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