Zapi ECO SMART 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
ECO SMART
DISPLAY

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Copyright © 1975-2009 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
2GENERAL CHARACTERISTICS..........................................................................................6
2.1 Technical specifications..............................................................................................6
2.1.1 Dashboard ....................................................................................................6
2.1.2 Alphanumeric LCD (Liquid Crystal Display)..................................................6
2.2 Functional descriptions ...............................................................................................6
2.2.1 LED function .................................................................................................6
2.2.2 Display function.............................................................................................7
3INSTALLATION HINTS.........................................................................................................9
3.1 Material overview........................................................................................................9
3.1.1 Connection cables ........................................................................................9
3.1.2 Fuses ............................................................................................................9
3.2 Installation of the hardware.........................................................................................9
3.2.1 Controller heating........................................................................................10
3.2.2 Wirings: CAN connections and possible interferences ...............................10
3.2.3 Wirings: I/O connections .............................................................................12
3.2.4 Insulation of truck frame..............................................................................12
3.3 Protection and safety features ..................................................................................13
3.3.1 Protection features......................................................................................13
3.3.2 Safety Features...........................................................................................13
3.4 EMC..........................................................................................................................13
4DIAGNOSIS.........................................................................................................................16
5DESCRIPTION OF CONNECTORS....................................................................................17
5.1 CNA connector: Molex Minifit 6 pins.........................................................................17
6DRAWINGS.........................................................................................................................18
6.1 Mechanical drawing ..................................................................................................18
6.2 Connection drawing ..................................................................................................19
7PROGRAMMING AND ADJUSTMENTS USING ZAPI HANDSET....................................20
7.1 Adjustment via console.............................................................................................20
7.2 Description of console and connection .....................................................................20
7.3 Description of standard console menu .....................................................................21
7.4 Description of programmable functions ....................................................................22
7.5 Special Adjustment menu .........................................................................................23
7.6 Parameter change menu ..........................................................................................23
7.7 Tester menu..............................................................................................................24
7.8 Description of console using.....................................................................................25
7.9 Other functions .........................................................................................................28
7.10 Description of Alarm menu .......................................................................................29
8STRUCTURE OF DISPLAY MENU.....................................................................................30
8.1 Performance rolling...................................................................................................32
8.2 Using of Password menu..........................................................................................32
8.3 Using dashboard like a console................................................................................33
9ANALYSIS OF ECO SMART DISPLAY RELATED ALARMS ...........................................34
9.1 Eco Smart Display alarms ........................................................................................34
9.2 Alarms visualisation ..................................................................................................34
9.2.1 Traction (node 02).......................................................................................37
9.2.2 Traction master (node 03)...........................................................................37

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9.2.3 Traction slave (node 04).............................................................................37
9.2.4 Pump (node 05).......................................................................................... 38
9.2.5 EPS-AC (node 06)...................................................................................... 38
9.2.6 Valves controller (node 09)......................................................................... 40
9.2.7 Eco Smart display (nodo 16) ...................................................................... 41
10 RECOMMENDED SPARE PARTS FOR INVERTER .........................................................42
11 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................43
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
MANAGER VISA PP
SALES MANAGER VISA MC
Publication N°: AEXZP0BB
Edition: June 2009

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1 INTRODUCTION
Eco Smart Display is an intelligent dashboard connected to the truck system by
CAN-BUS line.
This dashboard provides the diagnostic and set-up of the whole truck system:
Eco Smart Display itself, Traction controller, Pump controller, Valves controller.
Eco Smart Display has an alphanumeric liquid crystal display, built-in backlight.
Access to Eco Smart Display menu structure is provided by five operator buttons.
Furthermore Eco Smart Display has five built-in red LED, which provide the
operator with a easy information about the status of some truck devices.

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2 GENERAL CHARACTERISTICS
2.1 Technical specifications
2.1.1 Dashboard
Voltage:..............................................................................................24/36/48/80 V
Can interface [n°]: ..................................................................................................1
Keyboard buttons [n°]: ........................................................................................... 5
LED [n°]: ................................................................................................................ 5
Protection:.........................................................................................................IP65
External temperature range: standard version ...........................................0÷50 °C
External temperature range: frozen cell version ......................................-35÷50 °C
2.1.2 Alphanumeric LCD (Liquid Crystal Display)
Viewing area (WxH).......................................................................... 50.0x25.0 mm
Number of pixels [n°] ................................................................................... 128x64
Pixel size........................................................................................... 0.33x0.33 mm
White LED backlight average luminous intensity.....................................250 cd/m2
2.2 Functional descriptions
2.2.1 LED function
The Eco Smart Display has five built-in red LED, which provide the operator with
an easy information about the status of some truck devices.
Battery (1)
This led lights when the measured battery voltage is equal or less than 40%
nominal battery voltage.
Wrench (2)
This led blinks when truck is in alarm condition.
Thermometer (3)
This led blinks when one truck’s controller is in alarm due IMS high temperature.

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Seat (4)
This led lights when the operator is on the seat.
Handbrake (5)
This led lights when the handbrake is activated.
4When the Key Switch is closed, the Eco Smart Display makes a general test
lighting and switching off all the LED in sequence.
2.2.2 Display function
Battery’s state of charge
The battery's state of charge indication (number 1 in figure) is displayed on the
left side of the unit; it is shown by ten notches. Each notch represents the 10% of
the battery charge. As the battery becomes discharged, the notches turn off
progressively, one after the other, in proportion to the value of the residual
battery charge. When the residual battery charge is ≤40 % the notches displayed
start to blink. When BATTERY LOW alarm appears on the traction controller, the
battery symbol which is near the notches also blinks.
Performance
The number which appears in the rectangle displayed in the top right side of the
unit (number 2 in figure) shows the performance mode which is being used in the
controller.
Performances can be scrolled pressing button W. When one performance is
selected, the related information will be sent via can-bus to traction and pump
controllers that will manage this data. The standard functioning reduces truck
performance passing from performance mode #4 to performance mode #1.
The real meaning, in terms of parameters level of these performances, depends
on software present on pump and traction controllers:
- 4 corresponds to highest performance;
- 3 corresponds to medium performance;
- 2 corresponds to low performance;
- 1 corresponds to minimum performance.

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Turtle
The turtle symbol (number 3 in figure) is normally off; when it appears (fixed) it
shows activation of the “soft” mode of the truck, in which maximum speed and
acceleration are reduced.
Hour meter
The number displayed on the bottom right side of the unit (number 5 in figure)
shows the Hours Worked.
The letter present over the hour meter (number 4 in figure) shows which hour
meter is displayed:
- K: the key hour meter is displayed;
- S: the seat hour meter is displayed;
- M: the machine hour meter is displayed; it increases if traction or pump
control is working.
Accelerator
The accelerator level indication (number 6 in figure) is displayed on the central
top side of the unit; it is shown by eight notches. When the accelerator level is
minimum only a notch is displayed, when the accelerator level is maximum all the
eight notches are displayed. Each notch represents 1/8 of the difference between
maximum and minimum accelerator level.
Speed
The number displayed under the accelerator notches on the center of the unit
(number 7 in figure) shows the truck speed. The unit can be km/h or mph
depending on the SPEED UNIT parameter setting (see 7.4).
Wheel position and running direction
The notch displayed on the left of the hour meter (number 8 in figure) represents
the wheel (only one of the nine notches is displayed) and shows the steering
angle (it corresponds to the relative truck direction if the truck is running).
The arrow (number 9 in figure) shows the set truck running direction. The arrow
point is up when the truck is forward running; the arrow point is down when the
truck is reverse running. If the truck doesn’t run a dot is displayed instead of the
arrow.

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3 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
3.1 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.
3.1.1 Connection cables
For the auxiliary connections, use cables of 0.5-1.0 mm² section.
3.1.2 Fuses
- Use a 6.3 A Fuse for protection of the card.
- For Safety reasons, we recommend the use of protected fuses in order to
prevent the spread of fused particles should the fuse blow.
3.2 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 module to a battery with a nominal voltage different
than the value indicated on the label. A higher battery voltage may cause a
logic failure. A lower voltage may prevent the logic operating.

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3.2.1 Controller heating
Eco Smart Display does not need any means of heat dissipation. The frozen-cell
version, provided with a built-in heater, is strongly recommended for frozen-cell
applications.
3.2.2 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.
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.
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).
3.2.3 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”.
3.2.4 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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3.3 Protection and safety features
3.3.1 Protection features
- Connection Errors:
All inputs are protected against connection errors.
- External agents:
The controller is protected against dust and the spray of liquid to a degree of
protection meeting IP65.
3.3.2 Safety Features
UZAPI devices are designed according to the prEN954-1 specifications for
safety related parts of control system and to UNI EN1175-1 norm.
UThe 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.
3.4 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 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 as
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

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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
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 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, with serial communications (canbus)
which 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.
IMPORTANT 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.
1) 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.
2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions
are valid also for immunity. Additionally, further protection can be achieved
with ferrite beads and bypass capacitors.
3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent
damages from ESD:

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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 through a “safe” path; the
frame of a truck can works like a “local earth ground”, absorbing excess
charge. So it is strongly suggested to connect to truck frame all the
parts of the truck which can be touched by the operator, who is
most of the time the source of ESD.

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4 DIAGNOSIS
Main fault diagnostic function concern: parameter and password memory and
canbus interface.

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5 DESCRIPTION OF CONNECTORS
5.1 CNA connector: Molex Minifit 6 pins
A1 -BATT Eco Smart Display negative supply.
A2 -BATT Eco Smart Display negative supply.
A3 CAN-H Can signal high.
A4 CAN-L Can low signal.
A5 FREE Not used.
A6 KEY Eco Smart Display positive power supply.

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6 DRAWINGS
6.1 Mechanical drawing
Recommended panel cut out:
54 x 115 rectangular aperture
with 4 radius R5

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6.2 Connection drawing

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7 PROGRAMMING AND ADJUSTMENTS
USING ZAPI HANDSET
7.1 Adjustment via console
Adjustment of Parameters and changes to the display configuration are made
using the Digital Console. Eco Smart Display dosen’t have an external connector
dedicated to the console: Zapi console must be physically connected to another
controller in the CANBUS net, then virtually connected to Eco Smart Display
(which is node 16 of the net).
7.2 Description of console and connection