Brake is opened) and this alarm occurs.
- Remedy: Probably it is necessary to substituite the controller because the
driver of the Electromechanical Brake has a failure.
10) ERROR IV
MDI-PRC Code = 93
- Cause: This alarm occurs when the current in the phase V has not a
null medium voltage when the frequency is higher than 20Hz: a
sine wave must always has a null medium voltage.
- Remedy: If the problem occurs permanently it is necessary to substituite
the controller.
11) ERROR IW
MDI-PRC Code = 93
- Cause: This alarm occurs when the current in the phase W has not a
null medium voltage when the frequency is higher than 20Hz: a
sine wave must always has a null medium voltage.
- Remedy: If the problem occurs permanently it is necessary to substituite
the controller.
2) MOTOR TEMPERAT
MDI-PRC Code = 65
- Cause: In the encoder version, this is just a warning with no effect on
the truck performance. It occurs when the temperature of the
motor winding overtakes the MOTOR OVERTEMP setting.
In the sensorless version this alarm occurs when the MOTOR
TEMPERATURE overtakes 150°.
- Remedy: Check the thermal sensor inside the motor (use the MOTOR
TEMPERATURE reading in the TESTER menu). If the sensor is
OK, improve the air cooling of the motor.
2) DATA ACQUISITION
MDI-PRC Code = Null
- Cause: This is just a warning of the Sensorless configuration when the
check between the actual motor resistance end the
autoacquired value is in progress. This check is performed 5
Sec. after the travel demands are released.
- Remedy: No remedy required.
The Alarm Code List Sourced by the Controller (Source Device Code 02) is the
following:
1: WRONG CONFIG
8: WATCH DOG
13: EEPROM KO
16: AUX OUTPUT KO
17: LOGIC FAILURE #3
18: LOGIC FAILURE #2
19: LOGIC FAILURE #1
30: VMN LOW
31: VMN HIGH
37: CONTACTOR CLOSED
38: CONTACTOR OPEN
53: STBY I HIGH
55: PROGRAM LIFT LEVER
60: CAPACITOR CHARGE
61: HIGH TEMPERATURE
65: MOTOR TEMPERAT
67: CAN BUS KO
70: ENCODER ERROR OR MISMATCHED RM
71: HANDBRAKE
73: THERMIC SENS KO
76: COIL SHORTED
78: VACC NOT OK
79: INCORRECT START
80: FORW+BACK
86: PEDAL WIRE KO
88: EVP NOT OK
89: MOS SHORTED
90: LIFT+LOWER
91: LIFT LOW ACTIVE or INPUT ERROR #1
92: WRONG ZERO
The Alarm Code List Sourced by the MDI-PRC (Source Device Code 16) is the
following:
Check the wear and condition of the electromechanical brake. According with the
ISO 6292 the electromechanical brake must be able to lock the truck in the worst
case in terms of admitted gradient and load. The truck manufacturer has to take
care the ISO 6292 is fullfilled with a suited maintenance scheduling.
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.
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.