Zapi ZAPIMOS Series User manual

Page 1
INDEX
Page
1 Introduction.................................................................................................... 3
2 Specification .................................................................................................. 3
2.1 AC-3 Technical specifications ................................................................ 3
2.2 AC-4 Technical specifications ................................................................ 3
2.3 Block diagram ........................................................................................ 4
2.4 Control unit ............................................................................................. 4
2.4.a Microswitches ............................................................................... 4
2.4.b Accelerator unit ............................................................................. 4
2.4.c Other analog control unit ................................................................ 5
2.4.d Speed feedback............................................................................ 5
2.5 Protection features .......................................................................... 6
2.6 Operational features ............................................................................... 7
2.7 Diagnosis .............................................................................................. 8
2.8 Thermal consideration ............................................................................ 8
2.9 General instructions and precautions . .............................................. 8
2.10 Susceptibility and electromagnetic emission .................................. 9
2.11 Main contactor and emergency switch .................................................... 9
3 Installation .................................................................................................... 10
3.1 Connection cables ............................................................................... 10
3.2 Contactors ........................................................................................... 10
3.3 Fuses ................................................................................................... 10
3.4 Description of connectors - Traction configuration ............................... 11
3.4.a Amp Saab connector ................................................................... 11
3.4.b Molex Minifit connectors .............................................................. 13
3.5 Description of connectors - Pump configuration .................................... 15
3.5.a Amp Saab connector ................................................................... 15
3.5.b Molex Minifit connectors .............................................................. 17
3.6 Encoder installation .............................................................................. 19
3.7 Description of power connections......................................................... 20
3.8 AC-3 Mechanical drawing .................................................................... 21
3.9 AC-4 Mechanical drawing .................................................................... 22
3.10 Connection drawing - Traction configuration ......................................... 23
3.10.a Amp Saab connector ................................................................ 23
3.10.b Molex Minifit connectors ........................................................... 24
3.11 Connection drawing - Pump configuration ............................................ 25
3.11.a Amp Saab connector ................................................................ 25
3.11.b Molex Minifit connectors ........................................................... 26
3.12 Connection drawing - Combi configuration ........................................... 27
3.12.a Amp Saab connector ................................................................ 27
3.12.b Molex Minifit connectors ........................................................... 28

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= The informations included into the marked paragraphs by this symbol are
essential for the safety.
SIGNATURES TABLE
SECIVRES.TPEDYNAPMOCSECIVRES.TPEDYNAPMOC SECIVRES.TPEDYNAPMOC SECIVRES.TPEDYNAPMOCSECIVRES.TPEDYNAPMOCEVITUCEXETNEMEGANAMEVITUCEXETNEMEGANAM EVITUCEXETNEMEGANAM EVITUCEXETNEMEGANAMEVITUCEXETNEMEGANAM
EVITUCEXENOITCESGNIREENIGNE
REGANAMTROPXE
Publications N°: ADWZP0AB
Edition: July 2001
4 Programming & Adjustments using Digital Console ................................ 29
4.1 Adjustments via Console ...................................................................... 29
4.2 Description of Console & Connection ................................................... 29
4.3 Description of Standard Console Menu ................................................ 30
4.3.a Traction configuration .................................................................. 30
4.3.b Pump configuration...................................................................... 31
4.4 Function configuration .......................................................................... 32
4.4.a Traction ....................................................................................... 32
4.4.b Pump .......................................................................................... 36
4.5 Parameter regulation: Traction configuration ........................................ 42
4.6 Parameter regulation: Pump configuration ............................................ 44
4.7 Programming console functions ........................................................... 46
4.8 Sequence for AC Inverter Traction setting ............................................. 47
4.9 Tester: description of the function; Traction configuration ...................... 48
4.10 Tester: description of the function; Pump configuration ......................... 50
5 Other functions ............................................................................................ 52
5.1 Description of the Console Save function ............................................. 52
5.2 Description of Console Restore function. .............................................. 53
5.3 Description of Alarms menu ................................................................. 54
5.4 Description of Console Program Vacc function .................................... 55
6 AC Inverter diagnostic - Traction configuration ........................................ 56
6.1 Analysis of alarms displayed on console .............................................. 56
7 AC Inverter diagnostic - Pump configuration ............................................ 60
7.1 Analysis of alarms displayed on console .............................................. 60
8 Recommended Spare parts for inverter .................................................... 64
9 Periodic Maintenance to be repeated at times indicated. ......................... 65

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1 INTRODUCTION
Within the ZAPIMOS family, the AC3 inverter is the model suitable for control of 7÷12 KW
motors; the AC4 inverter is the model suitable for control of 12kW to 20kW motors. They
have been expressly designed for battery electric traction.
They are fit for electric truck, electric cars, tractors and buses.
2 SPECIFICATION
2.1 AC-3 TECHNICAL SPECIFICATIONS
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage: ......................................................................................... 36 - 48 - 72 - 80V
Maximum current (36V,48V): ......................................................... 600A (RMS) for 3'
Maximum current (72V,80V): ......................................................... 450A (RMS) for 3'
Booster (all version) .............................. 10% of maximum current for some seconds;
Operating frequency: ..........................................................................................8kHz
External temperature range: ................................................................. -30°C ÷ 40°C
Maximum inverter temperature (at full power): .................................................... 75°C
2.2 AC-4 TECHNICAL SPECIFICATIONS
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage: ................................................................................................ 48 - 72 - 80V
Maximum current(48V): ................................................................ 700A (RMS) for 3'
Maximum current (72V,80V): ......................................................... 550A (RMS) for 3'
Booster (all version) .............................. 10% of maximum current for some seconds;
Operating frequency: ..........................................................................................8kHz
External temperature range: ................................................................. -30°C ÷ 40°C
Maximum inverter temperature (at full power): .................................................... 75°C

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2.3 BLOCK DIAGRAM
2.4 CONTROL UNIT
2.4.a Microswitches
- The microswitches must have a contact resistance lower than 0.1W and a leakage
current lower than 100µA.
- When full load connected, the voltage between the key switch contacts must be lower
than 0.1V.
- The microswitches send a voltage signal to the microprocessor when a function request
(for ex.: running request) is made.
2.4.b Accelerator unit
The accelerator unit can consist of a potentiometer or an Hall effect device.
It should be in a 3-wire configuration.
CPOT (A11, Saab connector version; A1, Molex Minifit version) signal ranges from 0 to
10V.
Potentiometer value should be in the 0.5 - 10 Kohm range; generally, the load should be in
the 1.5mA to 30 mA range. Faults can occur if it is outside this range.

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The Procedure for automatic potentiometer signal acquisition is carried out using the
Console. This enables adjustment of the minimum and maximum useful signal level
(PROGRAM VACC function), in either direction. This function is unique when it is neces-
sary to compensate for asymmetry with the mechanical elements associated with the
potentiometer, especially relating to the minimum level.
The sequence of procedure is described in the programming console manual.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the point where
the direction switches close. 0 represents the mechanical zero of the rotation.
The Left Hand graph shows the relationship of the motor voltage without signal acquisition
being made. The Right Hand Graph shows the same relationship after signal acquisition
of the potentiometer.
2.4.c Other analog control unit
1) Input A13 (Saab connector version), A8 (Molex Minifit version) is an analog input,
whose typical application is for proportional braking. It should be in a 3 wire configura-
tion. Potentiometer value should be in the 0.5-10KW range. Generally, the load should
be in the 1.5mA to 30 mA range.
The CPOTB (A13, A8) signal range is from 0 to 10V.
2) Connections A3 (Saab), B6 (Minifit) (PTHERM) and A4 (Saab), B12 (minifit)
(NTHERM) are used for a motor thermal sensor. It can be digital (on/off sensor, nor-
mally closed) or analog. See also chapter 4.4 for more explanation.
2.4.d Speed feedback
The motor control is based upon the motor speed feedback. The speed transducer is an
incremental encoder, with two phases shifted at 90°. The encoder can be of different types
:
- power supply: +5V or +12V
- electric output: open collector ( NPN or PNP), push-pull, line driver
- standard (A and B) or differential (A, A, B, B) output
For more details about encoder installation see also chapter 3.6.

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2.5 PROTECTION FEATURES
- Battery polarity inversion:
It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery
polarity and for safety reasons.
- Connection Errors:
All inputs are protected against connection errors.
- Thermal protection
If the chopper temperature exceeds 75°C, the maximum current is reduced in
proportion to the thermal increase. The temperature can never exceeds 100°C.
- External agents:
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP54.
- Protection against uncontrolled movements:
The main contactor will not close if:
- The Power unit is not functioning.
- The Logic is not functioning perfectly.
- the output voltage of the accelerator does not fall below the minimum voltage value
stored, with 1V added.
- Running microswitch in closed position.
-Low battery charge:
when the battery charge is low, the maximum current is reduced to the half of the maxi-
mum current programmed.
- 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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2.6 OPERATIONAL FEATURES
- Speed control.
- Optimum behavior an a slope due to the speed feedback:
- the motor speed follows the accelerator, starting a regenerative braking if the speed
overtakes the speed set-point.
- the system can perform an electrical stop on a ramp (the machine is electrically hold
on a slope) for a programmable time (see also chapter 4.4)
- Stable speed in every position of the accelerator.
- Regenerative release braking based upon deceleration ramps.
- Regenerative braking when the accelerator pedal is partially released (deceleration).
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the main
contactor is present.
- The release braking ramp can be modulated by an analog input, so that a proportional
brake feature is obtained.
- Optimum sensitivity at low speeds.
- Voltage boost at the start and with overload to obtain more torque (with current control).
- The inverter can drive an electromechanical brake
- Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to the pump inverter
on the can-bus line (see also OPTION chapter 4.4)
- moreover , if the pump inverter is not present (for ex: tractor application), the traction
inverter can manage an "hydraulic steering function" by driving a hydro contactor which
drive a hydraulic steering motor (output A7 (Saab), B9 (Minifit), see also OPTION chap-
ter)
2) pump inverter
- the pump inverter manage an "hydraulic steering function". That is, it drives the pump
motor at the programmed speed for the programmed time.
- High efficiency of motor and battery due to high frequency commutations.
- Self diagnosis with indication of the fault shown by a flashing led.
- Modification of parameters through the programming console.
- Internal hour-meter with values that can be displayed on the console.
- Memory of the last five alarms with relative hour-meter and temperature displayed on the
console.
- Test function within console for checking main parameters.

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2.7 DIAGNOSIS
The microprocessor continually monitors the inverter and carries out a diagnostic proce-
dure on the main functions. The diagnosis is made in 4 points
1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capaci-
tor charging, phase's voltages, contactor drives, can-bus interface, if the switch se-
quence for operation is correct and if the output of accelerator unit is correct.
2) Standby diagnosis at rest that checks: watchdog circuit, phase's voltages, contactor
driver, current sensor, can-bus interface.
3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current
sensors, can-bus interface.
4) Continuos diagnosis that check: temperature of the inverter, motor temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus.
2.8 THERMAL CONSIDERATION
- 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.
2.9 GENERAL INSTRUCTIONS AND PRECAUTIONS .
- Never connect SCR low frequency chopper with ASYNCHRONOUS INVERTER be-
cause the ASYNCHRONOUS filter capacitors alter the SCR choppers' work. If it is
necessary to use two or more control units (traction + lift. for ex.), they must belong to the
ZAPIMOS family.
- Do not connect the inverter to a battery with a nominal value different from the value
indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it is
lower, the control unit does not "power up".
- During battery charge, disconnect ASYNCHRONOUS from the battery.
- Supply the ASYNCHRONOUS only with battery for traction; do not use a power supply.
- When the chopper is installed, make tests with the wheels raised from the ground, in
order to avoid dangerous situations due to connection errors.
- After the chopper is switched off (key off), the filter capacitor remains charged for some
minutes; if you need to work on the inverter, discharge them using a
10W ÷ 100W resistance connected from the +Batt to the -Batt.

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2.10 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION
Electromagnetic susceptibility and emission 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. Therefore ZAPI declines any responsibility for
noncompliance if correct testing is not made (the irradiated emission directive is
EN50081-2).
2.11 MAIN CONTACTOR AND EMERGENCY SWITCH
- The connection of the battery line switches must be carried out following ZAPI instruc-
tions.
- If a mechanical battery line switch is installed, it is necessary that the key supply to the
inverter is open together with power battery line; 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.

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3 INSTALLATION
Install the chopper with the base-plate on a flat metallic surface that is clean and unpainted.
Apply a light layer of thermo-conductive grease between the two surfaces to permit better
heat dissipation.
Ensure that the wiring of the cable terminals and connectors is carried out correctly.
Fit transient suppression devices to the horn, solenoid valves, and contactors not con-
nected to the chopper such as those for activating the pump motor or steering motor.
3.1 CONNECTION CABLES
For the auxiliary circuits, use cables of 0.5mm² section.
For power connections to the motor and to the battery, use cables having section in the
35÷50 mm² range (as a minimum).
For the optimum inverter performance, the cables to the battery should be run side by side
and be as short as possible.
3.2 CONTACTORS
The main contactor must be installed. Depending on the position of a jumper installed in
the logic board:
- 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 duty cicle of 70%; this feature is useful to decrease the power dissipation of the
contactor coil.
3.3 FUSES
- Use a 6.3A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, refer to diagrams.. The Fuse value shown is the maxi-
mum allowable. For special applications or requirements these values can be reduced.
- For Safety reasons, we recommend the use of protected fuses in order to prevent the
spread of fused particles should the fuse blow.

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3.4 DESCRIPTION OF CONNECTORS - TRACTION CONFIGURATION
The AC3 and AC4 have been designed to be produced with two different types of I/O
connector: One AMP SAAB 29 poles connector or six Molex Minifit connectors.
3.4.a Amp Saab connector
A1 PPOT Potentiometer positive: 10V output; keep load > 1KW.
A2 NPOTB -Batt.
A3 PTHERM Input for motor temperature sensor.
A4 NTHERM -Batt.
A5 -BATT Battery negative.
A6 NLC Negative of main contactor coil.
A7 NBRAKE Output for driving a brake or an hydraulic steering contactor coil;
drives the load to -Batt maximum current : 3A.
A8 PLC Positive of main contactor coil.
A9 CM Common of FW / BW / SR / PB / SEAT / BACK. FW / BACK. BW /
EXCLUSIVE HYDRO microswitches.
A10 KEY Connected to the power supply through a microswitch (CH) with a
10A fuse in series.
A11 CPOT Accelerator potentiometer wiper.
A12 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.
A13 CPOTB Brake potentiometer wiper.
A14 CAN-H High level CAN-BUS voltage I/O.
A15 CAN-L Low level CAN-BUS voltage I/O.
A16 FORW Forward direction request input. Must be connected to the forward
direction microswitch, active high.
A17 BW Backward direction request input. Must be connected to the back-
ward direction microswitch, active high.

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A18 BACK. FORW Inching function, forward direction input. Must be connected to the
inching forward switch. Active high.
A19 BACK. BACK Inching function, backward direction input. Must be connected to the
inching backward switch. Active high.
A20 ENCODER Incremental ENCODER connector (see chapter 3.6).
A21 ENCODER Incremental ENCODER connector (see chapter 3.6).
A22 ENCODER Incremental ENCODER connector (see chapter 3.6).
A23 ENCODER Incremental ENCODER connector (see chapter 3.6).
A24 MODE This input allows the customer to select the software for traction or
lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A5) Pump inverter
A25 SAFETY If not connected to -Batt the MC coil power output will be disabled.
Can also be used as a general purpose input.
A26 PB Brake request input. Must be connected to the brake pedal switch,
active high.
A27 EX. HYDRO Exclusive hydro function input. Must be connected to the exclusive
hydro microswitch. Active high (see also OPTION chapter)
A28 SR/HB Speed reduction (handbrake) input. Active low (switch opened). See
also OPTION chapter.
A29 SEAT SEAT input; must be connected to the SEAT microswitch; it is active
high.

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3.4.b Molex Minifit connectors
A1 CPOT Accelerator potentiometer wiper.
A2 PPOT Potentiometer positive: 10V output; keep load > 1KW.
A3 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.
A4 CM Common of FW / BW / SR / PB / SEAT / BACK. FW / BACK. BW /
EXCLUSIVE HYDRO microswitches.
A5 FORW Forward direction request input. Must be connected to the forward
direction microswitch, active high.
A6 BW Backward direction request input. Must be connected to the back-
ward direction microswitch, active high.
A7 PB Brake request input. Must be connected to the brake pedal switch,
active high.
A8 CPOTB Brake potentiometer wiper.
A9 PPOTB Brake potentiometer positive. 10V output; keep load >1KW.
A10 NPOTB -Batt.
A11 -BATT -Batt.
A12 BACK. FORW Inching function, forward direction input. Must be connected to the
inching forward switch. Active high.
A13 BACK. BACK Inching function, backward direction input. Must be connected to the
inching backward switch. Active high.
A14 EX. HYDRO Exclusive hydro function input. Must be connected to the exclusive
hydro microswitch. Active high (see also OPTION chapter)
B1 KEY Connected to the power supply through a microswitch (CH) with a
10A fuse in series.
B2 PLC Positive of main contactor coil.
B3 PBRAKE Positive of the electromechanical brake coil.
B4 SEAT SEAT input; must be connected to the SEAT microswitch; it is active
high.

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B5 SAFETY If not connected to -Batt the MC coil power output will be disabled.
Can also be used as a general purpose input.
B6 PTHERM Input for motor temperature sensor.
B7 CM Common of FW / BW / SR / PB / SEAT / INCHING FW / INCHING
BW / EXCLUSIVE HYDRO microswitches.
B8 NLC Negative of main contactor coil.
B9 NBRAKE Output for driving a brake or an hydraulic steering contactor coil;
drives the load to -Batt maximum current : 3A.
B10 SR/HB Speed reduction (handbrake) input. Active low (switch opened). See
also OPTION chapter.
B11 GND -Batt.
B12 NTHERM -Batt.
C1 CAN-L Low level CAN-BUS voltage I/O.
C2 CAN-L-OUT Low level CAN-BUS voltage I/O.
C3 CAN-H High level CAN-BUS voltage I/O.
C4 CAN-H-OUT High level CAN-BUS voltage I/O.
D1 -BATT -Batt.
D2 MODE This input allows the customer to select the software for traction or
lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A5) Pump inverter
E1÷E6 Incremental ENCODER connector (see chapter 3.6).
F1 PCLRXD Positive serial reception.
F2 NCLRXD Negative serial reception.
F3 PCLTXD Positive serial transmission.
F4 NCLTXD Negative serial transmission.
F5 GND Negative console power supply.
F6 +12 Positive console power supply.
F7 FLASH Must be connected to F8 for the Flash memory programming (if
used).
F8 FLASH Must be connected to F7 for the Flash memory programming (if
used).

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3.5 DESCRIPTION OF CONNECTORS - PUMP CONFIGURATION
The AC3 and AC4 have been designed to be produced with two different types of I/O
connector: One AMP SAAB 29 poles connector or six Molex Minifit connectors.
3.5.a Amp Saab connector
A1 PPOT Potentiometer positive: 10V output; keep load > 1KW.
A2 NPOTB -Batt.
A3 PTHERM Input for motor temperature sensor.
A4 NTHERM -Batt.
A5 -BATT Battery negative.
A6 NAUX This output can be used for drive the main contactor coil (single
pump configuration) or to drive an auxiliary load (combi configura-
tion)
A7 NBRAKE Output for driving an hydraulic steering contactor coil; drives the load
to -Batt maximum current : 3A.
A8 PAUX Positive of the auxiliary output.
A9 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED
/ 4th SPEED / HYDRO / SR microswitches.
A10 KEY Connected to the power supply through a microswitch (CH) with a
10A fuse in series.
A11 CPOT Potentiometer wiper input.
A12 NPOT Negative of lifting potentiometer, tested for wire disconnection diag-
nosis.
A13 AN. IN. Free analog input.
A14 CAN-H High level CAN-BUS voltage I/O.
A15 CAN-L Low level CAN-BUS voltage I/O.
A16 LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.
A17 1st SPEED Input for first speed request; it is active HIGH.
A18 HYDRO REQ. Input for hydraulic steering request. Active high.
A19 SR Speed reduction input. Active low (switch opened).

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A20 ENCODER Incremental ENCODER connector (see chapter 3.6).
A21 ENCODER Incremental ENCODER connector (see chapter 3.6).
A22 ENCODER Incremental ENCODER connector (see chapter 3.6).
A23 ENCODER Incremental ENCODER connector (see chapter 3.6).
A24 MODE This input allows the customer to select the software for traction or
lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A5) Pump inverter
A25 SAFETY If not connected to -Batt the MC coil power output will be disabled.
Can also be used as a general purpose input.
A26 3rd SPEED Input for third speed request; it is active HIGH.
A27 DIG. IN. This is a digital input, free for customer request.
A28 2nd SPEED Input for second speed request; it is active HIGH.
A29 4th SPEED Input for fourth speed request; it is active HIGH.

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3.5.b Molex Minifit connectors
A1 CPOT Accelerator potentiometer wiper.
A2 PPOT Potentiometer positive: 10V output; keep load > 1KW.
A3 NPOT Negative of accelerator unit, tested for wire disconnection diagnosis.
A4 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED
/ 4th SPEED / HYDRO / SR microswitches.
A5 LIFT ENABLE Input for potentiometer lifting enable input; it is active HIGH.
A6 1st SPEED Input for first speed request; it is active HIGH.
A7 3rd SPEED Input for third speed request; it is active HIGH.
A8 AN. IN. Free analog input.
A9 PPOT Potentiometer positive: 10V output; keep load > 1KW.
A10 -BATT -Batt.
A11 -BATT -Batt.
A12 HYDRO REQ. Input for hydraulic steering request. Active high.
A13 SR Speed reduction input. Active low (switch opened).
A14 DIG. IN. This is a digital input, free for customer request.
B1 KEY Connected to the power supply through a microswitch (CH) with a
10A fuse in series.
B2 PAUX Positive of the auxiliary output.
B3 PHYDRO Positive for the hydraulic steering contactor.
B4 4th SPEED Input for fourth speed request; it is active HIGH.
B5 SAFETY If not connected to -Batt the MC coil power output will be disabled.
Can also be used as a general purpose input.
B6 PTHERM Input for motor temperature sensor.
B7 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED / 3rd SPEED
/ 4th SPEED / HYDRO / SR microswitches.

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B8 NAUX This output can be used for drive the main contactor coil (single
pump configuration) or to drive an auxiliary load (combi configura-
tion)
B9 NHYDRO Output for driving an hydraulic steering contactor; drives the load to -
Batt. Maximum current: 3A.
B10 2nd SPEED Input for second speed request; it is active HIGH.
B11 GND -Batt.
B12 NTHERM -Batt.
C1 CAN-L Low level CAN-BUS voltage I/O.
C2 CAN-L-OUT Low level CAN-BUS voltage I/O.
C3 CAN-H High level CAN-BUS voltage I/O.
C4 CAN-H-OUT High level CAN-BUS voltage I/O.
D1 -BATT -Batt.
D2 MODE This input allows the customer to select the software for traction or
lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A5) Pump inverter
E1÷E6 Incremental ENCODER connector (see chapter 3.6).
F1 PCLRXD Positive serial reception.
F2 NCLRXD Negative serial reception.
F3 PCLTXD Positive serial transmission.
F4 NCLTXD Negative serial transmission.
F5 GND Negative console power supply.
F6 +12 Positive console power supply.
F7 FLASH Must be connected to F8 for the Flash memory programming (if
used).
F8 FLASH Must be connected to F7 for the Flash memory programming (if
used).

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3.6 ENCODER INSTALLATION
1) AC4 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 en-
coder power supply can be +5 or +12V. It can have different electronic output.
Minifit Saab
E1 A20 +5V/+12V positive of encoder power supply.
E2 A23 GND negative of encoder power supply.
E3 A21 A phase A of encoder.
E4 - A phase A inverted (encoder with differential output).
E5 A22 B phase B of encoder.
E6 - B phase B inverted (encoder with differential output).
2) Connection of encoder with differential outputs; +5V power supply (Minifit connectors).
3) Connection of encoder with open collector output; +5V power supply (Minifit connec-
tors)..
4) Connection of encoder with open collector output: +12V power supply (Minifit connec-
tors).
VERY 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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3.7 DESCRIPTION OF POWER CONNECTIONS
View of the power bars:
-BATT Negative of the battery.
+BATT Positive of the battery.
U; V; W Connection bars of the three motor phases; follow this sequence and the indica-
tion on the motor.