Zapi VCM 2uC 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
VCM ZAPI
2uC

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Copyright © 1975-2014 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
1INTRODUCTION ...................................................................................................................5
2SPECIFICATION...................................................................................................................7
2.1Technical specifications VCM Standard .....................................................................7
2.2Technical specifications VCM Premium ....................................................................7
3BLOCK DIAGRAM................................................................................................................8
4SPECIFICATION FOR THE I/O INTERACES.......................................................................9
4.1Digital inputs ...............................................................................................................9
4.1.1DI1 ÷ DI11 technical details ..........................................................................9
4.1.2Microswitches ...............................................................................................9
4.2Analog inputs ..............................................................................................................9
4.3Outputs .....................................................................................................................10
4.4Incremental encoder .................................................................................................11
4.5CAN BUS..................................................................................................................12
5ADDITIONAL FEATURES ..................................................................................................14
5.1Real Time Clock .......................................................................................................14
5.2High Side Driver........................................................................................................14
6INSTALLATION HINTS.......................................................................................................15
6.1Material overview......................................................................................................15
6.1.1Connection cables ......................................................................................15
6.1.2Fuses ..........................................................................................................15
6.2Installation of the hardware.......................................................................................15
6.2.1Wirings: CAN connections and possible interferences ...............................16
6.2.2Wirings: I/O connections .............................................................................18
6.2.3Insulation of truck frame..............................................................................18
6.3Protection features....................................................................................................18
6.3.1Hardware Protection ...................................................................................18
6.3.2Safety Features...........................................................................................18
6.3.3Double microcontroller architecture ............................................................19
6.4EMC..........................................................................................................................19
7DESCRIPTION OF THE CONNECTORS............................................................................21
7.1CNA Ampseal 35 poles.............................................................................................21
7.2CNB Ampseal 23 poles (only for VCM PREMIUM) ..................................................23
8DRAWINGS.........................................................................................................................24
8.1Mechanical drawing ..................................................................................................24
8.1.1VCM STANDARD .......................................................................................24
8.1.2VCM PREMIUM ..........................................................................................25
8.2Functional drawing....................................................................................................26
8.2.1VCM STANDARD .......................................................................................26
8.2.2VCM PREMIUM ..........................................................................................27
9PROGRAMMING & ADJUSTMENTS .................................................................................28
9.1Description of programmable functions ....................................................................28
9.2Description of the TESTER function .........................................................................35
9.3Description of the console SAVE function ................................................................37
9.4Description of the console RESTORE function ........................................................38
9.5Description of the throttle regulation .........................................................................38
9.6Description of the battery charge detection setting...................................................39
9.7Description of ALARMS menu ..................................................................................40

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10CONTROLLER DIAGNOSTIC............................................................................................41
10.1Diagnostic features................................................................................................... 41
10.2Description of alarms displayed on the console ....................................................... 42
11RECOMMENDED SPARE PARTS FOR CONTROLLER...................................................53
12PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................54
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
Publication N°: AFDZP0BA
Edition: November 2013

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1 INTRODUCTION
The Vehicle Control Master is an intelligent module designed to provide a central
control of multiple vehicle functions.
The high number of I/Os accommodates a large number and wide range of
vehicle controls and sensors.
It can easily work in conjunction with Zapi motor controllers and other CAN
devices.
The VCM offers many digital and analog inputs for interfacing with microswitches
or potentiometers. Moreover it has an interesting feature, which are not in many
small I/O cards:
it has a double-microcontroller structure with 2 CAN communication ports that
make the VCM ideal for a safe single-point “Master” control.
The VCM has also many outputs in order to control proportional hydraulic valves,
PWM voltage controlled loads or other loads.
The VCM small package offers a high flexibility for placement in complex
machines and it has a very high IP protection too.
Features include:
16 bits microcontroller for main functions 384+ Kbytes embedded Flash
memory
16 bits microcontroller for safety functions, 384+ Kbytes embedded Flash
memory
Up to 11 active high digital inputs
Up to 10 analog inputs with 10 bit resolution
2 incremental encoder interfaces
2 CAN communication ports that allow interconnection to a wide range of
devices, including ZAPI AC controllers
Standard communication: CIA, CANopen
Communication speed up to 500Kbit/sec
11 and 29 bits communication supported
+12V output supply (up to 500mA)
+5V output supply (up to 150mA)
8 power outputs with precise current feedback to control proportional
hydraulic valves (up to 2A per output)
1 power output PWM current control up to 4Amps
3 PWM voltage control outputs
Built-in freewheeling diodes
Different built-in programmable levels for dither amount & frequency
Real-time clock
Overload protection, short circuit protection and open load protection
ESD protection
Operating ambient temperature range from -40°C to + 40°C
Sealed connectors (35 pins Ampseal + 23 pins Ampseal)
IP65 rated

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Easy access to service, status and diagnostic information
The VCM can be supplied in two different configurations:
- Standard Version 36/48V, 80V, with a 35 poles Ampseal connector
- Premium Version 36/48V, 80V, with an additional second 23 poles
Ampseal connectors, enhanced I/O
STANDARD VERSION
PREMIUM VERSION

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2 SPECIFICATION
2.1 Technical specifications VCM Standard
Voltage [V]............................................................................................ 36, 48, 80V
Digital inputs [n°] ....................................................................................................7
Analog inputs [n°]...................................................................................................2
Proportional Output for external loads [n°] .............................................................8
PWM Voltage Controlled Output for external loads [n°] .........................................2
+12V output supply [n°]..........................................................................................1
+5V output supply [n°]............................................................................................1
CAN Interface[n°] ...................................................................................................2
IP Protection..................................................................................................... IP65
External Operating temperature range................................................ -40°C;+50°C
VCM can be operated with 36V or 48V battery without any hardware
modification.
2.2 Technical specifications VCM Premium
Voltage [V]............................................................................................. 36, 48, 80V
Digital inputs [n°] ..................................................................................................11
Analog inputs [n°].................................................................................................10
Proportional Output for external loads [n°] .............................................................9
PWM Voltage Controlled Output for external loads [n°] .........................................3
+12V output supply [n°]..........................................................................................1
+5V output supply [n°]............................................................................................2
CAN Interface[n°] ...................................................................................................2
IP Protection..................................................................................................... IP65
External Operating temperature range................................................ -40°C;+50°C
VCM can be operated with 36V or 48V battery without any hardware
modification.

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3 BLOCK DIAGRAM

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4 SPECIFICATION FOR THE I/O INTERACES
The VCM inverter needs some external parts in order to work. The following
devices complete the kit for the VCM installation.
4.1 Digital inputs
Related command devices (microswitches) must be connected to positive
(typically to key voltage).
Functional devices 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 microswitch opens.
Pull-down resistances are built-in.
Some inputs are read by both master microcontroller and the slave
microcontroller:
The safety level related to these input signal is higher since both microcontrollers
check the status of the input pins.
4.1.1 DI1 ÷ DI11 technical details
Nominal Voltage [V] 36-48V 80V
Input resistance [Ω] 11,2k [±0,5kOhm] 3,2k [±0,1kOhm]
Maximum Input Voltage [V] 60V 24V
Logic level High High
High-level [V] min. 13 9
Low-level [V] max. 12 8
4.1.2 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.
4.2Analog inputs
The analog units can consist of potentiometers or Hall effect devices.
They could be in a 3-wire configuration. The potentiometers can be supplied
through PPOT1, PPOT2 or PPOT3 (CNA#33, CNA#34 or CNB16) and the output
signals must be input to CPOT pins.
Potentiometer value should be in the 0.5 – 10 krange; 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 next

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figure (potentiometer on one end at rest) in combination with a couple of
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 demand switches.
Some inputs are read by both master microcontroller and the slave
microcontroller:
The safety level related to these input signal is higher since both microcontrollers
check the status of the input pins.
Some analog inputs are designed to be properly hardware configured in order to
interface with digital devices or special device that supply a current signal
(typically 4-20mA).
It is suggested to discuss about analog inputs and their application with Zapi
technicians to properly configure each input signal range according to the analog
device connected .
The Procedure for automatic potentiometer signal acquisition is carried out using
the Zapi CAN PC Console. This enables adjustment of the minimum and
maximum useful signal level, in either direction.
4.3 Outputs
The VCM module has several controlled outputs for driving external loads: 8
current controlled outputs and 2 pwm voltage controlled outputs.
They share the following characteristics:
1. they drive the pin to ground (low-side outputs)
2. they can drive loads supplied from Battery Voltage
3. built-in freewheeling diode
4. maximum dc current 2.0A
5. the control of each output depends on both microcontrollers
6. Different built-in programmable levels for dither amount & frequency
7. Overload protection, short circuit protection and open load protection
In the VCM Premiun version 1 additional pwm voltage controlled output is
available.
Further an additional special pwm current controlled output is available.
It has the following characteristics:
1. It drives the pin to ground (low-side outputs)
2. It can drive loads supplied from Battery Voltage

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3. built-in free-wheel diode
4. maximum dc current 4.0A
5. the control of the output depends on both microcontrollers
6. Different built-in programmable levels for dither amount & frequency
7. Overload protection, short circuit protection and open load protection
4Please refers to chapter 7 or contact Zapi for further information about outputs.
4All the output pins can be converted to input pins if necessary. Please contact
Zapi for further information
4.4 Incremental encoder
The VCM is fit for two incremental encoder interfaces (PREMIUM version).
These interfaces have the following characteristics
1. It can read signal from encoders with push-pull output or with open-
collector output.
2. Input voltage range [0; 12]V
3. Input impedance >3 k
The encoder power supply can be +5V or +12 V
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.

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4.5 CAN BUS
The VCM is fit for two CAN bus interfaces. Built in termination 120R is present on
both the interfaces.
It is possible configure them via hardware in order to obtain one of these two
possible configurations:
1) Two independent lines, each one managed by only one uC.
Master and Supervisor uC are able to communicate each other by local
Can Bus.

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2) Two independent lines, one managed by both the uC, the other one
managed only by Master uC.
Master and Supervisor uC are able to communicate each other by local
Can Bus.
UVERY IMPORTANT
It is necessary to specify in the order the type of configuration used
because the logic unit must be set in the correct way by Zapi.

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5 ADDITIONAL FEATURES
5.1 Real Time Clock
Real-time clock function is available.
It is possible to modify the calendar using the Zapi Console and adjusting
properly the related parameters in the menu “ADJUSTMENT” (See Chapter 9).
Built in 3V battery is present.
5.2 High Side Driver
Two additional high side drivers is available.
The first one is available for both versions, STANDARD and PREMIUM; it can be
properly configured to cut only one or all positive supply pins for the outputs
(A13, A14, A15, A16).
The maximum carrying current for this driver is 6A.
The second one is available only for VCM PREMIUM. It cuts the positive supply
pin of the additional outputs (B8)
The maximum carrying current for this driver is 6A.

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6 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
6.1 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.
6.1.1 Connection cables
For the auxiliary connections, use cables of 0.5 mm² section.
For the valves connections, use cables of 0.75 mm² section.
6.1.2 Fuses
- Use a proper fuse for protection of the auxiliary circuits.
- For Safety reasons, we recommend the use of protected fuses in order to
prevent the spread of fused particles should the fuse blow.
6.2 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.
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 valves driver section failure. A lower voltage may prevent the
logic operating.

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6.2.1 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 correct operation of the CANbus is of critical importance for the CAN I/O
because all functional messages and safety-related messages pass through
CAN wires. Moreover the CAN is used to interface master and slave
microcontrollers: an incorrect CAN communication will create mismatches
between the two microcontrollers and will lead to a stop of all functions.
- 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:
Module
1
Module
3
Module
2
R
R
Can Bus
Power cables

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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).
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
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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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.
6.2.2 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”.
6.2.3 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.
6.3 Protection features
6.3.1 Hardware Protection
- Battery polarity inversion
The board is protected against reverse battery polarity
- Overvoltage
All input/output pins can withstand, for a short time, an applied voltage up to
+B.
- Undervoltage
The VCM is fully operative for key voltages down to 11V
- Connection Errors
All input/output pins are protected against:
- short circuit to positive battery voltage
- short circuit to negative battery voltage.
- Open-circuit and cable disconnection
- External agents:
The controller is protected against dust and the spray of liquid to a degree of
protection meeting IP65.
6.3.2 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

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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.
6.3.3 Double microcontroller architecture
The VCM module has two separated microcontrollers in a master/slave
architecture. The communication between them is realized by the local CANbus
line.
Many input and output pins are connected to both master and slave
microcontroller (see chapter 7) . These pins can be used as part of safety
functions whose requested Performance Level is high. The double-
microcontroller architecture operates as follows:
For inputs: both master and slave read the status of the input pin, through
two independent circuits. Then the two microcontrollers use the local CANbus
line to check if the two read status are equal. Any mismatch during the read
process is detected and it can be used to enter an alarm condition or to start
other actions.
For outputs: the master transmits the control command to the output driver
(which can be a current command or a PWM command) while the slave gives
an enable signal which can block the master command. No output can be
turned on unless both microcontrollers has agreed on the activation.
6.4 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
device. So the analysis works in multiple directions:
2) Emission problems, the disturbances generated by the device and the
possible countermeasure to prevent the propagation of that disturbances. It is
used to talk about “conduction” issues when guiding structures such as wires
and cables are involved, “radiated emissions” when the propagation of
electromagnetic energy happens through the open space. In the CAN I/O

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case there is no power bridge commutating large current at high frequency
thus the problems related to emission should be less relevant than in other
Zapi product. The main source of emission may be the CANbus because its
wire is often very long and it can be a quite good antenna. As usual, a good
layout of the cables and their shielding can solve the majority of the emission
problems.
3) The electromagnetic immunity concerns the susceptibility of the controller
with regard to external electromagnetic fields and their influence on the
function of 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. Normally the same prescriptions (cable layout, shielding..) used to
solve emission problems can be applied to solve immunity problems too.
4) The 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, where CANbus lines 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.
UIt is always much easier and cheaper to avoid ESD from being generated,
than to increase the level of immunity of the electronic devices.
The VCM can be prone to electrostatic discharge because it is normally
connected to many command devices. These devices, which are touched by the
operator, are common sources of generation and propagation of ESD.
The best way to avoid ESD is through isolation and grounding of the propagating
devices. It is strongly suggested to connect to truck frame all the parts of
the truck which can be touched by the operator.