Zapi SMART CONSOLE 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
User Manual
SMART
CONSOLE
EN

Page - 2/50 AFGZP0BA – SMART CONSOLE - User Manual
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.

AFGZP0BA - SMART CONSOLE - User Manual Page - 3/50
Contents
1INTRODUCTION ...................................................................................................................5
2OVERVIEW............................................................................................................................6
2.1Features......................................................................................................................6
2.2Operational ratings .....................................................................................................6
2.2.1Electrical .......................................................................................................6
2.2.2Environmental ...............................................................................................8
2.3Operational Modes .....................................................................................................8
2.3.1Current-loop serial connection (internal supply) ...........................................8
2.3.2CANBUS connection and internal supply .....................................................9
2.3.3CANBUS connection and external supply ....................................................9
2.4Supported products ....................................................................................................9
2.4.1CAN communication .....................................................................................9
2.4.2Serial communication..................................................................................10
2.5Update of SMART Console firmware........................................................................11
3QUICK START ....................................................................................................................12
3.1How it looks ..............................................................................................................12
3.1.1The display..................................................................................................12
3.1.2The keyboard..............................................................................................12
3.1.3The Main connector ....................................................................................13
3.1.4The USB connector.....................................................................................13
3.2Use of internal batteries............................................................................................13
3.3Serial connection (internal AA batteries) ..................................................................16
3.4CAN connection (internal AA batteries) ....................................................................23
3.5CAN connection (external supply) ............................................................................27
4HARDWARE LAYOUT........................................................................................................28
4.1Cover ........................................................................................................................28
4.2CNX Connector.........................................................................................................30
4.2.1Layout .........................................................................................................30
4.2.2Pin description ............................................................................................30
4.3Cables.......................................................................................................................31
4.3.1Serial cable .................................................................................................31
4.3.2CAN cable and connector...........................................................................33
4.3.3Cable for console update............................................................................33
4.4Keyboard ..................................................................................................................34
4.4.1LED.............................................................................................................34
4.4.2ON button....................................................................................................35
4.4.3F1 F2 F3 keys.............................................................................................35
4.5USB ..........................................................................................................................35
4.5.1USB and console supply source.................................................................36
5SPECIAL FUNCTIONS .......................................................................................................37
5.1DOWNLOAD PARAMETER LIST TO USB STICK...................................................37
5.1.1File format...................................................................................................37
5.1.2Download procedure...................................................................................37
5.2DATALOG OF CAN TRAFFIC..................................................................................39
5.2.1File format...................................................................................................39
5.2.2Download procedure...................................................................................40
5.3GRAPHICAL TESTER..............................................................................................41

Page - 4/50 AFGZP0BA – SMART CONSOLE - User Manual
5.4DATALOG OF TESTER VARIABLES ...................................................................... 41
5.5PROGRAMMING A CONTROLLER......................................................................... 41
5.6FORCED RESET .....................................................................................................41
6MENU CONSOLE ...............................................................................................................42
6.1Console parameter................................................................................................... 42
6.2Read Ram and Read Eeprom ..................................................................................43
6.3Clear eeprom............................................................................................................ 43
6.4Config rtc ..................................................................................................................43
6.5Password management............................................................................................ 44
7ALARMS AND ICONS ........................................................................................................46
7.1READ-ONLY warning...............................................................................................46
7.2BATTERY LOW warning .......................................................................................... 46
7.3Alarms ......................................................................................................................47
7.3.1WATCHDOG alarm ....................................................................................47
7.3.2EEPROM KO alarm.................................................................................... 47
7.3.3SUPPLY FAILURE alarm ...........................................................................47
8ACKNOWLEDGMENTS ..................................................................................................... 49
9PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 50
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
Publication N°: AFGZP0BA
Edition: October 2014

AFGZP0BA - SMART CONSOLE - User Manual Page - 5/50
1 INTRODUCTION
The Smart Console is an handheld tool developed to improve setup and
programming of all Zapi products installed in any application.
It features a clean and easy-to-use interface and a bright display which simplifies
access to parameters and troubleshooting.
Moreover it is not limited to visualize parameters and alarms, like the standard
Zapi Console Ultra, but it has advanced functions like capability to download
parameters or CAN messages to a USB memory stick.
This manual will detail all characteristics of the Smart Console.
For new customer willing to test the Smart Console as much quickly as possible a
dedicated chapter is available: see Chapter 3 “Quick Start”.

Page - 6/50 AFGZP0BA – SMART CONSOLE - User Manual
2 OVERVIEW
2.1 Features
3.2’’ TFT LCD with backlight for easy viewing in low light conditions
Plastic cover to protect against mechanical shocks
Silicone keyboard resistant to industrial environment
Key placement to navigate easily through console menu
Communication through:
oCurrent-loop serial line as standard Zapi console
oCANBUS line
CAN speed up to 500kpbs
CAN protocols supported:
oPC CAN CONSOLE (standard)
oZAPI CANOPEN
It can accommodate different types of connection cables
Power supply can be sourced by:
oExternal Battery or dc-source (for CANbus communication)
oInternal supply: 4xNiMh or Alkaline batteries placed in the
dedicated holder (CANbus or serial line)
Simple and straightforward user-interface
TESTER menu can display more fields at once
Parameter SAVE/RESTORE
Password to protect parameters from unauthorized modifications
USB Embedded Host to permit additional functions
2.2 Operational ratings
2.2.1 Electrical
External power supply
Parameter Value Comment
Maximum supply voltage on CNX8 (+Batt) supply pin 92V
Minimum supply voltage CNX8 (+Batt) supply pin 11V Internal dc/dc
switches off
Supply current
115mA
Supply
voltage=28V,
console idle and
not connected
200mA
Supply
voltage=28V,
CAN connected
and exchanging
data

AFGZP0BA - SMART CONSOLE - User Manual Page - 7/50
Internal power supply
Parameter Value Comment
Size of battery AA
Supported types of battery NiMh,
Akaline
Maximum supply voltage (Sum of 4 cells) 6.5V
Threshold voltage for battery discharge warning (Sum of 4
cells) 5V
NiMh cells,
console idle and
not connected
Running time
4hours
4x1950mAh NiMh
batteries, CAN
connected and
exchanging data,
USB stick
inserted and
supplied
5h 30’
4x1950mAh NiMh
batteries, CAN
connected and
exchanging data
Current-loop serial line
Parameter Value Comment
Maximum output current on CNX4 (NCLTXD) 35mA built-in 100R
resistor
Maximum voltage on CNX4 (NCLTXD) 18V Output not
active
Maximum current sink at CNX5 (PCLTXD) 30mA built-in 470R
resistor
Maximum voltage on CNX3 (NCLRXD) 0.5V
In order to
guarantee
reception
Absolute maximum voltage on CNX3 (NCLRXD) 96V
CANBUS line
Parameter Value Comment
Absolute voltage range on CNX6 (CANL) and CNX7
(CANH) -80÷80V Respect to ground
CNX6 (CANL) output voltage 0÷2V During
communication
CNX7 (CANH) output voltage 3÷5V During
communication
Maximum CAN speed 500kbps

Page - 8/50 AFGZP0BA – SMART CONSOLE - User Manual
USB line
Parameter Value Comment
USB version 2.0
USB class Host
VBUS supply voltage 5 ±0.2 V
VBUS supply current Internally
limited
Supported file system FAT
FAT32
2.2.2 Environmental
Keyboards has an anti-scratching treatment.
IP grade:
oIP51 (front side)
oIP20 (all other sides)
Tested against falling from 1m height, all sides
Operational temperature: -10°C ÷ 50 °C
2.3 Operational Modes
The Smart Console has been designed to have multiple ways of operation. Three
modes can be identified:
Serial connection powered by four standard AA size batteries placed in the
battery holder of the console.
CANBUS connection powered by four standard AA size batteries placed in
the battery holder of the console.
CANBUS connection with Smart Console supplied by an external dc source.
This source may be a standard battery (lead-acid or other type) or a dc/dc
converter
2.3.1 Current-loop serial connection (internal supply)
The Smart Console offers the same serial connection as the well-known Console
Ultra.
Main characteristics of this operational mode:
Current-loop serial communication
Console is connected to a single controller only (even if Remote Console
option is available)
Baud-rate selectable
Smart Console powered by 4 AA batteries instead of being powered by the
target controller like the Console Ultra
USB active to provide additional functions (see chapter 5)
Zapi can provide the serial cable compatible with Molex SPOX connector
used in Console Ultra (see section 4.3.2)
Please refer to section 2.4.2 to check which Zapi products with a serial
connection are supported by the Smart Console.

AFGZP0BA - SMART CONSOLE - User Manual Page - 9/50
2.3.2 CANBUS connection and internal supply
The Smart Console can connect to an existing CAN line and connect with any
Zapi controller inside this line.
Operation is similar to the PC CAN Console software but it is not needed to have
a Personal Computer.
Main characteristics of this operational mode:
It can be connected to a CAN line composed of any combination of modules,
both Zapi ones and not-Zapi ones
Supported speeds: 125, 250, 500kbps
It sees the entire CAN line and all CAN modules.
Smart Console powered by 4 AA batteries
USB active to provide additional functions (see chapter 5).
2.3.3 CANBUS connection and external supply
Operation is similar to 2.3.2 but supply source is different:
It can be connected to a CAN line composed of any combination of modules,
both Zapi ones and not-Zapi ones
Supported speeds: 125, 250, 500kbps
It sees the entire CAN line and all CAN modules.
Power supply must derive from a dc source. Typical supply sources are:
oMain battery of the application, like a lead-acid traction battery
oOutput voltage of a dc/dc converter
Wide supply voltage: nominal battery voltage from 12V to 80V.
USB active to provide additional functions (see chapter 5).
2.4 Supported products
2.4.1 CAN communication
In general CAN communication is possible to almost every Zapi controller with a
standard CAN interface . The few exceptions are listed below.
Different CAN protocol
The Zapi controller may use a CAN protocol which is not accepted by the Smart
Console.
In this case the only possibility to overcome this issue is to modify the Smart
Console firmware.
4To update the Smart Console firmware please refer to section 2.5
Isolated CAN
In some application the CANBUS might be isolated from the main supply source.
This means that CANL and CANH signals are referenced to a ground signal
(NCAN) and a positive supply voltage (PCAN) which are isolated by the main
supply source.
NCAN and PCAN are used to supply the isolated CAN transceivers of each
module of the CAN line.

Page - 10/50 AFGZP0BA – SMART CONSOLE - User Manual
Smart Console has no isolated CAN transceiver but it is possible to connect to
this type of line in two ways:
Use internal batteries. In this case connect NCAN to the ground of the
console: don’t connect any other ground signal from the application!
CAN communication will run normally
Connect the console ground to NCAN and the positive supply pin CNX8 to
PCAN. If PCAN is within limits of CNX8 supply voltage and if it can deliver
enough supply current (see section 2.2.1), the console will turn on and it will
operate normally.
CAN speed
The Smart Console supports CAN speed up to 500kbps. Larger speeds are not
supported.
If a Smart Console is connected to a CANBUS running at large speed, every
communication attempt will return an error message.
2.4.2 Serial communication
The Smart Console retains the same serial communication as the Console Ultra.
Because the Console Ultra has been on the market for many years, it is
supported by a wide range of products ranging from the very old chopper series
to the latest “E” family AC controllers.
The Smart Console has been developed to cover the same range of products so
it is expected to be compatible with all controllers which can connect the old
console.
Following list contains all product which have been tested successfully with the
Smart Console serial interface:
AC2 FLASH
AC3 FLASH (standard and 2µc version)
ACE2 (standard and 2µc version)
ACE5 (standard and 2µc version)
ACX
AC0
AC1
COMBIAC1
DUALAC2
EPS-AC0
SEM0
H0
H2
Moreover the Smart Console is compatible with all latest generation controllers
whose serial connector is not reachable unless cover is removed:
COMBIAC0
COMBIACX
ACE3
VCM

AFGZP0BA - SMART CONSOLE - User Manual Page - 11/50
UIt is possible to try connecting to a controller not listed above. Serial
interface has been designed to avoid failures to the target controller
circuits. It is always possible that incompatibility towards some controller
may arise, causing a systematic “NO COMMUNICATION” error. In majority
of cases this will happen in presence of a “custom” serial protocol. Contact
Zapi for support.
2.5 Update of SMART Console firmware
The firmware installed in the Smart Console can be modified if needed. There are
many reasons behind the need to update the firmware:
Zapi has delivered a new firmware adding new functions to the Smart
Console
Zapi has delivered a new firmware which removes bugs present in previous
versions
A special firmware has been developed for a specific application/customer
See 4.3.3 too.
UFirmware update is a procedure which must be carried out under
assistance of a Zapi technician.
UPlease contact Zapi for further information

Page - 12/50 AFGZP0BA – SMART CONSOLE - User Manual
3 QUICK START
This chapter is dedicated to new users who wants to get started quickly without
entering too much into details.
Since description is minimal, read it carefully and don’t skip any paragraph.
For a more detailed description about hardware and the software functions
please refer to Chapters 4 and 5.
3.1 How it looks
There are four main parts which must draw attention of new users
3.1.1 The display
A bright 3.2’’ TFT LCD display is the core of the console.
Every time it turns on it will display first the Zapi logo and then the HOME
SCREEN.
Majority of menus has a simple colour palette with white text on black
background.
4By itself the display is very fast. While showing information on screen a certain
level of latency is always present. This latency is due to the console-controller
communication speed and it is not related to the display speed.
UEnd-of-line tests in Zapi have been developed to intercept all display
defects before shipping. Anyway, when the display is turned on for the first
time, it is strongly suggested to verify that no fixed or burnt pixels are
present inside the viewing area.
3.1.2 The keyboard
The keyboard is used to navigate in the different menu. It features some key with
special functions and a green led.
Different button functions are shown below.
UP and DOWN keys
In most cases a menu is a list of items: these items are ordered in rows. Selected
item is highlighted in light blue .
Up and down keys are used to move the selection up and down: in other words
they are used to “scroll”.
LEFT and RIGHT keys
Normally used to increase and decrease the value associated with the selected
item inside a menu.

AFGZP0BA - SMART CONSOLE - User Manual Page - 13/50
OK and ESC keys
OK key is used either to confirm actions or to enter a submenu.
ESC is used either to cancel an action or to exit a menu.
F1, F2, F3 keys
These buttons have a contextual use. The display will say which F button can be
used and its function.
ON key
Used while operating with internal batteries. See section 3.2 for further details.
4While the Smart Console is powered from external sources on pin CNX8 the
button ON is deactivated regardless of the presence of the batteries.
GREEN LED
When the console is powered on and running the green led is on.
Green led can blink in certain cases which will be described better in following
sections.
3.1.3 The Main connector
The main connector is placed in the top part of the Smart Console. It is a 15 pin
D-subminiature (DA-15) female connector.
4The main connector is called CNX in this manual. When referring to a single pin
“k”, the name CNXk will be used
All communication signals are in this connector
Its pin layout is described in section 4.2.
The CNX connector hosts more signals than what is needed for a typical use.
Moreover its D-sub layout is not suitable to be connected to Zapi products.
It is up to the cable the task of picking up the correct signals from the
application/controller and direct them to CNX connector: for example the
cable for serial communication takes only six signals from CNX and it directs
them to the standard Molex SPOX plug.
3.1.4 The USB connector
Placed in the bottom part of the console, it is a standard type-A socket.
USB functionality is discussed in next chapters.
3.2 Use of internal batteries
Smart Console operates using four AA batteries placed inside the battery holder.
With this power supply, it can communicate either via serial line or

Page - 14/50 AFGZP0BA – SMART CONSOLE - User Manual
CANBUS.
SUPPORTED BATTERIES
Preferred battery type is rechargeable NiMh. Use a mAh rating as much large as
possible to increase battery life.
Alkaline 1.5V batteries are supported too but, before installing them, it is
necessary to change parameter BATTERY TYPE: see section 6.1.
UDon’t use batteries with leakages! They can damage the electronic board!
UDon’t mix battery types: use four batteries of the same type and with same
level of charge.
UDon’t exceed voltage ratings shown in 2.2.1. Larger voltages will damage
internal circuits. Smaller voltages will prevent console starting.
PLACING BATTERIES
1. With Smart Console turned off, open the battery holder by removing its cover.
Notice that this operation exposes part of the electronic board: do this
operation while in a clean environment!
2. Place the four batteries as indicated by the holder.
3. Close the cover
If the batteries are in place the Smart Console can still operate from external
supplies as described in 3.5.
When an external supply is used the internal dc/dc will isolate the AA batteries so
that they are not discharged.
Batteries can remain inside the battery holder even if they are not used.
URemove batteries if they are not going to be used for a lot of time
CONNECTING CABLE
When supplied by internal batteries, the Smart Console can use either the
serial cable (see 4.3.1) or any available CAN cable (see 4.3.2).
4The Smart Console ground reference is unrelated to the controller/application
ground unless a physical connection is set up.
4Ground reference shall always be connected or communication will be difficult
unless connecting cable is very short and there is no disturbance.
4It is strongly suggested to tighten the lateral screws of the cable to avoid
unexpected disconnections.

AFGZP0BA - SMART CONSOLE - User Manual Page - 15/50
POWER ON THE CONSOLE
The console can be turned on with or without the cable already inserted.
1) Press ON key and keep it pressed. The Smart Console will turn on.
2) Notice that the led is off and it remains off for about three second even if the
console is booting. If ON button is released while the led is turned off, the
console will turn off too.
3) As soon as the led lights up, release the ON button: the console is now
operating correctly. HOME SCREEN has appeared.
4) Jump to related section: either 3.3 or 3.4 for further instructions.
BATTERY LIFE
Battery life depends on many variables so it is difficult to determine an estimated
time. In general battery consumption is larger in the following conditions :
Serial/CAN communication running continuously at high speed;
USB device connected
When batteries reach a low charge level:
the display will show a battery icon in the top part of the display (see
chapter 7)
led will start blinking fast
Once battery low is signaled, replace the batteries as soon as possible to avoid
sudden switching off.
4It is not possible to recharge the batteries while they are placed inside the Smart
Console. They must be removed and an external charger must be used.
4There is no indications for discharged batteries if the console is not powered by
them.
To save battery life there is an option which automatically switches off the
console after a certain time of inactivity has elapsed.
This function is activated by parameter MAX IDLE TIME: see section 6.1.
EMERGENCY SUPPLY (CAN connection only)
In case battery charge is low and it is absolutely necessary to avoid the console
switching off, there is a possibility to keep the console alive.
If a valid supply source is at hand and:
Power supply voltage is within CNX8 ratings (see 2.2.1)
Supply voltage is referenced to console ground
It is possible to connect this power supply to console CNX8: the console will start
taking supply from CNX8 and it will disable the internal batteries.
From this point console operation falls in the same case as in section 3.5
POWER OFF THE CONSOLE
To switch off the console press again the ON key and keep it pressed until the
led switches off.
At this point the console can be turned off safely: release the ON key to complete
shutdown.

Page - 16/50 AFGZP0BA – SMART CONSOLE - User Manual
3.3 Serial connection (internal AA batteries)
The use of the Smart Console with serial connection is very similar to the use of
the Console Ultra.
CONNECT THE CONSOLE
To connect the Smart Console to the target, it is required to have a CNX-to-
Molex SPOX cable. This cable must end with a Molex SPOX plug which is
exactly the same as in the standard Zapi console Ultra.
Further details about this cable are in section 4.3.1.
1) Verify batteries are in the battery holder
2) Connect the cable
3) Turn on the console by pressing the ON button. This passage can be
skipped if desired because the console can be turned on in later passages
too.
4) Connect the Molex SPOX plug to target controller.
5) Turn on the controller by closing its key switch,
6) If console wasn’t turned on at step 3), turn it on now.
UBy default the Smart console turns on with CAN interface active. However it
detects by itself the presence of the serial cable. The console will disable
the submenus which are not usable with the chosen connection mean. So,
when connected to serial cable, it won’t be possible to access menu about
CAN connection.
HOME SCREEN
After showing the Zapi logo, the HOME SCREEN will appear on the display:
From top:
First line tells which firmware version is running inside the console, in this
case ZP 0.15
RS232 Console: enter this menu to start a serial connection as in the
Console Ultra

AFGZP0BA - SMART CONSOLE - User Manual Page - 17/50
CAN Console: enter this menu to start a CAN connection
AUTOSCAN CAN: another way to start a CAN connection
Console Utilities and Menu Console: ignore them at the moment
The current hour is shown in the bottom right.
Moreover the green led must be turned on and still.
The “RS232” line is already highlighted so press OK key.
Display prompts a message to inform you that a connection attempt is ongoing.
If serial connection fails a “NO COMMUNICATION” warning will be shown after
some second: press ESC key and look for what is preventing the connection.
4Please notice the red dot appearing in the top right of the display every time you
press a button. It indicates that the console has received the command and it is
elaborating the request. If the red dot does not appear when a button is pressed,
there is probably a failure inside the keyboard or the console has stalled.
CONNECTED
If connection is successful the display will show an image similar to the next one.
This menu shows basic information about the controller, in a way similar to
console Ultra.
First line tells the controller firmware
Second line shows controller voltage, controller current and hourmeter
Last line shows the current alarm code, if present
Press OK to access the MAIN MENU

Page - 18/50 AFGZP0BA – SMART CONSOLE - User Manual
MAIN MENU contains the complete list of menus available in the controller.
Contrary to Console Ultra there are no “hidden” menus which must be reached
by pressing many buttons at once: now all menus are visible.
Use UP and DOWN keys to navigate the list: once you find the desired menu
press OK to enter it.
MODIFY A PARAMETER
From MAIN MENU enter the PARAMETER CHANGE menu.
With UP and DOWN keys you can scroll the whole list: once you have highlighted
a parameter that you want to modify, use LEFT or RIGHT keys to decrease or
increase the parameter value.
4Keep LEFT/RIGHT button pressed to continuously repeat the value modification
(“autorepeat” function): this function will speed up the procedure in case many
parameter values must be changed.
You can press ESC to exit the menu at any time. In case some parameter has
been modified, the console will prompt a request to confirm/discard changes.

AFGZP0BA - SMART CONSOLE - User Manual Page - 19/50
4Description above is valid for every menu which contains parameters and options
like SET OPTIONS, ADJUSTMENTS, HARDWARE SETTINGS, etc.
TESTER
Compared to standard console Ultra, the TESTER menu has been modified
deeply. Now it shows four variables at once: use UP/DOWN keys to scroll the list
as usual.
It is possible to “block” a variable so that it remains displayed during scrolling.
Once the desired variable is highlighted press RIGHT: it will be highlighted in a
different colour.

Page - 20/50 AFGZP0BA – SMART CONSOLE - User Manual
As soon as you restart scrolling up or down the “blocked” variable will be placed
in first line from top: from now it will not move anymore but its current value will
be updated continuously as usual. The “blocked” variable will be highlighted in
light blue.
Blocking procedure can be repeated up to three time thus three variables can be
fixed on screen while the fourth one always scrolls. See example below.
In this way it is possible to keep track of four variables, placed far from one
another in the complete list, in a single view.
To “unblock” the last blocked variable, press LEFT button. Pressing LEFT up to
three times will unblock all variables
Press ESC to go back to MAIN MENU.
4Notice that pressing F1 will activate graphical representation over time of the
selected variables
4Graphic tester feature isn’t fully operative yet: it will be activated in a future
firmware.