Zapi ACE0 2mC 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
User Manual
ACE0 2µC
COMBIAC0 2µC
Publication: AF6ZP0CA
Edition: March 1, 2018
EN

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Copyright © 1975-2018 Zapi S.p.A.
All rights reserved
Contents of this publication are 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 DEFINITIONS
4This symbol is used in this publication to indicate an annotation or a suggestion
you should pay attention to.
UThis symbol is used inside this publication to indicate an action or a
characteristic very important for security. Pay special attention to the
annotations pointed out with this symbol.

AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 3/155
Contents
1INTRODUCTION ...................................................................................................................6
1.1About this document ...................................................................................................6
1.1.1Scope of this manual ....................................................................................6
1.1.2Manual revision.............................................................................................6
1.1.3Warnings and notes......................................................................................6
1.2About the controller.....................................................................................................7
1.2.1Safety............................................................................................................7
1.2.2OEM’s Responsibility ....................................................................................7
1.2.3Technical support..........................................................................................7
2SPECIFICATIONS.................................................................................................................8
2.1General features .........................................................................................................8
2.2Technical specifications..............................................................................................8
2.3Current ratings ............................................................................................................9
2.4Voltage ratings..........................................................................................................10
3DRAWINGS.........................................................................................................................11
3.1Mechanical drawings ................................................................................................11
3.1.1Base plate version ......................................................................................11
3.1.2Longitudinal heat sink version.....................................................................12
3.2Connection drawings ................................................................................................13
3.2.1AC Traction configuration ...........................................................................13
3.2.2AC Pump configuration ...............................................................................14
3.2.3AC CAN Open configuration .......................................................................15
3.2.4PMSM Traction configuration......................................................................16
3.2.5PMSM Pump configuration .........................................................................17
4I/O INTERFACE DESCRIPTION.........................................................................................18
4.1Power connectors .....................................................................................................18
4.2Ampseal connector ...................................................................................................18
4.3Internal connector .....................................................................................................21
4.4External devices .......................................................................................................22
4.4.1Key Input.....................................................................................................22
4.4.2Digital inputs ...............................................................................................22
4.4.3Analog inputs ..............................................................................................24
4.4.4Special inputs..............................................................................................25
4.4.5Encoder inputs............................................................................................25
4.4.6MC output ...................................................................................................26
4.4.7EB output ....................................................................................................28
4.4.8Auxiliary outputs..........................................................................................29
4.4.9High-side driver...........................................................................................31
4.4.10Motor temperature measurement input.......................................................32
4.4.11Sensor supply .............................................................................................32
4.4.12Analog supply .............................................................................................32
4.4.13CAN bus......................................................................................................33
5INSTALLATION HINTS.......................................................................................................34
5.1Material overview......................................................................................................34
5.1.1Connection cables ......................................................................................34
5.1.2Contactors...................................................................................................34
5.1.3Fuses ..........................................................................................................34

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5.2Installation of the hardware ...................................................................................... 35
5.2.1Positioning and cooling of the controller.....................................................35
5.2.2Wirings: CAN bus connections and possible interferences ........................ 36
5.2.3Wirings: I/O connections............................................................................. 38
5.2.4Connection of an encoder .......................................................................... 39
5.2.5Connection of a sin/cos sensor ..................................................................40
5.2.6Connection of Hall sensors......................................................................... 40
5.2.7Connection of main contactor and key switch ............................................41
5.2.8Insulation of the truck frame .......................................................................41
5.3EMC .........................................................................................................................42
5.4Various suggestions .................................................................................................43
6FEATURES.........................................................................................................................44
6.1Operational features................................................................................................. 44
6.2Dual traction motor ................................................................................................... 45
6.3Pump motor.............................................................................................................. 45
6.4Torque mode ............................................................................................................45
6.5Speed mode ............................................................................................................. 45
6.6Protection and safety features.................................................................................. 45
6.6.1Protection features .....................................................................................45
6.6.2Safety features ...........................................................................................46
7START-UP HINTS...............................................................................................................47
7.1Check prior to initial power up .................................................................................. 47
7.2Configuring motor controller for the application........................................................ 47
7.3Set-up procedure for AC traction inverter.................................................................48
7.3.1Sin/cos-sensor case ...................................................................................48
7.4Set-up procedure for AC pump inverter....................................................................49
8PROGRAMMING & ADJUSTEMENTS ..............................................................................51
8.1Settings overview .....................................................................................................52
8.2Settings description ..................................................................................................53
8.2.1PARAMETER CHANGE............................................................................. 53
8.2.2SET OPTIONS ........................................................................................... 59
8.2.3ADJUSTMENTS ......................................................................................... 67
8.2.4SPECIAL ADJUST. .................................................................................... 72
8.2.5HARDWARE SETTING .............................................................................. 75
8.3TESTER function......................................................................................................77
8.3.1TESTER – Master microcontroller..............................................................77
8.3.2TESTER – Supervisor microcontroller........................................................ 85
9OTHER FUNCTIONS..........................................................................................................87
9.1PROGRAM VACC function ...................................................................................... 87
9.2PROGRAM LIFT / LOWER function......................................................................... 87
9.3PROGRAM STEER function .................................................................................... 88
9.4Acceleration time ...................................................................................................... 88
9.5Braking time ............................................................................................................. 89
9.6Acceleration smoothness ......................................................................................... 91
9.7Steering curve ..........................................................................................................91
9.8Description of the throttle regulation......................................................................... 92
9.9NMC & NEB output ..................................................................................................93
9.10Battery-charge detection ..........................................................................................94
9.11EVP Setup................................................................................................................ 95

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9.12Torque Profile ...........................................................................................................97
9.13Steering Table ..........................................................................................................99
9.14Motor thermal protection.........................................................................................100
10DIAGNOSTIC SYSTEM.....................................................................................................101
10.1ALARMS menu .......................................................................................................101
10.2Diagnoses...............................................................................................................101
10.3Alarms from master µC...........................................................................................103
10.3.1Troubleshooting of alarms from master µC...............................................107
10.4Alarms from supervisor µC .....................................................................................131
10.4.1Troubleshooting of alarms from supervisor µC.........................................131
10.5Info code for electrovalves......................................................................................136
11SPARE PARTS .................................................................................................................137
12PERIODIC MAINTENANCE..............................................................................................138
13APPENDICES....................................................................................................................139
13.1Appendix A: PC CAN Console user guide..............................................................139
13.1.1PC CAN Console configuration.................................................................139
13.1.2Parameter download.................................................................................141
13.1.3How to modify the parameters ..................................................................142
13.1.4Program Vacc ...........................................................................................143
13.1.5Lift & Lower command acquiring
...............................................................143
13.1.6Steer acquiring..........................................................................................144
13.1.7Tester Functionality...................................................................................144
13.1.8Alarm Logbook..........................................................................................145
13.2Appendix B: Zapi Smart Console user guide..........................................................146
13.2.1Operational Modes....................................................................................146
13.2.2The keyboard............................................................................................146
13.2.3Home Screen ............................................................................................147
13.2.4Connected.................................................................................................148
13.2.5How to modify a parameter.......................................................................149
13.2.6Program VACC .........................................................................................150
13.2.7Lift and Lower commands acquiring .........................................................151
13.2.8Steer command acquiring.........................................................................152
13.2.9Tester........................................................................................................152
13.2.10Alarms.......................................................................................................152
13.2.11Download parameter list to USB stick.......................................................153
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA

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1 INTRODUCTION
1.1 About this document
1.1.1 Scope of this manual
This manual provides important information about ACE0/COMBIAC0 controller: It
presents instructions, guidelines and diagrams related to installation and
maintenance of the controller in an electrically powered vehicle.
1.1.2 Manual revision
This revision replaces all previous revisions of this document. Zapi has put much
effort to ensure that this document is complete and accurate at the time of
printing. In accordance with Zapi policy of continuous product improvement, all
data in this document are subject to change or correction without prior notice.
1.1.3 Warnings and notes
In this manual, special attention must be paid to information presented in warning
and information notices.
Definitions of warning and information notices are the following.
4This is an information box, useful for anyone is working on the installation, or for
a deeper examination of the content.
UThis is a warning box, it can 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.
UThis is a further warning within the box. Pay special attention to the
annotations pointed out within warning boxes.

AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 7/155
1.2 About the controller
1.2.1 Safety
Zapi provides this and other manuals to assist manufacturers in using the motor
controller in a proper, efficient and safe manner. Manufacturers must ensure that
all people responsible for the design and use of equipment employing the motor
controller have the proper professional skills and equipment knowledge.
UBefore doing any operation, ensure that the battery is disconnected and
when the installation is completed start the machine with the drive wheels
raised from the ground to ensure that any installation error does not
compromise safety.
UAfter the inverter turn-off, even with the key switch open, the internal
capacitors may remain charged for some time. For safe operation onto the
setup, it is recommended to disconnect the battery and to discharge the
capacitors by means of a resistor of about 10 – 100 Ohm between +B and -
B terminals of the inverter.
1.2.2 OEM’s Responsibility
Zapi motor controllers are intended for controlling motors in electric vehicles.
These controllers are supplied to original equipment manufacturers (OEMs) for
incorporation into their vehicles and vehicle control systems.
Electric vehicles are subject to national and international standards of
construction and operation which must be observed. It is responsibility of the
vehicle manufacturer to identify the correct standards and to ensure that the
vehicle meets these standards. As a major electrical control component, the role
of a Zapi motor controller should be carefully considered and relevant safety
precautions taken. It has several features which can be configured to help the
system integrator meeting vehicle safety standards.
Zapi does not accept responsibility for incorrect application of its products.
1.2.3 Technical support
For additional information on any topic covered in this document or application
assistance on other Zapi products, contact Zapi sales department.

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2 SPECIFICATIONS
2.1 General features
COMBIAC0/ACE0 inverters are controllers designed to control AC induction,
BLDC and PMSM motors, in the range from 2 kW to 5 kW continuous power,
used in a variety of battery-powered material handling trucks.
COMBIACE0 is designed to control series-wound DC motors too, typically
employed as pump motor; AC and DC sections are combined in the same device.
Typical applications include, but are not limited to: walkie trucks and rider pallet
trucks, stackers, low level order pickers, small counterbalanced trucks, aerial-
access equipment.
The main inverter features are:
16-bits microcontroller for motor control and main functions, 576+ kByte
embedded flash memory.
16-bits microcontroller for safety functions, 320+ kByte embedded flash
memory.
Controller for AC motors from 2 kW to 5 kW.
Pump controller for series-wound DC motors (only for COMBIAC0).
Field-oriented motor control.
Smooth low-speed control and zero-speed holding control.
Zapi patented sensorless and sense-coil control.
Driver for a line contactor.
Low-side and high-side drivers for an electromechanical brake (short
circuit protected).
Drivers for PWM voltage-controlled electrovalves and for two proportional
valves (PWM current controlled).
Short-circuit and open-load protection.
Thermal cutback, warnings and automatic shutdown for protection of
motor and controller.
ESD-protected CAN bus interface.
Software downloadable via serial link (internal connector) or CAN bus
(external connector).
Diagnostic provided via CAN bus using Zapi PC CAN Console.
Rugged sealed housing and connectors meet IP65 environmental sealing
standards for use in harsh environments.
2.2 Technical specifications
Motor type:.......................................induction AC, synchronous AC, brushless DC
Control mode: ..................................................................... speed or torque control
Operating frequency of the AC inverter: .........................................................8 kHz
Operating frequency of the DC chopper (COMBIAC0 only): ........................16 kHz
Ambient operating temperature range: .............................................-40 °C ÷ 40 °C
Ambient storage temperature range: ................................................-40 °C ÷ 85 °C
Maximum inverter temperature (at full power): ...............................................85 °C
Connector: .................................................................................... 35-pins Ampseal
Package environmental rating: .........................................................................IP65

AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 9/155
2.3 Current ratings
Model Nominal DC
voltage
Maximum
2-min rated
current [Arms]
Continuous
rated current
[Arms]
DC maximum
current [A]
ACE0
24V 220 110
-
36/48V 180 90
COMBIAC0
24V 220 110 270
36/48V 180 90 220
ACE0 PW
24V 320 160
-
36/48V 280 140
36/48V 320 140
80V 200 100
COMBIAC0 PW
24V 320 160 400
36/48V 280 140 300
36/48V 320 140 300
80V 200 100 200
4Combinations of DC choppers and 3-phase inverters different from those
reported in the previous table are also available.
4Internal algorithms automatically reduce the maximum current limit when heat
sink temperature is above 85°C. Heat sink temperature is measured internally
near the power MOSFETs (see paragraph 6.6).
4Two-minute ratings are referred to an inverter equipped with a base plate. No
additional external heat sink or fans are used for the 2-minute rating test. Ratings
are based on an initial controller base plate temperature of 40°C and a maximum
base plate temperature of 85°C.
4The inverter can deliver the rated continuous current only if it is adequately
cooled. When it is equipped with its own finned heat sink, a proper dissipation is
obtained by applying a 100 m3/h airflow. In case it is provided with the base plate,
it is customer’s duty to design an adequate cooling system that can dissipate the
heat produced by the inverter, keeping its temperature below 85 °C. Otherwise,
the inverter will deliver a continuous RMS current lower than the rated one.

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2.4 Voltage ratings
Nominal DC voltage 24V 36/48V 80V
Conventional working voltage range 19.2 V ÷ 28.8 V 28.8 V ÷ 57.6 V 57.8 V ÷ 96 V
Non-operational overvoltage limits 35V 65V 115V
Non-operational undervoltage limits 10V 10V 30V
4Conventionally, the controller can be set to operate without alarm in the range
from 80% to 120% of the nominal battery voltage. With a different DC voltage
than specified, the controller raises an alarm.
4Undervoltage and overvoltage thresholds are defined by hardware. After start-up,
controller is fully operative if the supply voltage stays within these limits.
4Undervoltage is evaluated on the KEY input (A10); overvoltage is evaluated on
the positive battery terminal +B.

AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 11/155
3 DRAWINGS
3.1 Mechanical drawings
3.1.1 Base plate version
0.5 X 45°
R 1
1:2 A3
COMBIAC0 AMPSEAL FRAMELESS DIMENSIONS
1/1 AS
26/05/15
AF6ZP7AA

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3.1.2 Longitudinal heat sink version
0.5 X 45°
R 1
1:2 A3
COMBIAC0 AMPSEAL FRAMELESS LONGITUDINAL HEAT SINK DIMENSIONS
1/1 AS
26/05/15
AF6ZP7BA

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3.2 Connection drawings
3.2.1 AC Traction configuration

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3.2.2 AC Pump configuration

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3.2.3 AC CAN Open configuration

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3.2.4 PMSM Traction configuration

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3.2.5 PMSM Pump configuration

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4 I/O INTERFACE DESCRIPTION
4.1 Power connectors
Power connections are on vertical posts where to bolt power-cables lugs. On the
cover of the converter they are labeled as:
Terminal name Description
+B Positive battery termination
-B Negative battery termination
U, V, W Motor phase terminations.
-P Negative terminal of pump DC motor (COMBIAC0 only).
In combination with COMBIAC0, DC pump motor must be connected between
terminals +B and -P. PWM frequency at -P is 16 kHz. Terminal -P is protected by
short circuit detection, voltage and current measurements. Freewheeling diodes
to +B are built in (MOSFETs internal diodes).
4.2 Ampseal connector
Inverter is equipped with a 35-poles Ampseal connector like that of the figure.
Each of the 35 pins is referred to as “A#”, where “A” denotes the connector name
and “#” the pin number, from 1 to 35.
35-poles Ampseal connector.
The following table lists the functional associations for the pins of the 35-poles
Ampseal connector.
4For each I/O pin, the default Zapi function is indicated. The function of each pin
can be changed in customized software.
4Some I/O pins can have special functionalities depending on the controller
configuration.

AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 19/155
Pin Type Name Description
A1 Input DI0
Digital input DI0.
The input is activated when it is connected to +B. With the logic
hardware properly configured it can be used to supply the positive
terminals of EB and MC.
The default function is as TILLER input.
A2 Output PEB Positive supply of the electromechanical brake. For the 24V
version only, it is supplied through a high-side driver.
A3 Input PEV
Positive supply of electrovalves: EV1, EV2, EV3, EV4, EV5,
EVP1, EVP2, HORN. With the hardware properly configured, it
can be used to supply the positive terminal of EB.
This input is to be supplied with positive voltage taken after main
contactor.
A4 Output NEB Driving output for the electromechanical brake (driving to -B);
PWM controlled; 2 A maximum continuous current.
A5 Output NENC
Negative supply for external devices (encoder, potentiometers,
etc.)
A6 Input DI2
Digital input DI2.
The input is activated when the external switch is closed.
By default, if HARD & SOFT option is ON (see 8.2.2Errore.
L'origine riferimento non è stata trovata.), the H&S function is
activated when the switch is closed.
A7 Input DI1
Digital input DI1. Active high.
The input is activated when it is connected to +B.
The default function is as QI/PB input (quick inversion/pedal
brake). Closing the switch quick inversion function is activated.
A8 Output EV 5 /
PPOT
Driving output for the on/off electrovalve EV5; 1 A maximum
continuous current (driving to -B).
Depending on internal jumper configuration it can be used as
positive supply for external devices (+12V/+5V, max150 mA).
A9 Output EV1 Driving output for the on/off electrovalve EV1 (driving to -B); 1 A
maximum continuous current.
A10 Input KEY Input of the key switch signal.
A11 Output EV2 Driving output for the PWM voltage-controlled electrovalve EV2
(driving to -B); 1 A maximum continuous current.
A12 Output NMC Driving output for the main contactor (driving to -B); PWM voltage-
controlled; 1 A maximum continuous current.
A13 Input ENCB Phase B of the traction motor encoder.
A14 Input ENCA Phase A of the traction motor encoder.

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Pin Type Name Description
A15 Input CPOT1
Analog input 1.
The default function is as accelerator reference (wiper contact of
the accelerator potentiometer).
A16 Input DI10
Digital input DI10.
The input is activated when it is connected to +B.
The default function is as 2ND input, closing the switch valve EV2
is activated.
A17 Input DI8
Digital input DI8.
The input is activated when it is connected to +B.
The default function is as 1ST input, closing the switch valve EV1
is activated.
A18 Input DI11 /
CPOT3
Digital input DI11.
The input is activated when the external switch is closed to -B.
The default function is as CUTBACK SPEED 1 input.
In the sense coil version, this input is connected to the AC motor
sense coil.
Hardware can be properly configured as additional analog or
digital input.
A19 Input DI5
Digital input DI5.
The input is activated when it is connected to +B.
The default function is as HORN input. Closing the switch, the
horn is activated.
A20 Input DI6
Digital input DI6.
The input is activated when it is connected to +B.
The default function is as LOWERING input.
A21 Input DI12 /
CPOT4
Digital input DI12.
The input is activated when the external switch is closed to -B.
The default function is as CUTBACK SPEED 2 input.
In the sense coil version, this input is connected to the AC motor
sense coil.
Hardware can be properly configured as additional analog or
digital input.
A22 Input PTH
Analog input for the thermal sensor of the traction motor.
Internal pull-up consists of a fixed 2 mA (max 5 V) current source.
A23 Output EVP2 Driving output for the second PWM current-controlled electrovalve
(driving to -B).
A24 Output EVP1
Driving output for the first PWM current-controlled electrovalve
(driving to -B).
Default function is as LOWERING valve.
A25 Output PENC
Positive supply for external devices (encoder, potentiometers,
etc.) +12 /+5 V, 150 mA maximum.
A26 Output HORN Driving output for the horn electrovalve (driving to -B). Protected.