Zapi AC-0 SSL User manual

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel [phone] (r.a.) – Fax [phone]
e-mail: [email protected] – web: www.zapispa.it
EN
FREE VERSION
User Manual
AC-0 SSL
SENSORED

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Copyright © 1975-2009 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.
is a registered trademark property of Zapi S.p.A.
NOTES LEGEND
4The symbol aboard is used inside this publication to indicate an annotation or a
suggestion you should pay attention.
UThe symbol aboard is used inside this publication to indicate an action or a
characteristic very important as for security. Pay special attention to the
annotations pointed out with this symbol.

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Contents
1INTRODUCTION ...................................................................................................................6
2SPECIFICATION...................................................................................................................7
2.1 Technical specifications..............................................................................................7
2.2 Block diagram.............................................................................................................7
3SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......8
3.1 Microswitches.............................................................................................................8
3.2 Accelerator unit...........................................................................................................8
3.3 Other analog control unit ............................................................................................9
3.4 Analog motor thermal sensor input.............................................................................9
3.5 Speed feedback..........................................................................................................9
4INSTALLATION HINTS.......................................................................................................10
4.1 Material overview......................................................................................................10
4.1.1 Connection cables ......................................................................................10
4.1.2 Contactors...................................................................................................10
4.1.3 Fuses..........................................................................................................10
4.2 Installation of the hardware.......................................................................................11
4.2.1 Positioning and cooling of the controller.....................................................11
4.2.2 Wirings: power cables.................................................................................11
4.2.3 Wirings: CAN connections and possible interferences...............................12
4.2.4 Wirings: I/O connections.............................................................................14
4.2.5 Connection of the encoder..........................................................................14
4.2.6 Main contactor and key connection ............................................................15
4.2.7 Insulation of truck frame..............................................................................15
4.3 Protection and safety features..................................................................................15
4.3.1 Protection features......................................................................................15
4.3.2 Safety Features...........................................................................................16
4.3.3 Passive emergency cell..............................................................................16
4.4 EMC..........................................................................................................................17
5OPERATIONAL FEATURES ..............................................................................................20
5.1 Diagnosis..................................................................................................................20
6DESCRIPTION OF THE CONNECTORS............................................................................22
6.1 Connectors of the logic – Traction configuration ......................................................22
6.1.1 Standard version with Encoder...................................................................22
6.1.2 MDI PRC version with Encoder ..................................................................24
6.2 Connectors of the logic – Pump configuration..........................................................26
6.3 Description of power connections.............................................................................28
7DRAWINGS.........................................................................................................................29
7.1 Mechanical drawing..................................................................................................29
7.2 Connection drawing – Traction configuration ...........................................................30
7.2.1 Standard version with Encoder...................................................................30
7.2.2 MDI-PRC Version with Encoder..................................................................31
7.3 Connection drawing – Pump configuration...............................................................32
8ONE SHOT INSTALLATION PROCEDURE.......................................................................33
8.1 Traction configuration...............................................................................................33
8.1.1 Sequence for Ac traction Inverter setting....................................................34
8.2 Pump configuration...................................................................................................35
8.2.1 Sequence for Ac pump Inverter setting.......................................................35

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9PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE ..................................37
9.1 Adjustments via console...........................................................................................37
9.2 Description of console (hand set) & connection.......................................................37
9.3 Description of standard console menu.....................................................................38
9.3.1 Traction configuration.................................................................................38
9.3.2 Pump configuration.....................................................................................40
9.4 Function configuration..............................................................................................41
9.4.1 Traction.......................................................................................................41
9.4.2 Pump..........................................................................................................48
9.5 Parameter regulation................................................................................................54
9.5.1 Traction.......................................................................................................54
9.5.2 Pump..........................................................................................................58
9.5.3 Zapi menu “HARDWARE SETTINGS” functions list ..................................62
9.5.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list................................63
9.6 Main menu “TESTER” functions list .........................................................................64
9.6.1 Traction.......................................................................................................64
9.6.2 Pump..........................................................................................................67
10 OTHER FUNCTIONS..........................................................................................................71
10.1 Description of console “SAVE” function ...................................................................71
10.2 Description of console “RESTORE” function............................................................73
10.3 Description of console “PROGRAM VACC” function................................................75
10.4 Shortform table of the aux output #1 setting (traction version).................................77
10.5 Description of the throttle regulation.........................................................................78
10.6 Description of the battery charge detection setting ..................................................79
11 AC-0 ALARMS LIST – TRACTION CONFIGURATION.....................................................80
11.1 Main menu “ALARMS” list........................................................................................80
11.1.1 One Blink Alarms........................................................................................80
11.1.2 Two Blinks Alarms......................................................................................81
11.1.3 Three Blinks Alarms ...................................................................................82
11.1.4 Four Blinks Alarms .....................................................................................83
11.1.5 Five Blinks Alarms......................................................................................84
11.1.6 Six Blinks Alarms........................................................................................85
11.1.7 Seven Blinks Alarms...................................................................................87
11.1.8 Eigth Blinks Alarms.....................................................................................87
11.1.9 No Blink Alarms..........................................................................................88
11.1.10 Thirty Two Blinks Alarms............................................................................88
11.2 MDI-PRC “ALARMS” List .........................................................................................89
12 AC-0 ALARMS LIST – PUMP CONFIGURATION .............................................................91
12.1 Main menu “ALARMS” list........................................................................................91
12.1.1 One Blink Alarms........................................................................................91
12.1.2 Two Blinks Alarms......................................................................................92
12.1.3 Three Blinks Alarms ...................................................................................92
12.1.4 Four Blinks Alarms .....................................................................................93
12.1.5 Five Blinks Alarms......................................................................................94
12.1.6 Six Blinks Alarms........................................................................................94
12.1.7 Seven Blinks Alarms...................................................................................96
12.1.8 Eigth Blinks Alarms.....................................................................................96
12.1.9 No Blink Alarms..........................................................................................96
12.1.10 Thirty Two Blinks Alarms............................................................................97

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12.2 MDI-PRC “ALARMS” List..........................................................................................98
13 RECOMMENDED SPARE PARTS .....................................................................................99
14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.......................100
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
GRAPHIC AND LAYOUT CP
PROJECT MANAGER MI
TECHNICAL ELECTRONIC
MANAGER VISA PP
SALES MANAGER VISA PN
Publication N°: AE0ZP0EC
Edition: September 2006

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1 INTRODUCTION
The AC-0 SSL inverter has been developed for applications such as transpallet
trucks, stacker trucks and cleaning machines with Asynchronous (AC) traction
and pump motors up to 1.2 kW (Vbatt=24 V), 1.8 kW (Vbatt=36 V) and 2 kW
(Vbatt=48 V).
The AC-0 SSL can be supplied in two versions:
1) Sensored version using an Encoder (Sensor Bearing) in the Motor axle
2) SenseCoils version using special auxiliary windings in the motor.
Here the Sensored Version is described: it adopts an Encoder integrated in the
Ball Bearing (Sensor Bearing).
The Encoder fills up the truck performance, respect to the Sensorless and Sense
Coils versions, with lower minimum speed, the “stop on the ramp” service and a
smoother inversion; on the other hand the reliability gets penalized by the fragile
mechanics and inaccessible position of the Sensor Bearing.
The correct part number for the 24 V AC-0 SSL with Encoder is FZ2008. The 36
V has a different part number is FZ3006.
AC-0 has also a big brother controller called AC-1, both are available in the
Sensored version. The only differences between AC-0 and AC-1 are the
maximum current (150 A vs. 250 A) and the dimensions.
All the Zapi AC controllers have the CAN Bus communication peripheral and a
Serial Link embedded: the SW for the communication via CAN Bus between the
AC-0 and the MDI-PRC has been already developed in a standard handling here
described.
MDI-PRC is a Zapi module to be mounted on the dashboard of the truck to inform
with a display about the state of the truck and provided with a Leds battery
charge indicator. Besides, the MDI-PRC can drive four electrovalves (two
proportional and two On/Off type) for an advanced hydraulics handling. MDI-PRC
is the natural choice to fill the AC-0’s services with those extra functions asked
only on the high level trucks.
AC-0 SSL has an additional analogue input (CNA #13) suited to receive a motor
thermal sensor (KTY84-130).
The reference SW release for this manual is AC0TXXX ZP1.07.

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2 SPECIFICATION
2.1 Technical specifications
Inverter for AC asynchronous 3-phase motors
Regenerative braking
Can-bus interface
Digital control using a microcontroller
Encoder Interface
Voltage:....................................................................................................24 – 36 V
Maximum current (24 V, 36 V):..................................................150 A (RMS) for 2'
Maximum current (48 V):............................................................120 A (RMS) for 2'
Booster (all version):..................................................170 A (RMS) for 10 seconds
Operating frequency:..............................................8 kHz with center aligned PWM
External temperature range: ............................................................ -30 °C ÷ 40 °C
Maximum inverter temperature (at full power): ...............................................78 °C
2.2 Block diagram
Figure 2–1

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3 SPECIFICATION FOR THE INPUT DEVICES
FILLING UP THE INSTALLATION KIT
The AC-0 controller needs some external parts in order to work. The following
devices complete the kit for the AC-0 installation.
3.1 Microswitches
- The microswitches must have a contact resistance lower than 0.1 Ωand a
leakage current lower than 100 µA.
- When full load connected, the voltage between the key switch contacts must
be lower than 0.1 V.
- The microswitches (if not otherwise noted) must connect or break a battery
voltage to the inputs pins.
3.2 Accelerator unit
The accelerator unit can consist of a potentiometer or an Hall effect device.
It should be in a 3-wire configuration. The potentiometer is supplied through
CNB#12 with about 12 Vdc.
CPOT (CNB#10) signal ranges is from 0 to 10 V.
Potentiometer value should be in the 0.5 - 10 kΩrange; generally, the load
should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this
range.
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 10.3 PROGRAM VACC function), in either direction.

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3.3 Other analog control unit
Input CNA#18 is an analog input, whose typical application is a proportional
command to enable a lifting and a lowering proportional Valves. It is possible to
use this input for an alternative function is a proportional braking. It should be in a
3 wire configuration. Potentiometer value should be in the 0.5-10 kΩrange.
Generally, the load should be in the 1.5 mA to 30 mA range.
The CPOTB (CNA#18) signal range is from 0 to 10 V.
3.4 Analog motor thermal sensor input
Input CNA#13 is an analog input to receive an analog Thermal Sensor Model
Philips KTY84-130 to measure the Motor Winding Temperature. This is a PTC
polarized two terminals device: connect the positive end to CNA#13 and a the
negative end to a minus battery voltage (e.g. CNA#8).
3.5 Speed feedback
The motor control is based upon the motor speed feedback. The speed
transducer is an incremental encoder, with two phases shifted at 90°. The
encoder can be of different types:
- power supply: +5 V or +12 V
- electric output: open collector ( NPN or PNP), push-pull.
The wished resolution must be specified when ordering the controller. The
suggested resolution is from 32 pulses/rev up to 64 pulses/rev.
For more details about encoder installation see also chapter 4.2.5.
4Note: 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:
AC0T2BE ZP1.10
That means:
AC0T=AC-0 traction controller
(AC0P= AC-0 pump controller)
2= poles pair number
B= 64 pulses/rev encoder
E= identifier for an extended memory hardware release inside
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

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4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
4These are information useful for anyone is working on the installation, or a
deeper examination of the content
UThese are Warning boxes, they describe:
- operations that can lead to a failure of the electronic device or can be
dangerous or harmful for the operator;
- items which are important to guarantee system performance and safety
4.1 Material overview
Before to start it is necessary to have the required material for a correct
installation. Otherwise a wrong choice of cables or other parts could lead to
failures/ misbehaviour/ bad performances.
4.1.1 Connection cables
For the auxiliary circuits, use cables of 0.5 mm² section.
For power connections to the motor and to the battery, use cables having section
of 16 mm² (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.
4.1.2 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 AUX VOLTAGE #1
option in “Set options” submenu):
- 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.
4.1.3 Fuses
- Use a 6.3-10 A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, use a 120-150 A 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.

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4.2 Installation of the hardware
UBefore 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 inverter using a
Resistor between 10 ohm and 100 ohm.
4.2.1 Positioning and cooling of the controller
Install the inverter 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 controller.
- 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.
4.2.2 Wirings: power cables
- The power cables length must be as short as possible to minimize power
losses.
- They must be tightened on controller power posts with a Torque of 13-15
Nm.
- The inverter should only be connected to a traction battery. Do not use
converters outputs or power supplies. For special applications please contact
the nearest Zapi Service Centre.
- During battery charge, disconnect the controller from the battery.
- Never connect SCR low frequency chopper with AC Motor Inverter because
the Rail 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.
UDo not connect the inverter to a battery with a nominal voltage different
than the value indicated on the controller label. A higher battery voltage
may cause power section failure. A lower voltage may prevent the logic
operating.

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4.2.3 Wirings: CAN connections and possible interferences
4CAN 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.
UWrong Layout:
The red lines are can wires.
The black boxes are different modules, for example traction controller, pump
controller and display connected by canbus.
The black lines are the power cables.
Module
1
Module
3
Module
2
R
R
Can Bus
Power cables

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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.
UCorrect Layout:
Note: Module 1 power > Module 2 power > Module 3 power
The chain starts from the –BATT post of the controller that works with the highest
current, and the others are connected in a decreasing order of power.
Otherwise, if two controllers are similar in power (for example a traction and a
pump motor controller) and a third module works with less current, the best way
to deal this configuration is to create a common ground point (star configuration).
UCorrect Layout:
Note: Module 1 power
≈ Module 2 power > Module 3 power
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground
point (pointed by the arrow in the image) must be dimensioned taking into
account thermal and voltage drop problems.
Module
1Module
2
Module
3
R
R
Can Bus
Power cables
Center of the Ground connection
Module
1Module
2
Module
3
R
R
Can Bus
Power cables

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4Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
- lower costs (less and smaller cables )
- improved reliability (fewer connections)
- analysis of problems improved (easy connection with a pc to read the data
flowing through the cable).
4.2.4 Wirings: I/O connections
- After crimping the cable, verify that all strands are entrapped in the wire
barrel.
- Verify that all the crimped contacts are completely inserted on the connector
cavities.
UA 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”.
4.2.5 Connection of the encoder
1) AC-0 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 +12 V. It can have
different electronic output.
A9 +5V/+12V positive of encoder power supply.
A10 GND negative of encoder power supply.
A19 A phase A of encoder.
A20 B phase B of encoder.
2) Connection of encoder with open collector output; +5 V power supply.
3) Connection of encoder with open collector output: +12 V power supply.

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UVERY 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).
4.2.6 Main contactor and key connection
- The connection of the main contactor can be carried out following the
drawing in Figure 4–1.
- An intrinsic protection is present inside the logic when the voltage on the
battery power connection overtakes the battery nominal voltage more than a
certain percentage. Thank to this protection, it is allowed that the Main
Contactor (or an emergency switch) breaks the Battery positive in every
moment regardless of the state of the key (without this protection, if the Main
Contactor breaks when a regenerative braking is in progress, the rail
capacitor voltage increases and the overvoltage could damage the Power
Mosfets).
Figure 4–1
4.2.7 Insulation of truck frame
UAs stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7,
“there shall be no electrical connection to the truck frame”. So the truck
frame has to be isolated from any electrical potential of the truck power
line.
4.3 Protection and safety features
4.3.1 Protection features
The AC-0 is protected against some controller injuries and malfunctions. These
are:
- Battery polarity inversion
It is necessary to fit a MAIN CONTACTOR to cut off the Battery Positive
connection to protect the inverter against reverse battery polarity and for

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safety reasons.
- Connection Errors:
All inputs are protected against connection errors.
- Thermal protection
If the controller temperature exceeds 78 °C, the maximum current is reduced
in proportion to the thermal increase. The cut off temperature is 100 °C.
- 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 a threshold is
1V higher than the minimum voltage value stored with the PROGRAM
VACC operation.
- Running microswitch in closed position.
- An important improvement against the uncontrolled movements is given
by the Passive Emergency Cell (see paragraph 4.3.3 below).
- Low battery charge:
In the encoder release, when the battery charge is low, the maximum speed
is reduced to the 25% of the maximum programmed. The Lifting Operation
inhibited.
- 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.
4.3.2 Safety Features
UZAPI controllers are designed according to the prEN954-1 specifications for
safety related parts of control system and to UNI EN1175-1 norm. The
safety of the machine is strongly related to installation; length, layout and
screening of electrical connections have to be carefully designed.
ZAPI is always available to cooperate with the customer in order to evaluate
installation and connection solutions. Furthermore, ZAPI is available to
develop new SW or HW solutions to improve the safety of the machine,
according to customer requirements.
Machine manufacturer holds the responsibility for the truck safety features
and related approval.
AC-0 inverter electronic implements an hardware safety circuit, which is able to
switch off the three phase Power Bridge stopping the machine via HARDWARE,
that is bypassing the software control.
This safety Circuit is actuated releasing the Tiller Switch and the handling is
descripted in detail in the next Paragraph (see paragraph 4.3.3 PASSIVE
EMERGENCY CELL).
4.3.3 Passive emergency cell
The Tiller Switch input is processed by two separated devices: the uC and a PLD
(GAL). When the Tiller Switch turns open, both, the uC and the PLD device
switch off the power mosfets distinctly one from the other. The PLD does that
with a delay of 800 msec. So, this PLD is a separate device (distinct from the uC)

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that automatically prevent operation of the travel circuit when the operator leaves
the truck.
τ
Figure 4–2
One of the reason for the adoption of this Passive Emergency cell is to comply
with the EN1175-5.9.5: “A separate device independent 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 (together with the Elaboration Unit) reads this
separate device and stops the truck distinctly from the Elaboration Unit. This is
exactly what the Passive Emergency Cell does.
In a system with a single microprocessor technology, the weak point is that just
one unit (uC) processes the Inputs and decides alone to keep the motor moving
or not. If this elaboration unit (uC) fails it is possible it keeps the motor moving
against of the state of the commands. To avoid this risk, the Passive Emergency
cell provides a further step of safety that is a redundancy in processing the
motion request (Tiller or Seat Switch). In our controller the truck will be stopped,
releasing the tiller, disregarding if the main Elaboration Unit (uC) is right working
or not.
4.4 EMC
UEMC and ESD performances of an electronic system are strongly
influenced by the installation. Special attention must be given to the
lengths and the paths of the electric connections and the shields. This
situation is beyond ZAPI's control. Zapi can offer assistance and
suggestions, based on its years experience, on EMC related items.
However, ZAPI declines any responsibility for non-compliance,
malfunctions and failures, if correct testing is not made. The machine
manufacturer holds the responsibility to carry out machine validation,
based on existing norms (EN12895 for industrial truck; EN50081-2 for other
applications).
EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetic energy generated or received by an electrical

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device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the
device and the possible countermeasure to prevent the propagation of that
energy; we talk about “conduction” issues when guiding structures such as
wires and cables are involved, “radiated emissions” issues when it is studied
the propagation of electromagnetic energy through the open space. In our
case the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate
RF energy, but wires and cables have the key role to propagate the
disturbs because they works as antennas, so a good layout of the cables
and their shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The 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
simulate external undesired disturbances and verify the electronic devices
response.
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 happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
A) 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
information.
B) in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from
being generated, than to increase the level of immunity of the electronic devices.
There are different solutions for EMC issues, depending on level of emissions/
immunity required, the type of controller, materials and position of the wires and
electronic components.
1) EMISSIONS. Three ways can be followed to reduce the emissions:
A) SOURCE OF EMISSIONS: finding the main source of disturb and work
on it.
B) SHIELDING: enclosing contactor and controller in a shielded box; using
shielded cables;
C) LAYOUT: a good layout of the cables can minimize the antenna effect;
cables running nearby the truck frame or in iron channels connected to

AE0ZP0EC - AC-0 SSL SENSORED - User Manual Page - 19/100
truck frames is generally a suggested not expensive solution to reduce
the emission level.
2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions
are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent
damages from ESD:
A) PREVENTION: when handling ESD-sensitive electronic parts, ensure the
operator is grounded; test grounding devices on a daily basis for correct
functioning; this precaution is particularly important during controller
handling in the storing and installation phase.
B) ISOLATION: use anti-static containers when transferring ESD-sensitive
material.
C) GROUNDING: when a complete isolation cannot be achieved, a good
grounding can divert the discharge current trough a “safe” path; the
frame of a truck can works like a “local earth ground”, absorbing excess
charge. So it is strongly suggested to connect to truck frame all the
parts of the truck which can be touched by the operator, who is
most of the time the source of ESD.

Page - 20/100 AE0ZP0EC - AC-0 SSL SENSORED - User Manual
5 OPERATIONAL FEATURES
- 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 speed.
- Voltage boost at the start and with overload to obtain more torque (with
current control).
- The inverter drives an electromechanical brake
- High efficiency of motor and battery due to high frequency commutations.
- Self diagnosis.
- 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.
- 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 10.4 and
STOP ON RAMP option in “Set options” submenu).
- Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to
the pump inverter on the can-bus line (see also “Set options”
submenu).
- moreover, if the pump inverter is not present (for ex: tractor
application), the traction inverter can manage an "hydraulic steering
function" by driving a hydro contactor which drive a hydraulic steering
motor (output CNA#3), see also “Set options” submenu.
2) pump inverter
- the pump inverter manage an "hydraulic steering function". That is, it
drives the pump motor at the programmed speed for the
programmed time.
5.1 Diagnosis
The microcontroller 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 in standby that checks: phase's voltages, contactor driver,