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

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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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

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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

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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”.

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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

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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

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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.

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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.

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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