Zapi COMBI ACE0 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
User Manual
COMBIAC0
&
ACE0

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Copyright © 1975-2010 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 ...................................................................................................................5
2SPECIFICATION...................................................................................................................6
2.1 Technical specifications Combi AC0 / ACE0 ..............................................................6
2.2 Technical specifications Combi AC0 Power / ACE0 Power........................................6
2.3 Block diagrams ...........................................................................................................7
2.3.1 Traction control .............................................................................................7
2.3.2 Pump control.................................................................................................7
3SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......8
3.1 Digital inputs ...............................................................................................................8
3.1.1 DI0 ÷ DI10 technical details – 24 V system .................................................8
3.1.2 DI0 ÷ DI10 technical details – 48 V system .................................................8
3.1.3 Microswitches ...............................................................................................8
3.2 Analogue unit..............................................................................................................8
3.3 Other analogue control unit ........................................................................................9
3.4 Analogue motor thermal sensor input.........................................................................9
3.5 Speed feedback........................................................................................................10
4INSTALLATION HINTS.......................................................................................................11
4.1 Material overview......................................................................................................11
4.1.1 Connection cables ......................................................................................11
4.1.2 Contactors...................................................................................................11
4.1.3 Fuses ..........................................................................................................12
4.2 Installation of the hardware.......................................................................................12
4.2.1 Positioning and cooling of the controller .....................................................12
4.2.2 Wirings: power cables.................................................................................13
4.2.3 Wirings: CAN connections and possible interferences ...............................13
4.2.4 Wirings: I/O connections .............................................................................15
4.2.5 Connection of the encoder..........................................................................16
4.2.6 Main contactor and key connection ............................................................17
4.2.7 Insulation of truck frame..............................................................................17
4.3 Protection and safety features ..................................................................................18
4.3.1 Protection features......................................................................................18
4.3.2 Safety Features...........................................................................................19
4.4 EMC..........................................................................................................................19
4.5 Various suggestions .................................................................................................21
5OPERATIONAL FEATURES ..............................................................................................22
5.1 Diagnosis ..................................................................................................................22
6DESCRIPTION OF THE CONNECTORS............................................................................23
6.1 Connectors of the logic .............................................................................................23
6.1.1 CNA external connector..............................................................................23
6.1.2 CND internal connector...............................................................................25
6.1.3 CNE internal connector...............................................................................25
7DESCRIPTION OF POWER CONNECTIONS ....................................................................26
8DRAWINGS.........................................................................................................................27
8.1 Mechanical drawing ..................................................................................................27
8.2 Connection drawing ACE0........................................................................................28
8.3 Connection drawing CombiAC0................................................................................29
9ONE SHOT INSTALLATION PROCEDURE.......................................................................30

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9.1 Sequence for Ac Inverter traction setting .................................................................31
10 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE ..................................32
10.1 Adjustments via console........................................................................................... 32
10.2 Description of console (hand set) & connection ....................................................... 32
10.3 Description of the console menu .............................................................................. 33
10.3.1 ACE0/ COMBIAC0 Menu ...........................................................................33
10.4 Function configuration ..............................................................................................34
10.4.1 Config menu “SET OPTIONS” functions list............................................... 34
10.4.2 Config menu “ADJUSTMENTS” functions list ............................................38
10.4.3 Main menu “PARAMETER CHANGE” functions list................................... 41
10.4.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list................................ 46
10.4.5 Main menu “TESTER” functions list ...........................................................47
11 OTHER FUNCTIONS..........................................................................................................51
11.1 Description of console “SAVE” function ...................................................................51
11.2 Description of console “RESTORE” function............................................................52
11.3 Description of console “PROGRAM VACC” function................................................ 53
11.4 Description of the throttle regulation......................................................................... 55
11.5 Description of the battery charge detection setting .................................................. 56
12 ACE0 / COMBI AC0 ALARMS LIST...................................................................................58
12.1 Faults diagnostic system .......................................................................................... 58
12.2 Alarms overview .......................................................................................................59
12.3 Analysis and troubleshooting of microcontroller alarms ...........................................61
12.4 Warnings overview ...................................................................................................69
12.5 Analysis and troubleshooting of warnings ................................................................ 71
13 RECOMMENDED SPARE PARTS.....................................................................................78
14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................79
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
Publication N°: AF6ZP0AL
Edition: December 2010

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1 INTRODUCTION
The COMBI AC0 / ACE0 inverter has been developed to perform all the electric
functions that are usually presents in walkie and rider pallet trucks, stackers, low
level order pickers.
The controller can perform the following functions:
- Controller for Ac 700W to 2,5 Kw AC motors;
- Pump controller for series wounded DC motors up to 5 KW (only for Combi
AC0).
- Drivers for ON/OFF electrovalves and for two proportional valves (electro-
distributor)
- Can bus interface
- Interface for canbus tiller
- Zapi patented sensorless and sense coil control
- 128 Kbytes Flash memory embedded.
- Software downloadable via Serial link or JTAG (internal connectors) or
Canbus (external connector)
- ESD protection on CAN BUS inputs CANL and CANH

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2 SPECIFICATION
2.1 Technical specifications Combi AC0 / ACE0
Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series
pump motors.
Regenerative braking functions.
Digital control based upon microcontroller
Voltage:..................................................................................................24, 36, 48V
Inverter maximum current (24V, 36V):........................................ 220A (RMS) for 2'
Inverter maximum current (36V, 48V):........................................ 180A (RMS) for 2'
Continuous output current (24V, 36V): ..............................105A (RMS) continuous
Continuous output current (36V, 48V): ................................90A (RMS) continuous
Inverter operating frequency:...........................................................................8kHz
Dc chopper Maximum current (24V,36V)(1): ......................................... 270A for 2'
Dc chopper Maximum current (36V, 48V)(1): .........................................220A for 2’
Chopper Operating frequency(1): ..................................................................16kHz
External temperature working range:..................................................-40°C ÷ 40°C
Maximum heatsink temperature (start of the thermal cutback)........................85°C
4Note(1): The DC chopper specifications are related to Combi AC0
2.2 Technical specifications Combi AC0 Power / ACE0 Power
Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series
pump motors.
Regenerative braking functions.
Digital control based upon microcontroller
Voltage:..................................................................................................24, 36, 48V
Inverter maximum current (24V, 36V):........................................ 320A (RMS) for 2'
Inverter maximum current (36V, 48V):........................................ 280A (RMS) for 2'
Continuous output current (24V, 36V): ..............................130A (RMS) continuous
Continuous output current (36V, 48V): ..............................110A (RMS) continuous
Inverter operating frequency:...........................................................................8kHz
Dc chopper Maximum current (24V,36V)(1): ......................................... 270A for 2'
Dc chopper Maximum current (36V, 48V)(1): .........................................220A for 2’
Chopper Operating frequency(1): ..................................................................16kHz
External temperature working range:..................................................-40°C ÷ 40°C
Maximum heatsink temperature (start of the thermal cutback)........................85°C
4Note(1): The DC chopper specifications are related to Combi AC0

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2.3 Block diagrams
2.3.1 Traction control
2.3.2 Pump control

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3 SPECIFICATION FOR THE INPUT DEVICES
FILLING UP THE INSTALLATION KIT
3.1 Digital inputs
COMBI AC0 / ACE0 digital inputs work in the voltage range [-Batt; +Batt].
Related command devices (microswitches) must be connected to +B (typically to
key voltage).
Pull-down resistance to –Batt is built-in.
Functional devices (like FW, BACK, LIFT, DESCENT, HORN, H&S, TILLER,
BELLY switches) are Normally Open; so related function becomes active when
the microswitch closes.
Safety devices (like CUTBACK switches) are Normally Closed; so related
function becomes active when the microswitches opens.
The DI11 and DI12, which are not available in the Sense Coil version, are
activated closing the external microswitch to –Batt.
3.1.1 DI0 ÷ DI10 technical details – 24 V system
- Switching threshold: 4V [±0,5V]
- Input impedance: 4,5kOhm [±0,5kOhm]
3.1.2 DI0 ÷ DI10 technical details – 48 V system
- Switching threshold: 4,3V [±0,5V]
- Input impedance: 13,5kOhm [±1kOhm]
3.1.3 Microswitches
- It is suggested that microswitches have a contact resistance lower than
0,1Ohm and a leakage current lower than 100µA.
- When full load connected, the voltage between the key switch contacts must
be lower than 0.1V.
- If the microswitch to be used has different characteristic, it is suggested to
discuss them and their application with Zapi technicians.
3.2 Analogue unit
The analog input can be connected to an accelerator unit if the Zapi can or serial
tiller is not used.
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
CNA#25.
Potentiometer output signal must be input to CPOT1 (CNA#15) signal range is
from 0 to 10V.
If the pedal wire disconnection diagnosis is implemented (“PEDAL WIRE KO”
warning) the negative supply of the potentiometer has to be taken from NPOT
(CNA#30), otherwise has to be taken from CNA#5 (GND).
Potentiometer value should be in the 0.5 - 10 KOhm range; generally, the load
should be in the 1.5mA to 30mA range. Faults can occur if it is outside this range.
The standard connection for the potentiometer is the one in the Left side of next

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figure (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
next figure (potentiometer in the middle at rest) still in combination with a couple
of Travel demand switches.
The Procedure for automatic potentiometer signal acquisition is carried out using
the Hand Set. This enables adjustment of the minimum and maximum useful
signal level, in either direction.
3.3 Other analogue control unit
If the Zapi can tiller is not used, input CNA#30 can be used as analogue input
(the “PEDAL WIRE KO” warning is lost), whose typical application is a
proportional command to enable a lifting/lowering function. It is possible to use
this input for an alternative function like a proportional braking.
It should be in a 3 wire configuration. Potentiometer value should be in the 0.5-
10Kohm range. Generally, the load should be in the 1.5mA to 30 mA range.
The CPOTL (CNA#30) signal range is from 0 to 10V.
Use CNA#25 (positive) and CNA#5 (negative) to supply it.
3.4 Analogue motor thermal sensor input
Input CNA#22 is an analogue input to receive an analogue thermal sensor signal
to measure the Traction Motor Winding Temperature. The analogue device
installed in the motor has to be specified, in order to insert the correct look-up
table in the software. A digital device can also be used.

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3.5 Speed feedback
The motor control is based upon the motor speed feedback (sensored software).
The speed transducer is an incremental encoder, with two phases shifted at 90°.
The encoder can be of different types :
- power supply: +12V / +5V
- electric output: open collector ( NPN ), push-pull.
COMBI AC0 / ACE0 could also be used without encoder, sensorless control.
This solution has to be discussed with Zapi technicians.
4Note (1): The encoder resolution and the motor poles pair (the controller can
handle), is specified in the home page display of the handset showing following
headline:
CA0Z2A ZP1.00
That means:
CA0Z= COMBIAC0 Zapi controller
2 = motor’s poles pair number
A = 32 pulses/rev encoder
The encoder resolution is given by the second-last letter in the following list:
A = 32 pulses/rev
K = 48 pulses/rev
B = 64 pulses/rev
C = 80 pulses/rev

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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 informations 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 0.5mm² section at least.
For power connections to the motor and to the battery, use cables having a
minimum section of 15 mm².
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
IT IS STRONGLY RECCOMENDED TO USE A MAIN CONTACTOR to connect
and cut off the battery to the controller. Depending on the setting of a parameter
in the controller:
- 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.
UThe EN1175 states the main Contactor is not mandatory (under proper
conditions); anyway it is recommended to protect the inverter against
reverse battery polarity and to cut off the battery from the power mosfets
when a failure in the three phase bridge occurs.

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4.1.3 Fuses
- Use a 6.3-10A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, use a 350A 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.
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 chopper using a
Resistor between 10 Ohm and 100 Ohm. Minimum 5 Watts.
4.2.1 Positioning and cooling of the controller
CONTROLLER WITH BASE PLATE: Install the controller with the base-plate on
a flat metallic surface that is clean and unpainted; suggested characteristics are:
planarity 0.05 mm and rugosity 1.6 µm
- Apply a light layer of thermo-conductive grease between the two surfaces to
permit better heat dissipation.
- 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.
CONTROLLER WITH FINNED HEATSINK: Sometimes the base plate
installation cannot be adopted. Due to positioning problems or to the lack of a
thick enough truck frame, it is necessary to adopt a finned dissipation combined
with one or more fans.
- The air flux should hit the fins directly, to maximize the cooling effect.
- In addition to fans, also air ducting systems can be used to maintain low the
temperature of the controller.
- It is necessary to ensure that cold air is taken from outside the controller
compartment and hot air is easily pushed away from the controller
compartment.
- It is mandatory to avoid that the cooling air is recirculated inside the controller
compartment.

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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 7 ± 1.4
Nm
- The COMBIAC0 module 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.
UDo not connect the controller to a battery with a nominal voltage different
than the value indicated on the controller label. A higher battery voltage
may cause MOS failure. A lower voltage may prevent the logic operating.
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.

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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.
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)
Module
1 Module
2
Module
3
Module
1 Module
2
Module
3

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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 dimensioned taking into account
thermal and voltage drop problems.
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”
Module
1 Module
2
Module
3

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4.2.5 Connection of the encoder
1) COMBI AC0/ ACE0 card is fit for different types of encoder. To control AC
motor with Zapi inverter, it is necessary to install an incremental encoder with
2 phases shifted of 90°. The encoder power supply can be +5 or +12V. It can
have different electronic output.
AMPSEAL CONNECTOR
A25 +5V/+12V positive of encoder power supply.
A5 GND negative of encoder power supply.
A14 A phase A of encoder.
A13 B phase B of encoder.
2) Connection of encoder with open collector output; +5V power supply.
Connection of encoder with open collector output: +12V power supply.
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).

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4.2.6 Main contactor and key connection
- The connection of the main contactor can be carried out following the
drawing in the figure.
- The connection of the battery line switches must be carried out following
ZAPI instructions.
- If a mechanical battery line switch is installed, it is strongly recommended
that the key supply to the inverter is open together with power battery line
(see picture below); if not, the inverter may be damaged if the switch is
opened during a regenerative braking.
- An intrinsic protection is present inside the logic when the voltage on the
battery power connection overtakes 40% more than the battery nominal
voltage or if the key is switched off before the battery power line is
disconnected.
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.

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4.3 Protection and safety features
4.3.1 Protection features
The COMBI AC0/ ACE0 is protected against some controller injuries and
malfunctions:
- Battery polarity inversion
It is necessary to fit a LINE CONTACTOR to protect the controller against
reverse battery polarity and for safety reasons.
- Connection Errors
All inputs are protected against connection errors.
- Thermal protection
If the controller temperature exceeds 85°C, the maximum current is reduced in
proportion to the thermal increase. The temperature can never exceeds 105°C.
- External agents
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP65. Nevertheless, it is suggested to carefully study
controller installation and position. With few simple shrewdness, the degree of
controller protection can be strongly increased.
- Protection against uncontrolled movements
The main contactor will not close if:
- The Power unit is not functioning.
- The Logic or CANBUS interface is not functioning perfectly.
- The Can Tiller is not operating correctly.
- Running microswitches are in open position.
- Low battery charge
when the battery charge is low, the maximum current is reduced to the half of the
maximum current programmed; additionally an alarm message is displayed.
- Protection against accidental Start up
A precise sequence of operations are necessary before the machine will start.
Operation cannot begin if these operations are not carried out correctly.
Requests for drive must be made after closing the key switch.

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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.
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 responsability 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 electromagnetical energy generated or received by an electrical
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 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

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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 happen when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
- this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus) which
are spread everywhere on the truck and which carry critical informations.
- in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
UIMPORTANT 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.
4) 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
truck frames is generally a suggested not expensive solution to reduce
the emission level.
5) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions
are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
6) 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