Afczp0bb (Combiacx Acex Ing)

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: [email protected] – web: www.zapispa.it
EN
User Manual
COMBIACX
&
ACEX
Copyright © 1975-2011 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
4 The symbol aboard is used inside this publication to indicate an annotation or a

suggestion you should pay attention.
U The 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.
Page - 2/81 AFCZP0BB- COMBIACX & ACEX - User Manual

Contents
1 INTRODUCTION ...................................................................................................................5
2 SPECIFICATION................................................................................................................... 6
2.1 Technical specifications COMBIACX / ACEX............................................................. 6
2.2 Technical specifications COMBIACX Power / ACEX Power ...................................... 6
2.3 Block diagrams ........................................................................................................... 7
2.3.1 Traction control............................................................................................. 7
2.3.2 Pump control ................................................................................................ 7
3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT ...... 8
3.1 Digital inputs ............................................................................................................... 8
3.1.1 DI0 ÷ DI10 technical details – 24 V system ................................................. 8
3.1.2 DI0 ÷ DI10 technical details – 36/48 V system ............................................ 8
3.1.3 Microswitches ............................................................................................... 8
3.2 Analog unit ................................................................................................................. 8
3.3 Other analogue control unit ........................................................................................ 9
3.4 Analog motor thermal sensor input............................................................................. 9
3.5 Speed feedback ....................................................................................................... 10
4 INSTALLATION HINTS ...................................................................................................... 11
4.1 Material overview ..................................................................................................... 11
4.1.1 Connection cables ...................................................................................... 11
4.1.2 Contactors .................................................................................................. 11
4.1.3 Fuses.......................................................................................................... 12
4.2 Installation of the hardware ...................................................................................... 12
4.2.1 Positioning and cooling of the controller..................................................... 12
4.2.2 Wirings: power cables ................................................................................ 12
4.2.3 Wirings: CAN connections and possible interferences............................... 13
4.2.4 Wirings: I/O connections............................................................................. 15
4.2.5 Connection of the encoder ......................................................................... 16
4.2.6 Main contactor and key connection ............................................................ 17
4.2.7 Insulation of truck frame ............................................................................. 17
4.3 Protection and safety features.................................................................................. 18
4.3.1 Protection features ..................................................................................... 18
4.3.2 Safety Features .......................................................................................... 19
4.4 EMC ......................................................................................................................... 19
4.5 Various suggestions ................................................................................................. 21
5 OPERATIONAL FEATURES .............................................................................................. 22
5.1 Diagnosis.................................................................................................................. 22
6 DESCRIPTION OF THE CONNECTORS ........................................................................... 23
6.1 Connectors of the logic............................................................................................. 23
6.1.1 CNA external connector ............................................................................. 23
6.1.2 CNB external connector ............................................................................. 24
6.1.3 CNC external connector ............................................................................. 24
6.1.4 CND external connector ............................................................................. 25
6.1.5 CNE internal connector .............................................................................. 25
7 DESCRIPTION OF POWER CONNECTIONS .................................................................... 26
8 DRAWINGS......................................................................................................................... 27
8.1 Mechanical drawing COMBIACX.............................................................................. 27
8.2 Mechanical drawing ACEX ....................................................................................... 28
AFCZP0BB – COMBIACX & ACEX - User Manual Page - 3/81

8.3 Connection drawing COMBIACX.............................................................................. 29
8.4 Connection drawing ACEX ....................................................................................... 30
9 ONE SHOT INSTALLATION PROCEDURE ...................................................................... 31
9.1 Sequence for Ac Inverter traction setting ................................................................. 32
10 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE .................................. 34
10.1 Adjustments via console........................................................................................... 34
10.2 Description of console (hand set) & connection ....................................................... 34
10.3 Description of the console menu .............................................................................. 35
10.3.1 COMBIACX / ACEX Menu.......................................................................... 35
10.4 Function configuration .............................................................................................. 36
10.4.1 Config menu “SET OPTIONS” functions list............................................... 36
10.4.2 Config menu “ADJUSTMENTS” functions list ............................................ 39
10.4.3 Main menu “PARAMETER CHANGE” functions list................................... 43
10.4.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list................................ 49
10.4.5 Main menu “TESTER” functions list ........................................................... 50
11 OTHER FUNCTIONS .......................................................................................................... 54
11.1 Description of console “SAVE” function ................................................................... 54
11.2 Description of console “RESTORE” function............................................................ 55
11.3 Description of console “PROGRAM VACC” function................................................ 56
11.4 Description of the throttle regulation......................................................................... 58
11.5 Description of the battery charge detection setting .................................................. 59
12 COMBIACX /ACEX ALARMS LIST.................................................................................... 61
12.1 Faults diagnostic system .......................................................................................... 61
12.2 Alarms overview ....................................................................................................... 62
12.3 Warnings overview ................................................................................................... 72
12.4 Analysis and troubleshooting of warnings ................................................................ 74
13 RECOMMENDED SPARE PARTS ..................................................................................... 80
14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 81
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
Publication N°: AFCZP0BB

Edition: November 2010

1 INTRODUCTION
The COMBIACX / ACEX inverter has been developed to perform all the electric
functions that are usually presents in walkie and rider pallet trucks, stackers, low
level order pickers.
The controller can perform the following functions:
- Controller for AC 600W to 2 kW AC motors;

- Pump controller for series wounded DC motors up to 5 kW (only for
COMBIACX).
- Driver for Line Contactor coil
- Drivers for ON/OFF electrovalves and for one proportional valve (electro-
distributor)
- Low side and high side (short circuit protected) drives for electric brake coil
- Canbus interface
- Interface for Canbus tiller
- Zapi patented sensorless and sense coil control
- 192 kBytes Flash memory embedded.
- Software downloadable via Serial link (internal connectors) or Canbus (external
connector)
- ESD protection on Canbus inputs CANL and CANH

2 SPECIFICATION
2.1 Technical specifications COMBIACX / ACEX

Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series
pump motors.
Regenerative braking functions.
Digital control based upon microcontroller
Voltage:..................................................................................................24, 36, 48V
Inverter maximum current (24V): ................................................ 165A (RMS) for 2'
Continuous output current (24V):.........................................70A (RMS) continuous
Inverter maximum current (36/48V): ..............................................140 (RMS) for 2'
Continuous output current (36/48V):....................................60A (RMS) continuous
Inverter operating frequency:...........................................................................8kHz
Dc chopper Maximum current (24V)(1): ................................................ 280A for 2'
Dc chopper Maximum current (36V/48V)(1): ......................................... 240A for 2'
Chopper Operating frequency(1): ..................................................................16kHz
External temperature working range:..................................................-40°C ÷ 40°C
Maximum heatsink temperature (start of the thermal cutback)........................ 85°C
4 Note(1): The DC chopper specifications are related to COMBIACX only
2.2 Technical specifications COMBIACX Power / ACEX Power

Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series
pump motors.
Regenerative braking functions.
Digital control based upon microcontroller
Voltage:..................................................................................................24, 36, 48V
Inverter maximum current (24V): ................................................ 240A (RMS) for 2'
Continuous output current (24V):........................................ 90A (RMS) continuous
Inverter maximum current (36V/48V):......................................... 210A (RMS) for 2'
Continuous output current (36V/48V): .................................80A (RMS) continuous
Inverter operating frequency:...........................................................................8kHz
Dc chopper Maximum current (24V)(1): ................................................ 280A for 2'
Dc chopper Maximum current (36V/48V)(1): ......................................... 240A for 2'
Chopper Operating frequency(1): ..................................................................16kHz
External temperature working range:..................................................-40°C ÷ 40°C
Maximum heatsink temperature (start of the thermal cutback)........................ 85°C
4 Note(1): The DC chopper specifications are related to COMBIACX only

2.3 Block diagrams
2.3.1 Traction control
2.3.2 Pump control

3 SPECIFICATION FOR THE INPUT DEVICES
FILLING UP THE INSTALLATION KIT
3.1 Digital inputs

COMBIACX / ACEX digital inputs work in the voltage range [-Batt; +Batt]. Related
command devices (microswitches) must be connected to +BATT (typically to key
voltage).
Pull-down resistance to –Batt is built-in.
Functional devices (like FW, BACK, LIFT, DESCENT, HORN, H&S, TILLER, BELLY
switches) are Normally Open; so related function becomes active when the
microswitch closes.
Safety devices (like CUTBACK switches) are Normally Closed; so related function
becomes active when the microswitch opens.
The DI11 and DI12, which are not available in the Sense Coil version, are activated
closing the external microswitch to –Batt.
3.1.1 DI0 ÷ DI10 technical details – 24 V system
- Switching threshold: 4V [±0,5V]
- Input impedance: 4,5kOhm [±0,5kOhm]
3.1.2 DI0 ÷ DI10 technical details – 36/48 V system
- Switching threshold: 4,2V [±0,5V]
- Input impedance: 13,5kOhm [±1kOhm]
3.1.3 Microswitches
- It is suggested that microswitches have a contact resistance lower than 0,1Ohm
and a leakage current lower than 100µA.
- When full load connected, the voltage between the key switch contacts must be
lower than 0.1V.
- If the microswitch to be used has different characteristic, it is suggested to
discuss them and their application with Zapi technicians.
3.2 Analog unit

The analog input can be connected to an accelerator unit if the Zapi CAN or serial
tiller is not used.
The accelerator unit can consist of a potentiometer or an Hall effect device.
It should be in a 3-wire configuration. The potentiometer is supplied through CNC#8.
Potentiometer output signal must be input to CPOT1 (CNC#4) signal range is from 0
to 10V.
The negative supply of the potentiometer has to be taken from NPOT (CNC#3).
Potentiometer value should be in the 0.5 - 10 kOhm range; generally, the load
should be in the 1.5mA to 30mA range. Faults can occur if it is outside this range.
The standard connection for the potentiometer is the one in the Left side of next
figure (potentiometer on one end at rest) in combination with a couple of Travel
demand switches . On request it is also possible the handling in the Right side of
next figure (potentiometer in the middle at rest) still in combination with a couple of

Travel demand switches.
The Procedure for automatic potentiometer signal acquisition is carried out using the
Hand Set. This enables adjustment of the minimum and maximum useful signal
level, in either direction.
3.3 Other analogue control unit

If the Zapi can tiller is not used, input CNC#9 can be used as analogue input, whose
typical application is a proportional command to enable a lifting/lowering function. It
is possible to use this input for an alternative function like a proportional braking.
It should be in a 3 wire configuration. Potentiometer value should be in the 0.5-10
kOhm range. Generally, the load should be in the 1.5mA to 30 mA range.
The CPOTL (CNA#9) signal range is from 0 to 10V.
Use CNC#8 (positive) and CNA#3 (negative) to supply it.
3.4 Analog motor thermal sensor input

Input CND#3 is an analogue input to receive an analogue thermal sensor signal to
measure the Traction Motor Winding Temperature. The analogue device installed in
the motor has to be specified, in order to insert the correct look-up table in the
software. A digital device can also be used.

3.5 Speed feedback
The motor control is based upon the motor speed feedback (sensored software).
The speed transducer is an incremental encoder, with two phases shifted at 90°.
The encoder can be of different types :
- power supply: +12V / +5V;
- electric output: open collector ( NPN ), push-pull.
COMBIACX / ACEX can also operate without encoder, this using a sensorless
control.
This solution has to be discussed with Zapi technicians.
4 Note (1): The encoder resolution and the motor poles pair (the controller can
handle), is specified in the home page display of the handset showing following
headline:
ADXZ2A ZP1.00
That means:
ADXZ= COMBIACX Zapi controller
2 = motor’s poles pair number
A = 32 pulses/rev encoder
The encoder resolution is given by the second-last letter in the following list:
A = 32 pulses/rev
K = 48 pulses/rev
B = 64 pulses/rev
C = 80 pulses/rev

4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
4 These are informations useful for anyone is working on the installation, or a deeper
examination of the content
U These 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
4.1 Material overview

Before starting 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.
4.1.1 Connection cables
For the auxiliary circuits, use cables 0.5mm² section at least.
For power connections to the motor and to the battery, use cables having a
minimum section of 15 mm².
For the optimum inverter performance, the cables to the battery should be run side
by side and be as short as possible.
4.1.2 Contactors
IT IS STRONGLY RECCOMENDED TO USE A MAIN CONTACTOR to connect and
cut off the battery to the controller. Depending on the setting of a parameter in the
controller:
- 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 programmable duty cycle; this feature is useful to decrease the
power dissipation of the contactor coil.
U The EN1175 states the main Contactor is not mandatory (under proper
conditions); anyway it is recommended to protect the inverter against reverse
battery polarity and to cut off the battery from the power mosfets when a
failure in the three phase bridge occurs.

4.1.3 Fuses
- Use a 6.3-10A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, refer to chapter 13 (Recommended spare parts
for inverter). The Fuse value shown is the maximum 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.
4.2 Installation of the hardware
U Before 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.
After operation, even with the Key Switch open, the internal capacitors may
remain charged for some time. For safe operation, we recommend that the
battery is disconnected, and a short circuit is made between Battery Positive
and Battery Negative power terminals of the chopper using a Resistor
between 10 Ohm and 100 Ohm. Minimum 5 Watts.
4.2.1 Positioning and cooling of the controller

CONTROLLER WITH BASE PLATE: Install the controller with the base-plate on a
flat metallic surface that is clean and unpainted; suggested characteristics are:
planarity 0.05 mm and rugosity 1.6 µm
- Apply a light layer of thermo-conductive grease between the two surfaces to
permit better heat dissipation.
- 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.
CONTROLLER WITH FINNED HEATSINK: Sometimes the base plate installation

cannot be adopted. Due to positioning problems or to the lack of a thick enough
truck frame, it is necessary to adopt a finned dissipation combined with one or more
fans.
- The air flux should hit the fins directly, to maximize the cooling effect.
- In addition to fans, also air ducting systems can be used to maintain low the
temperature of the controller.
- It is necessary to ensure that cold air is taken from outside the controller
compartment and hot air is easily pushed away from the controller
compartment.
- It is mandatory to avoid that the cooling air is recirculated inside the controller
compartment.
4.2.2 Wirings: power cables
- The power cables length must be as short as possible to minimize power
losses.
- They must be tightened on controller power posts with a Torque of 7 ± 1.4 Nm
- The COMBIACX module should only be connected to a traction battery. Do not
use converters outputs or power supplies. For special applications please
contact the nearest Zapi Service Centre.
U Do not connect the controller to a battery with a nominal voltage different than
the value indicated on the controller label. A higher battery voltage may cause
MOS failure. A lower voltage may prevent the logic operating.
4.2.3 Wirings: CAN connections and possible interferences
4 CAN 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.

U Wrong Layout:
Module
Module
1
2
Module
3
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.
U Correct Layout:
Module
Module
1
2
Module
3
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)

U Correct Layout:
Module
Module
1
2
Module
3
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
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 dimensioned taking into account thermal
and voltage drop problems.
4 Can 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)
4.2.4 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
U A 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”

4.2.5 Connection of the encoder
1) COMBIACX/ ACEX card is fit for different types of encoder. To control an AC
motor with the Zapi inverter, it is necessary to install an incremental encoder
with 2 phases shifted of 90°. The encoder power supply can be +5V or +12V. It
can have different electronic output.
D2 +5V / +12V positive of encoder power supply.

D5 GND negative of encoder power supply.
D1 A phase A of encoder.
D4 B phase B of encoder.
2) Connection of encoder with open collector output; +5V and +12V power supply.
U 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.
The n° of pulses revolution the controller can handle is given by the second-
last letter in the software release name (see 3.5).

4.2.6 Main contactor and key connection
- The connection of the main contactor can be carried out following the drawing in
the figure.
- The connection of the battery line switches must be carried out following ZAPI
instructions.
- If a mechanical battery line switch is installed, it is strongly recommended that
the key supply to the inverter is open together with power battery line (see
picture below); 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.
4.2.7 Insulation of truck frame
U As 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.

4.3 Protection and safety features
4.3.1 Protection features
The COMBIACX / ACEX is protected against some controller injuries and
malfunctions:
- Battery polarity inversion
It is necessary to fit a LINE CONTACTOR to protect the controller against reverse
battery polarity and for safety reasons.
- Connection Errors
All inputs are protected against connection errors.
- Thermal protection
If the controller temperature exceeds 85°C, the maximum current is reduced in
proportion to the thermal increase. The temperature can never exceeds 105°C.
- External agents
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP65. Nevertheless, it is suggested to carefully study controller
installation and position. With few simple shrewdness, the degree of controller
protection can be strongly increased.
- Protection against uncontrolled movements
The main contactor will not close if:
- The Power unit is not functioning.
- The Logic or Canbus interface is not functioning perfectly.
- The Can Tiller is not operating correctly.
- Running microswitches are in open position.
- Low battery charge
when the battery charge is low, the maximum current is reduced to the half of the
maximum current programmed; additionally an alarm message is displayed.
- 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.

4.3.2 Safety Features
U ZAPI controllers are designed according to the EN13849-1 specifications for

safety related parts of control system and to UNI EN1175-1 norm. The 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.
4.4 EMC
U EMC 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 responsability 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 electromagnetical 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 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 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 happen when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important effects:
- 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 informations.
- 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.
U 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.
4) 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.
5) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are

valid also for immunity. Additionally, further protection can be achieved with
ferrite beads and bypass capacitors.
6) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent

damages from ESD:
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 trough 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.
4.5 Various suggestions

Never combine SCR low frequency choppers with COMBIACX / ACEX modules.
The filter capacitors contained in the COMBIACX / ACEX module would change the
SCR chopper operation and subject to excessive workload. If it is necessary to use
two or more control units, like the chopper should be of the Zapimos family.
During battery recharge, the COMBIACX / ACEX must be completely disconnected

from the battery. Beside changing the charging current seen by the battery charger,
the module can be damaged by higher than normal voltages supplied via the
charger.

5 OPERATIONAL FEATURES
- Speed control.
- Optimum behaviour on a slope if the speed feedback is used:
1. The motor speed follows the accelerator, starting a regenerative braking if
the speed overtakes the speed set-point
2. The system can perform an electrical stop on a ramp (the machine is
electrically hold on a slope) for a programmable time (if encoder is used)
- 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 analogue 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.
- High efficiency of motor and battery due to high frequency commutations.
- 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.
- Direct communication between traction AC inverter and pump DC chopper.
5.1 Diagnosis
The microcontrollers continually monitor the inverter and the chopper and carry out
diagnostic procedures on the main functions.
The diagnosis is made in 4 points:
1) Diagnosis at start-up that checks: watch-dog, Current Sensors, Capacitor
charging, phase’s voltages, pump motor output, contactor drivers, can-bus
interface, presence of a start requirement, connection with the Can Tiller.
2) Standby Diagnosis that checks: watch-dog, phase’s voltages, pump motor
output, Contactor Drivers, Current Sensors, can-bus interface.
3) Driving diagnosis that checks: Watchdog, Current sensors, Contactor(s), can-
bus interface.
4) Continuos Diagnosis that checks: power stage temperature, motor temperature,
Battery Voltage.
Error codes are 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.

6 DESCRIPTION OF THE CONNECTORS
6.1 Connectors of the logic

The COMBIACX / ACEX inverter use four Molex Minifit connectors
6.1.1 CNA external connector
A1 EV1 Output of the protected ON/OFF electrovalve driver; 1,5 A
maximum continuous current (driving to –Batt). Built-in
freewheeling diode to B2. This output is activated when
the 1ST function (input A12) is request.
the LIFT function (input A5) is request.
A3 NAUX2 Auxiliary output. Internal 330R resistance in series to the
driver (driving to –Batt). Max continuous current: 35mA.
Typical function: to drive a led. If the BATTERY CHECK
option is different than zero, this output blinks with a 1
sec. period when the calculated battery charge is between
10% and 30%, and it stays on when the calculated battery
charge is < = 10%.
A4 DI5 Input of the switch DI5. The input is activated when it is
connected to +Batt. The default function is the controller
“HORN” input, closing the switch the horn output is
activated.
“LIFT” enable input.
A6 DI9 Input of the switch DI9. The input is activated when the
external switch is opened. The default function is the
controller “PUMP CUTBACK” input, opening the switch
pump speed is reduced.
external switch is opened to ground. The default function
is the controller “CUTBACK1” input, opening the switch
truck speed is reduced. In the Sense Coil version this
input is connected to the AC motor sense coil.
the 2ND function (input A13) is request.
A9 NAUX1 Auxiliary output. Internal 330R resistance in series to the
driver (driving to –Batt). Max continuous current: 35mA.
Typical function: to drive a led. This output blinks with a 1
sec. period when a warning is displayed by the controller.
It also blinks with a 0.5 sec. period when an alarm is
displayed when no alarm are displayed, this output is
OFF.

A10 GND This is the ground of the logic board.
“LOWER” enable input.
“1ST” input: the pump motor turn at a defined speed.
“2ND” input: the pump motor turn at a defined speed.
external switch is opened to ground. The default function
is the controller “CUTBACK2” input, opening the switch
truck speed is reduced. In the Sense Coil version this
input is connected to the AC motor sense coil.
6.1.2 CNB external connector
B1 PEB This pin outputs the positive supply (equal to +Batt) of the
electromechanical brake coil. Depending on hardware
configuration this pin can be controlled by the
microcontroller or tied to the B2 input or to the C6 input.
See connection drawing for more details.
B2 PEV Connect the positive supply of all electrovalves (EV1,
EV2, EV3, LOWER EVP, HORN OUT) to this pin. Take
the positive supply immediately after main contactor.
B3 NEVP Output of the lower proportional electrovalve driver
(driving to –Batt). Built-in freewheeling diode to B2.
B4 DI3 Input of the switch DI3. The input is activated when it is
“FORWARD” request input, closing this input truck moves
in forward direction.
B5 NEB Electro mechanic brake coil driver output; PWM
controlled; 2.5A maximum continuous current (driving to –
Batt). Built-in freewheeling diode to B1.
B6 NLC Min Contactor coil driver output; PWM controlled; 1A
freewheeling diode.
B7 HORN Negative of the protected horn electrovalve driver (driving
to –Batt). Built-in freewheeling diode to B2.
B8 DI4 Input of the switch DI4. The input is activated when it is
“REV” request input, closing this input truck moves in
backward direction.
6.1.3 CNC external connector
C1 +KEY Input of the key switch signal.
C2 DI1 Input of the switch DI1. The input is activated when it is
“BELLY” input, closing the switch quick inversion function
is activated.
C3 NPOT Potentiometers negative reference (GND).

C4 CPOTTR Accelerator potentiometer wiper input.
C5 CANH High level CAN-BUS voltage I/O.
connected to +Batt. With the logic hardware properly
configured it can be used to supply the EB and MC
positive voltage. The default function is the controller
“TILLER” input.
“H&S” (Hard & Soft) request input, closing this input truck
performances are modified.
C8 PPOT Potentiometers positive supply. Hardware has to be
configured to output +12V or +5 V.
C9 CPOTL Lift/Lower potentiometer wiper input.
C10 CANL Low level CAN-BUS voltage I/O.
6.1.4 CND external connector

D1 ENC A Traction motor encoder phase A.
D2 PENC Encoder Positive Supply. Hardware has to be configured
to output +12V or +5 V
D3 PTHERM Traction motor thermal sensor input. The internal pull-up
is a fixed 2mA (Max 5V) source current.
D4 ENCB Traction motor encoder phase B.
D5 NENC Negative of the Encoder.
D6 NTHERM Negative reference (GND) for the motor thermal sensor.
6.1.5 CNE internal connector
The connector used is a 8 way STRIP
E1 Not used Internally disconnected.

E2 NCLRXD Negative serial reception pin.
E3 PCLTXD Positive serial transmission pin.
E4 NCLTXD Negative serial transmission pin.
E5 GND Serial communication negative reference.
E6 +12 +12V serial communication supply.
E7 FLASH BOOT To connect this pin to GND (E8) for software download
via serial communication.
E8 GND Serial communication negative reference.
This connector cannot be reached without removing the cover. It is used by Zapi for
software download with Zapi Flasher, for communicating with a Zapi Handset or a
lap-top, for controller setup and for diagnosis.

7 DESCRIPTION OF POWER CONNECTIONS
View of the power bars:
-B Negative of the battery.

+B Positive of the battery.
-P Output of the Pump Motor (COMBIACX only).
U; V; W Connection bars of the three motor phases; follow this sequence and the
indication on the motor.

8 DRAWINGS
8.1 Mechanical drawing COMBIACX

8.2 Mechanical drawing ACEX

8.3 Connection drawing COMBIACX

8.4 Connection drawing ACEX

9 ONE SHOT INSTALLATION PROCEDURE
This section of the manual describes the basic connection procedure.
To move, the truck needs a minimum I/O outfit that it is mandatory: this minimum
outfit is listed in the Steps from 1 to 8 below.
Step1 Connect a potentiometer in the range 0.5 to 10Kohms, to modify the

wished speed between +12V / +5V (CNC#8) and GND (CNA#3). The
potentiometer wiper is connected to CPOTTR (CNC#4).
Step2 Connect two travel demand switches. The FWD travel demand must
be connected between a battery (key) voltage and CNB#4. The REV
travel demand must be connected between a battery (key) voltage and
CNB#8. Only one of them can be active at the same time. They
become active when connected to a key.
Step3 Connect a tiller (or seat) switch enabling/disabling the truck motion
between CNC#6 and a key voltage. It becomes active, enabling the
motion, when closed to a key voltage.
Step4 Connect the encoder in the motor shaft between CND#2=VDD,
CND#5=GND, CND#1=CHA, CND#4=CHB. The VDD voltage may be
12V or 5V depending on a jumper inside the controller.
Step5 Connect the plus battery voltage through a key switch at the KEY input
CNC#1. This is the input for the controller supply.
Step6 Connect the Main Contactor Coil to CNC#1 and CNB#6. The contactor
must connect the battery positive to the +BATT power terminal of the
ACEX / COMBIACX.
Step7 Connect the motors and the minus battery to the corresponding power
terminals of the ACEX / COMBIACX.
Step8 Connect the Electromechanical Brake coil between CNB#1 and
CNB#5; when the tiller switch opens, the electromechanical brake gets
de-energized braking the truck.
The Steps from 1 to 8 describe the installation operations that is mandatory to do in

order your truck moves. Obviously the ACEX / COMBIACX may execute a wider set
of optional services as:
1) to handle some speed reductions requests.
2) to handle an analog sensor inside the motor.
3) to handle a proportional braking.
4) to handle a proportional forks lowering valve.
5) to handle a pump motor by a chopper.
6) to handle a belly switch, for truck quick inversion.
7) to handle a proportional input for the forks lifting/lowering.
8) to handle a number of on/off E-valves, driving a protected drivers.
9) to handle an Horn, driving a protected driver.
You must fill your I/O outfit with your optional functions. The optional functions are
shown in the connecting drawing and described in detail inside this manual. The
index may help you.

9.1 Sequence for Ac Inverter traction setting
This section of the manual describes the basic ACEX / COMBIACX set-up
procedure.
4 To complete this procedure it is necessary to use the Zapi console. Since the
COMBIACX/ACEX has no external serial connector, the Zapi console has to be
connected through a remote module, like a Zapi tiller card of a Zapi display. This
module has to be connected to the same Canbus line of the inverter.
4 Otherwise it is possible to connect a pc to the Canbus line and use the PC CAN
Console software. This tool is more powerful than the standard serial console.
When the "Key Switch" is closed, if no alarms or errors are present, the Console
Display will be showing the Standard Zapi Opening Display (Home Display).
For the setting of your truck, use the procedure below.
If you need to reply the same setting on different controller, use the Save and
Restore sequence as described in the 13.1 and 13.2 paragraphs. Remember to re-
cycle the Key Switch if you make any changes to the chopper’s configuration.
Step1 Fill your setting with the Options you need.

Step2 Select the Battery Voltage.
Step3 Check the correct installation of all wires. Use the Console’s TESTER
function to assist.
Step4 Perform the accelerator signal acquisition procedure using the Console
“PROGRAM VACC”. Procedure is detailed on paragraph 13.3.
Step5 Set the “MAXIMUM CURRENT” Current parameter.
Step6 Set the ACCELERATION DELAY requirements for the machine. Test
the parameters in both directions.
Step7 Set the FREQUENCY CREEP level starting from 0.6 Hz. The machine
should just move when the accelerator micro switch is closed. Increase
the Level accordingly.
Step8 Set the Speed Reductions as required. Use the parameters of the
“cutback speed” family in the PARAMETER CHANGE menu to specify
the reduced maximum truck speed as a percentage of the MAX
SPEED FWD and MAX SPEED REV.
Step9 RELEASE BRAKING. Operate the machine at full speed. Release the
accelerator. Adjust the level to your requirement. If the machine is a
forklift, check the performance with and without load.
Step10 INVERSION BRAKING. Operate the machine at 25% full speed. While
travelling invert the Direction Switch. Set the suited Level of Inversion
Braking. When satisfactory, operate the machine at Full Speed and
repeat. If the machine is a Forklift, repeat the tests and make
adjustments with and without load. The unloaded full speed condition
should be the most representative condition.
Step11 Set the parameter MAX SPEED FORW.

Step12 Set the parameter MAX SPEED BACK (Reverse).
Step13 Test the truck on the maximum ramp specification at full load.
Step14 Make the choice for the truck behaviour on a slope. If the "Stop on
ramp" option is ON, set the desired value of "auxiliary time" parameter.

10 PROGRAMMING & ADJUSTMENTS USING
DIGITAL CONSOLE
10.1 Adjustments via console
4 To access and adjust all parameters it is necessary to use the Zapi console. Since
the COMBIACX/ACEX has no external serial connector, the Zapi console has to be
connected through a remote module, like a Zapi tiller card of a Zapi display. This
module has to be connected to the same Canbus line of the inverter.
4 Otherwise it is possible to connect a pc to the Canbus line and use the PC CAN
Console software. This tool is more powerful than the standard serial console.
The following paragraphs describe the controller configuration in the case the
operator is using the Zapi console.
10.2 Description of console (hand set) & connection

10.3 Description of the console menu
10.3.1 COMBIACX / ACEX Menu

10.4 Function configuration
10.4.1 Config menu “SET OPTIONS” functions list
To enter the CONFIG MENU’ it is necessary to push in the same time the right side
top and left side top buttons. Then roll until the SET OPTION item appears on the
hand set display. Push the ENTER button.
ADXT2B ZP1.00
Opening Zapi Display 24V 165A 00000
Push ROLL UP + SET UP simultaneously to enter % ' %

CONFIG MENU ' ' '
CONFIG MENU
The Display will show : SET MODEL SET MODEL
Press ROLL UP or ROLL DOWN button until SET % ' '

OPTIONS menu appear. ' ' '
CONFIG MENU
The Display will show : SET OPTIONS SET OPTIONS
' % '
Press ENTER to go in the SET OPTIONS MENU ' ' '
HOURCOUNTER
The Display will show the first OPTION RUNNING
Press SET UP or SET DOWN button in order to ' ' %

modify the OPTION ' ' %
HOURCOUNTER
The Display will show the new option KEYON
' ' '

Press OUT to exit the menu ' % '
ARE YOU SURE?

The Display will ask “ARE YOU SURE”. YES=ENTER NO=OUT
' % ' ' ' '

Press ENTER for YES, or OUT for No ' ' ' ' % '
CONFIG MENU
The Display will show : SET OPTIONS SET OPTIONS
Press OUT again. Display now will show the ' ' '
opening Zapi menu. ' % '

1) TILLER SWITCH
This option handles the input CNC#6. This input opens when the operator
leaves the truck (tiller released). It is connected to a key voltage when the
operator is present. There are two levels:
- HANDLE: CNC#6 is managed as tiller input (no delay when released
and INCORRECT START if the input is active at startup).
- SEAT: CNC#6 is managed as seat input (with a delay when
released Æ de-bouncing function and NO INCORRECT
START if the input is active at startup).
- DEADMAN: CNC#6 is managed as deadman input, with the same delay
of a seat input, but with INCORRECT START if the input is
active at startup.
2) EB ON TILLER BRK
- ON: The EB is applied when the traction decelerates because
CNC#6 was deactivated whilst moving.
- OFF: The EB is NOT applied when the traction decelerates
because CNC#6 was deactivated whilst moving.
4 Note: if the positive of the EB is coming from the tiller input this option is
meaningless because EB is applied mechanically as soon as CNC#6 becomes OFF
3) HOUR COUNTER
This option specifies the hour counter mode. It can be set one of two:
- RUNNING: The counter registers travel time only
- KEY ON: The counter registers when the "key" switch is closed (controller
supplied)
4) EVP TYPE
Analog/digital: defines the type of the EVP electrovalve, current controlled:
Analog: the related output manages a proportional valve, current controlled
Digital: the related output manages an on/off valve
5) BATTERY CHECK
This option specifies the handling of the low battery charge detection.
There are tree levels:
- Level 0: Nothing happens, the battery charge level is calculated but is
ignored, it means no action is taken when the battery is discharged.
- Level 1: BATTERY LOW alarm is raised when the battery level is calculated
being less than or equal to 10% of the full charge. The BATTERY LOW
alarm reduces the maximum speed down to 24% of the full speed and
reduces the maximum current down to 50% of the full current.
being less or equal to 10% of the full charge.
being less or equal to 10% of the full charge. The BATTERY LOW alarm
reduces the maximum speed down to 24% of the full speed.
6) STOP ON RAMP
Only when the encoder is present, it is possible to electrically hold the truck on a
slope when the accelerator is released but the tiller is not released.
- ON: The stop on ramp feature (truck electrically hold on a ramp) is managed

for a time established by AUXILIARY TIME parameter.
- OFF: The stop on ramp feature is not performed. That means the truck
comes down slowly during the AUXILIARY TIME.
After this “auxiliary time”, the electromechanical brake is applied and the 3-
phase bridge is released; if the electromechanical brake is not present the truck
comes down very slowly (see the AUX OUTPUT #1 option programming and
see also 13.4).
7) QUICK INVERSION
It can be set:
- NONE: The quick inversion function is not managed (no effect when
CNC#2 switches over).
- TIMED: The quick inversion function is timed.
- BELLY: The quick inversion function is managed but not timed.
8) SET MOTOR TEMPERATURE

It can be set:
- OPTION#1: An analog sensor for the control of the motor temperature is
connected to CND#3. The temperature sensor is a KTY 84-130 PTC
(positive thermal coefficient resistance).
- OPTION#2: An analog sensor for the control of the motor temperature is
connected to CND#3. The temperature sensor is a KTY-83 PTC.
1. DIGITAL: A digital (on/off) sensor for the motor temperature monitoring is
connected to CND#3 input.
2. NONE: No temperature sensor is connected.
9) EPS
It can be set:
- NONE: NO EPS is present on the truck, CombiACX does not wait for
CAN messages by the EPS and it does not apply EPS and braking steer
cutback.
- OPTION#1: EPS is present and it is an EPS-AC0, ENCODER + TOGGLE
SWITCHES type.
- OPTION#2: EPS is present and it is an EPS-AC0, POT + ENCODER type.
10) INVERSION MODE

ON/OFF: This parameter sets the logic of the Quick Inversion input. If set = ON,
the Quick Inversion switch is Normally Closed (function active when switch
opens). If set = OFF, the Quick Inversion switch is Normally Open (function
active when switch closes).
11) EV1
PRESENT/ABSENT: If set = PRESENT the EV1 output is driven and the
diagnosis “EV1 DRIVER SHORTED” relative to the load connected to CNA#1 is
activated. When set = ABSENT the diagnosis is not implemented and the EV1
output is NOT driven.
12) EV2
13) EV3

14) HORN
PRESENT/ABSENT: If set PRESENT, the HORN output is driven. When set
ABSENT the HORN output is NOT driven.
15) HYDRO FUNCTION

KEY ON/RUNNING/NONE: Defines the activation of hydraulic steering fuction.
- KEY ON: the function is activated at key-on.
- RNNING: the function is activated during a traction or braking request.
- NONE: the function is never activated.
16) M.C. FUNCTION

PRESENT/ABSENT: When is set PRESENT the Main Contactor is closed after
the controller key-on if the initial diagnosis pass. If is set ABSENT the diagnosis
are masked and M.C. is not closed after controller Key-on.
17) AUX OUT FUNCTION

PRESENT/ABSENT: When is set PRESENT the Electro mechanic Brake is
driven after a traction request if all the related diagnosis pass. If is set ABSENT
the diagnosis are masked and E.B. is not closed after a traction request.
18) PROPORTION. PUMP

ON/OFF: When is set ON the lift functions are proportional. The pump motor
speed increase if the analog value of CPOTL increase. If is set ABSENT the
analog value CPOTL is not read and the speed of pump motor is set maximum
when the digital input is closed (LIFT).
10.4.2 Config menu “ADJUSTMENTS” functions list

To enter the CONFIG MENU it is necessary to push in the same time the right side
top and left side top buttons. Then roll until the ADJUSTMENTS item appears on the
hand set display. Push the ENTER button.
ADXT2B ZP1.00
1) Opening Zapi Menu 24V 165A 00000
2) Press Top Left & Right Buttons to enter % ' %

CONFIG MENU ' ' '
CONFIG MENU
3) The Display will show: SET MODEL SET MODEL
4) Press ROLL UP button until ADJUSTMENTS % ' '

MENU appears ' ' '
CONFIG MENU
5) ADJUSTMENTS appears on the display ADJUSTMENTS
6) Press ENTER to go into the ADJUSTMENTS ' % '

MENU ' ' '

BATTERY TYPE
7) The display will show: SET BATTERY TYPE 24V
8) Press ROLL UP or ROLL DOWN button until % ' '

the desired parameter is reached % ' '
TROTTLE 0 ZONE
9) The desired parameter appears 3%
10) Press SET UP or SET DOWN button to modify ' ' %

the adjustment ' ' %
TROTTLE 0 ZONE
7%
' ' '

11) Press OUT ' % '
' % '
12) Press ENTER to confirm ' ' '
13) Repeat the same from 5 to 12 points for the
other adjustments
1) SET BATTERY TYPE

Selects the nominal battery voltage.
2) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
3) THROTTLE 0 ZONE
Establishes a dead-band in the accelerator input curve.
4) THROTTLE X POINT
This parameter, together with the THROTTLE Y POINT, changes the
characteristic of the accelerator input curve : when the accelerator is de-
pressed to X point per cent, the corresponding truck speed is Y point per cent of
the Maximum truck speed. The relationship between the accelerator position
and the truck speed is linear between the THROTTLE 0 ZONE and the X point
and also between the X point and the maximum accelerator position but with
two different slopes.
5) THROTTLE Y POINT
This parameter, together with the THROTTLE X POINT, changes the
characteristic of the accelerator input curve (see also paragraph 13.5): when the
accelerator is de-pressed to X point per cent, the corresponding truck speed is
Y point per cent of the Maximum truck speed. The relationship between the
accelerator position and the truck speed is linear between the THROTTLE 0
ZONE and the X point and also between the X point and the maximum
accelerator position but with two different slope.
6) BAT. MIN ADJ.

Adjust the lower level of the battery charge table (Level 0 to 9).
7) BAT. MAX ADJ.

Adjust the upper level of the battery charge table (Level 0 to 9).

8) BDI ADJ START UP
It selects the type of algorithm used to estimate the battery discharge. Each
level corresponds to a different set of parameters of the algorithm.
9) LOAD HM FROM MDI

When set On, the HourMeter of the Controller is transferred and recorded on the
HourMeter of the MDI CAN, connected to CAN BUS network.
10) CHECK UP DONE

It can be ON/OFF. If it is ON it is possible to reset the last maintenance hour-
counter and the “CHECK UP NEEDED” warning.
11) CHECK UP TYPE

It specifies the handling of the CHECK UP NEEDED warning:
- NONE: No CHECK UP NEENED warning
- OPTION#1: CHECK UP NEENED warning shown on the hand set and
MDI/DISPLAY after 300 hours
- OPTION#2: Equal to OPTION#1 but Speed reduction after 340 hours
- OPTION#3: Equal to OPTION#2 but the truck definitively stops after 380
hours
12) MIN LIFT

This parameter stores the minimum voltage of lifting potentiometer output
connected to CNC#9. The min value acquisition is done closing the Lift SW and
bringing the potentiometer in its min output position.
13) MAX LIFT

This parameter stores the maximum voltage of lifting potentiometer output
connected to CNC#9. The max value acquisition is done closing the Lift SW
and bringing the potentiometer in its max output position.
14) MIN LOWER

%. This parameter stores the minimum voltage of lowering potentiometer output
connected to CNC#9. The min value acquisition is done closing the LOWER
SW (DI6) and bringing the potentiometer in its min output position.
15) MAX LOWER

%. This parameter stores the maximum voltage of lifting potentiometer output
connected to CNC#9. The min value acquisition is done closing the LOWER
SW (DI6) and bringing the potentiometer in its min output position.
16) MC VOLTAGE
%. This parameter stores the PWM value applied to MC coil during the first
second of the output activation. It is expressed in percentage of battery voltage.
17) MC VOLTAGE RED

%. This parameter stores the PWM value applied to MC coil after the first
second of the output activation. It is expressed in percentage of the voltage
applied during the first second (defined by the previous parameter).
18) EB VOLTAGE
%. This parameter stores the PWM value applied to EB coil during the first
second of the output activation. It is expressed in percentage of battery voltage.

19) EB VOLTAGE RED
%. This parameter stores the PWM value applied to EB coil after the first
second of the output activation. It is expressed in percentage of the voltage
applied during the first second (defined by the previous parameter).
20) PWM EV2

%. This parameter stores the PWM value applied to the EV2 coil. It is
expressed in percentage of battery voltage.
21) PWM EV3

%. This parameter stores the PWM value applied to the EV3 coil. It is
expressed in percentage of battery voltage.

10.4.3 Main menu “PARAMETER CHANGE” functions list
To enter the MAIN MENU’ it is just necessary to push the ENTER button from the
home display in the hand set.
ADXT2B ZP1.00
1) Opening Zapi Menu 24V 165A 00000
' % '
2) Press ENTER to go into the General Menu ' ' '
MAIN MENU
3) The Display will show: PARAMETER CHANGE PARAMETER CHANGE
4) Press ENTER to go into the Parameter ' % '

Change menu ' ' '
ACC DELAY
5) The Display will show the first parameter LEVEL = 5
6) Press either ROLL UP and ROLL DOWN to % ' '

display the next parameter % ' '
7) The names of the Parameters appear on the RELEASE BRAKING

Display LEVEL = 5
8) When the desired Parameter appears, it’s

' ' %
possible to change the Level by pressing either ' ' %
SET UP or SET DOWN buttons.
RELEASE BRAKING
9) The Display will show the new level. LEVEL = 2
10) When you are satisfied with the result of the ' ' '
changes you have made, press OUT. ' % '
ARE YOU SURE?

11) The Display asks: “ARE YOU SURE?” YES=ENTER
NO=OUT
12) Press ENTER to accept the changes, or press ' ' '
OUT to discard them. ' % '
MAIN MENU
13) The Display will show PARAMETER CHANGE
1) ACCELER. DELAY
Seconds. It determines the acceleration ramp. The parameter sets the time
needed to speed up the traction motor from 0Hz to 100Hz.
2) RELEASE BRAKING
Seconds. It controls the deceleration ramp when the travel request is released.
The parameter sets the time needed to decelerate the traction motor from
100Hz to 0Hz.

3) TILLER BRAKING
Seconds. It controls the deceleration ramp when the tiller is in braking position
(released). The parameter sets the time needed to decelerate the traction motor
from 100Hz to 0Hz
4) INVERS. BRAKING
Seconds. It controls the deceleration ramp when the direction switch is inverted
during travel. The parameter sets the time needed to decelerate the traction
motor from 100Hz to 0Hz.
5) DECEL. BRAKING
Seconds. It controls the deceleration ramp when the accelerator has turned
down but not completely released. The parameter sets the time needed to
decelerate the traction motor from 100Hz to 0Hz.
6) PEDAL BRAKING
Seconds. This parameter determines the deceleration ramp when the travel
request is released and the brake pedal switch is closed. It sets the time needed
to decelerate the traction motor from 100Hz to 0Hz.
7) SPEED LIMIT BRK

Seconds. It controls the deceleration ramp when a speed reduction has been
activated. The parameter sets the time needed to decelerate the traction motor
from 100Hz to 0Hz.
8) EPS STEER BRAK.

Seconds. It controls the deceleration ramp when a steer cutback is applied. The
parameter sets the time needed to decelerate the traction motor from 100Hz to
0Hz.
If EPS option is set to NONE, this parameter is useless.
9) MAX SPEED FORW

Percentage. It determines the maximum speed in forward direction.
10) MAX SPEED BACK

Percentage. It determines the maximum speed in backward direction.
11) CUTBACK SPEED 1

Typically from 10% to 100%. It determines the percentage of the max speed
applied when the cutback switch, CNA#7 connector, is active. When set to
100% the speed reduction is ineffective.
12) CUTBACK SPEED 2

applied when the cutback switch, CNA#14 connector, is active. When set to
13) H&S CUTBACK

applied when the Hard & Soft function, CNC#7 connector, is active. When set to
14) H&S CUTBACK

Typically from 10% to 100%. If H&S SWITCH option is PRESENT and
POSITIVE EB option is not LEVEL 1, it determines the percentage of the max

speed applied when the Hard & Soft function, CNC#7 connector, is active.
When set to 100% the speed reduction is ineffective.
15) EPS STEER CUTBCK

Tipically from 1% to 100%. It determines the percentage of the maximum speed
when the wheel is completely turned (tipiccally 90 degrees).
If the wheel angle is a percentage of the maximum angle, the steer cutback is
applied proportionally.
4 Note: the wheel angle is coming from EPS. If EPS option is set to NONE, this
parameter is useless.
16) FREQUENCY CREEP

Hz value. This is the minimum speed applied when the forward or reverse
switch is closed, but the accelerator is at its minimum.
17) MAXIMUM CURRENT

Maximum level of the current (percentage of the maximum current of the
controller).
18) ACCELERATION SMOOTH

It gives a parabolic form to the acceleration ramp.
19) INVERSION SMOOTH

It gives a parabolic form to the acceleration ramp after a direction inversion.
20) STOP SMOOTH

Hz. It sets the level of frequency where the smooth effect of the acceleration
parabolic form ends.
21) BRK SMOOTH

It gives a parabolic form to the deceleration ramp.
22) STOP BRK SMOOTH

Hz. It sets the level of frequency where the smooth effect of the deceleration
parabolic form ends.
23) AUXILIARY TIME

Time units value (seconds). For the encoder version, it determines the time
duration the truck is hold on the ramp if the STOP ON RAMP option is ON.
24) HYDRO TIME

Sec. It determines the time duration the pump motor is driven after the hydraulic
request is released.
25) PUMP IMAX

Level 0 to 9. Set the maximum current for the pump motor.
26) PUMP ACCELERATION DELAY

In seconds. Set the acceleration ramp for the pump motor.

27) PUMP DECELERATION DELAY
In seconds. Set the deceleration ramp for the pump motor.
28) MAX SPEED LIFT

From 0% to 100%. It limits the maximum speed of the lift function. Percentage
of the maximum voltage applied to the pump motor for the lift function. If it is set
0% the motor does not work when the lift request is ON.
29) LIFT CUTBACK

From 0% to 100%. It reduces the maximum speed of the lift function when the
pump cutback switch, CAN#6 connector, is active.
When set to a percentage which is higher than MAX SPEED LIFT, the pump
speed reduction is ineffective.
If set 0% the motor is stopped when the pump cutback switch is ON.
30) 1ST PUMP SPEED

From 0% to 100%. It limits the speed of the 1ST function. Percentage of the
voltage applied to the pump motor for the 1ST function. If it is set 0% the motor
don’t work when the 1ST request is ON.
31) 2ND PUMP SPEED

From 0% to 100%. It limits the speed of the 2ND function. Percentage of the
voltage applied to the pump motor for the 2ND function. If it is set 0% the motor
don’t work when the 2ND request is ON.
32) DESCENT SPEED

From 0% to 100%. It limits the maximum speed of the descent function.
Percentage of the maximum voltage applied to the pump motor for the descent
function. If it is set 0% the motor don’t work when the descent request is ON.
33) CREEP SPEED

Percentage. It sets the minimum speed (percentage of voltage applied) for the
pump motor. Percentage of the maximum voltage applied to the pump motor
when the Lift SW is closed.
34) COMPENSATION
From 0% to 100% This parameter sets the voltage compensation (∆V) applied
to the motor when the proportional lifting function is active. The value of this ∆V
applied to the motor is a function of the motor current. Aim of this function is to
reduce, as for as possible, the speed difference between the truck loaded and
unloaded.
35) HYD SPEED FINE

Percentage. Fine adjustment of the pump motor steering function speed.
36) HYDRO COMPENSATION

Percentage. Adjustment of the compensation function when the pump motor
steering function is active.
37) MIN EVP

0 to 100. This parameter determines the minimum current applied on the EVP
when the position of the potentiometer is at the minimum. This parameter is not
effective if the EVP is programmed like a On/Off valve.

38) MAX EVP
From 0 to 100. This parameter determines the maximum current applied to the
EVP when the position of the potentiometer is at the maximum. This parameter
also determines the current value when the EVP is programmed like an
ON/OFF valve.
39) EVP OPEN DELAY

Seconds. It determines the acceleration ramp on EVP.
The parameter sets the time needed to increase the current to the maximum
possible value.
40) EVP CLOSE DELAY

Seconds. It determines the deceleration ramp on EVP.
The parameter sets the time needed to decrease the current from the maximum
possible value to zero.

PARAMETER UNIT VALUE
ACCELERATION DELAY Sec. From 0 to 10 sec., resolution of 0.1
RELEASE BRAKING Sec. From 0 to 10 sec., resolution of 0.1
TILLER BRAKING Sec. From 0 to 10 sec., resolution of 0.1
INVERSION BRAKING Sec. From 0 to 10 sec., resolution of 0.1
DECEL. BRAKING Sec. From 0 to 10 sec., resolution of 0.1
PEDAL BRAKING Sec. From 0 to 10 sec., resolution of 0.1
SPEED LIMIT BRAKING Sec. From 0 to 10 sec., resolution of 0.1
MAX SPEED FW % From 0% to 100%, resolution of 1%
MAX SPEED BW % From 0% to 100%, resolution of 1%
CUTBACK SPEED 1 %Max Sp From 0% to 100%, resolution of 1%
CUTBACK SPEED 2 %Max Sp From 0% to 100%, resolution of 1%
H&S CUTBACK %Max Sp From 0% to 100%, resolution of 1%
FREQUENCY CREEP Hz From 0.6 to 4.0 Hz, resolution of 0.1 Hz
MAXIMUM CURRENT %IMAX From 0% to 100%, resolution of 1%
ACC SMOOTH Num. From 1 to 5, resolution 0,1
INV SMOOTH Num. From 1 to 5, resolution 0,1
STOP SMOOTH Hz From 3 to 20 Hz, resolution of 1Hz
BRK SMOOTH Num. From 1 to 5, resolution 0,1
STOP BRAKE SMOOTH Hz From 3 to 20 Hz, resolution of 1Hz
AUXILIARY TIME Sec. From 0 to 10 sec., resolution of 0.1
HYDRO TIME Sec. From 0 to 10 sec., resolution of 0.1
PUMP IMAX % Programmed level from 0 to 9
PU. ACCELER. DEL. Sec. From 0 to 10 sec., resolution of 0.1
PU. DECELER. DEL. Sec. From 0 to 10 sec., resolution of 0.1
MAX SPEED LIFT % From 0% to 100%, resolution of 1%
MAX SPEED LIFT % From 0% to 100%, resolution of 1%
LIFT CUTBACK % From 0% to 100%, resolution of 1%
ST
1 PUMP SPEED % From 0% to 100%, resolution of 1%
ND
2 PUMP SPEED % From 0% to 100%, resolution of 1%
DESCENT SPEED % From 0% to 100%, resolution of 1%
CREEP SPEED % From 0% to 100%, resolution of 1%
COMPENSATION % From 0% to 100%, resolution of 1%
HYD SPEED FINE % From 0% to 100%, resolution of 1%
HYDRO COMPENSATION % From 0% to 100%, resolution of 1%
MIN EVP % From 0% to 100%, resolution of 0.1%
MAX EVP % From 0% to 100%, resolution of 0.1%
EVP OPEN DELAY Sec. From 0 to 25.5 sec., resolution of 0.1
EVP CLOSE DELAY Sec. From 0 to 25.5 sec., resolution of 0.1

10.4.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list
4 Note: the below set-up description is for skilled persons only: if you aren’t, please
keep your hands off. To enter this Zapi hidden menu a special procedure is
required. Ask for this procedure, directly to a Zapi technician.
In the SPECIAL ADJUSTMENTS functions list, there are factory adjusted
parameters only.
1) ADJUSTMENT #01
(Factory adjusted). % value. This is the Gain of the first Current Sensing
Amplifier of traction motor.
NOTE: only Zapi technicians should change this value
2) ADJUSTMENT#02
(Factory adjusted). % value. This is the Gain of the second Current Sensing
Amplifier of traction motor.
NOTE: only Zapi technicians should change this value
3) SET CURRENT
(Factory adjusted). This is the traction motor maximum current.
4) SET TEMPERATURE
Set the temperature offset to have the correct value reading. This is a fine
calibration of the controller temperature sensor.
5) ADJUSTMENT#03
(Factory adjusted). % value. This is the gain of the Current Sensing Amplifier of
pump motor.
6) SET CURRENT PUMP

(Factory adjusted). This is the pump motor maximum current.
7) HIGH ADDRESS
To be used to have access to special memory address.
4 NOTE: only Zapi technicians should change this value
8) DITHER AMPLITUDE
It is the dither signal amplitude. The dither signal is a square wave which is
overlapped to the proportional valves set point. In this way the proportional
valves response to set point variations is optimized. This parameter is a
percentage of the valves maximum current. It can be adjusted in the 0% to
20.3% by nine levels. Setting the parameter to 0% means the dither isn’t used.
9) DITHER FREQUENCY
It is the dither signal frequency. It can be used one of three:
- 0: the dither signal frequency is 62.5 Hz
- 1: the dither signal frequency is 83 Hz
- 2: the dither signal frequency is 125 Hz.

10) CAN BUS SPEED
It determines the baudrate for the CAN communication
- 20: 20 kbaud/sec.
- 50: 50 kbaud/sec.
- 125: 125 kbaud/sec.
- 250: 250 kbaud/sec.
- 500: 500 kbaud/sec.
10.4.5 Main menu “TESTER” functions list

The TESTER functions are a real time feedback measurements of the state of the
controller/motor/command devices. It is possible to know the state (active / off) of
the digital I/Os, the voltage value of the analog inputs and the state of the main
variables used in the motor and hydraulics control. Enter the home page in the
hand-set display and roll for the TESTER item.
1) BATTERY VOLTAGE
Voltage value with 1 decimal digit. Battery voltage value measured at the key
on.
2) MOTOR VOLTAGE
Percentage value. It is the voltage generated by the inverter expressed in
percent of the actual battery voltage. 100% means the sine wave width is close
to the actual battery voltage; 0% means the sine wave width is null.
3) VOLTAGE BOOSTER
Percentage value. It is the booster contribute to the voltage really supplied to
the motor expressed in per cent of the actual battery voltage. (Note: when
DC_LINK COMPENSATION is set ON, the VOLTAGE BOOSTER reading will
not match perfectly the booster setting because this latest one is calculated
respect to the nominal battery voltage; VOLTAGE BOOSTER is expressed
respect to the actual battery voltage).
4) FREQUENCY
Hz value. This is the frequency of the sine waves the inverter is supplying.
5) ENCODER
Hz value. This is the speed of the motor measured with the encoder and
expressed in the same unit of the FREQUENCY reading.
6) SLIP VALUE
Hz value. This is the slip between the frequency and the speed of the motor
(SLIP VALUE = FREQUENCY-ENCODER).
7) CURRENT RMS
Ampere value. Root Mean Square value of the line current in the motor.
8) BATTERY CHARGE
Percentage value. It supplies the residual charge of the battery as a percentage
of the full charge level.
9) TEMPERATURE
°C value. This is the temperature of the inverter base plate. This temperature is
used for the HIGH TEMPERATURE alarm detection.

10) MOTOR TEMPERATURE
°C value. This is the temperature of the motor windings picked up with an
analog sensor inside the motor. Normally this sensor is a PTC Philips KTY84-
130 or a KTY83. It depends on SET MOT. TEMP. option.
11) PUMP CURRENT

Ampere. It is the continuous current in the pump motor.
12) PUMP VMN

It is the voltage applied to the pump motor. Expressed in percentage of the
maximum voltage.
13) ACCELERATOR
From 0.0V to 5.0V. The voltage on the wiper of the accelerator (CPOT on
CNC#4) is halved inside the controller and then recorded on this reading. That
means the actual wiper voltage is in the range 0 to 10V meanwhile the
corresponding ACCELERATOR reading is in the range 0.0 to 5.0Vdc.
14) LIFTING CONTROL

From 0.0 to 5.0V. The voltage on the wiper of the accelerator (CPOTLIFT on
CNC#9) is halved inside the controller and then recorded on this reading.That
means the actual wiper voltage is in the range 0 to 10V meanwhile the
corresponding ACCELERATOR reading is in the range 0.0 to 5.0Vdc
15) DI0/TILLER SWITCH

ON/OFF. This is the level of the digital input CNC#6 for the Tiller input.
- ON +VB = When it is closed to a battery (key) voltage, the Tiller input is
Active.
- OFF GND = When it is not connected to a battery (key) voltage (or it is
connected to GND), the Tiller input is not active.
16) DI1/BELLY SWITCH

ON/OFF. This is the level of the digital input CNC#2 ( belly button):
- ON +VB = When it is closed to a battery (key) voltage, the request of the
Belly (to stop the movement) is active.
connected to GND), the Belly request is not active.
17) DI2/ H&S CUTBACK

ON/OFF. This is the level of the digital input CNC#7 for the Hard & Soft request.
With the H&S service is possible to turn the truck moving (at reduced speed)
only by acting the H&S switch, and the accelerator, without to let down the tiller :
- ON +VB = When it is closed to a battery (key) voltage, the H&S request is
Active.
connected to GND), the H&S request is not active.
18) DI3/FORWARD SWITCH

ON/OFF. This is the level of the digital input CNB#4 for the forward travel
demand:
- ON +VB = When it is closed to a battery (key) voltage, the Forward Travel
demand is Active.
connected to GND), the Forward Travel demand is not active.

19) DI4/BACKWARD SW.
ON/OFF. This is the level of the digital input CNB#8 for the backward travel
demand:
- ON +VB = When it is closed to a battery (key) voltage, the Backward Travel
demand is Active.
connected to GND), the Backward Travel demand is not active.
20) DI5/HORN SWITCH

ON/OFF. This is the level of the digital CNA#4:
- ON +VB = When it is closed to a battery (key) voltage the HORN request is
active.
- OFF GND = When it is not closed to a battery (key) voltage (or connected to
GND) the HORN request is not active.
21) DI6/LOWERING SW.

ON/OFF. This is the level of the digital input CNA#11:
- ON +VB = When it is closed to a battery (key) voltage, the request of the
Lowering request is active.
connected to GND), the Lowering request is not active.
22) DI7/LIFT SWITCH

- ON +VB = When it is closed to a battery (key) voltage the voltage the
LIFTING request is active.
- OFF GND = When it is not closed to a battery (key) voltage (or connected to
GND) the voltage the LIFTING request is not active.
23) DI8/1ST P.SPEED

- ON +VB = When it is closed to a battery (key) voltage the 1ST request is
active.
- OFF GND = When it is not closed to a battery (key) voltage (or it is
connected to GND) the 1ST request is not active.
24) DI9/LIFT CUTBACK

- ON GND = When it is closed not to a battery (key) voltage (or it is
connected to GND), the PUMP CUTBACK request is not active.
- OFF +VB = When it is closed to a battery (key) voltage, the PUMP
CUTBACK request is active.
25) DI10/2ND P.SPEED

- ON +VB = When is closed to a battery (key) voltage the digital the 2ND
request is active.
- OFF GND = When is not connected to a battery (key) voltage (or it is
connected to GND) the 2ND request is not active.
26) DI11/CUTBACK1
ON/OFF. This is the level of the CNA#7 digital input:
- ON GND = When CNA#7 is not closed to GND the CUTBACK1 request not
is active.

- OFF +VB = When is not connected to GND (or it is connected to battery) the
CUTBACK1 request is active.
27) DI12 CUTBACK 2

- ON GND = When CNA#14 is not closed to GND the CUTBACK2 request
not is active.
- OFF +VB = When is not connected to GND (or it is connected to battery) the
CUTBACK2 request is active.
28) SET POINT EVP

This parameter shows the setpoint of EVP valve.
29) EV1 FEEDBACK

ON/OFF. This parameter shows the feedback of EV1 valve.
30) EV2 FEEDBACK

VOLTAGE %. This parameter shows the feedback of EV2 valve.
31) EV3 FEEDBACK

VOLTAGE %. This parameter shows the feedback of EV3 valve.
32) OUTPUT EV1

ON/OFF. This is the EV1 output command.
33) OUTPUT EV2

%. This is the EV2 output command (voltage %).
34) OUTPUT EV3

%. This is the EV3 output command (voltage %).
35) OUTPUT HORN

ON/OFF. This is the HORN output command.
36) MAIN CONT. VOLT.

%. This is the main contactor output command (voltage %).
37) ELEC. BRAKE VOLT.

%. This is the electrobrake output command (voltage %).

11 OTHER FUNCTIONS
11.1 Description of console “SAVE” function

The SAVE function allows the operator to transmit the Parameter values and
Configuration data of the controller into the Console memory. It is possible to load
64 different programmes. The information saved in the Console memory can then
be reloaded into another controller using the RESTORE function.
The data that is available via the SAVE function are listed here below:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET. OPTIONS).
- The Level of the Battery (ADJUST BATTERY).
Flow Chart showing how to use the SAVE function of the Digital Console.
ADXT2B ZP1.00
' % '
Press ENTER to go into the General menu ' ' '
MAIN MENU
The Display will show : PARAMETER CHANGE
Press ROLL UP or ROLL DOWN button until SAVE % ' '

PARAM. appears on the display % ' '
MAIN MENU
The Display will show : SAVE PARAMETERS
' % '
Press ENTER to go into the SAVE function ' ' '
If this feature has been used before, the type of

SELECT: MOD. 00
controller data stored appears on the top Main with FREE
a 2 digit reference
Keep pressing either ROLL UP or ROLL DOWN

% ' '
keys until the second Main indicates a FREE % ' '
storage facility
SELECT: MOD. 01
FREE
' % '
Press ENTER to commence SAVE routine ' ' '
You can see the items that are being stored whilst READING …
the SAVE routine is happening ACCEL. DELAY (ECC.)
SELECT: MOD. 01
When finished, the Console shows : FREE
' ' '

Press OUT to return to the Opening Zapi Display ' % '

4 NOTE: in reality the SAVE and RESTORE function requires the Windows PC-
Console.
11.2 Description of console “RESTORE” function

The RESTORE PARAM function allows transfer of the Console’s stored data into
the memory of the controller. This is achieved in a fast and easy way using the
method previously used with the SAVE PARAM. function.
The data that is available on the RESTORE PARAM. Function are listed here below:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET OPTIONS)
- The level of the Battery (ADJUST BATTERY)
ATTENTION: When the RESTORE operation is made, all data in the controller
memory will be written over and replaced with data being restored.
Flow Chart showing how to use the RESTORE function of the Digital Console.
ADXT2B ZP1.00
' % '
MAIN MENU
Press ROLL UP or ROLL DOWN button until % ' '

RESTORE PARAM. appears on the display % ' '
MAIN MENU
The Display will show : RESTORE PARAM.
Press ENTER to go into the RESTORE PARAM. ' % '

function ' ' '
The Display shows the type of Model stored, with a SELECT : MOD. 00
Code Number ACEX ZAPI V1
Keep pressing either ROLL UP and ROLL DOWN

% ' '
buttons until the desired model appears on the % ' '
Display
SELECT : MOD. 00
ACEX ZAPI V1
' % '
Press ENTER to commence the Restore operation ' ' '
ARE YOU SURE?

The Display will ask “ARE YOU SURE”. YES=ENTER NO=OUT

' % ' ' ' '
Press ENTER for YES, or OUT for No ' ' ' ' % '
You can see the items that are being stored in the
STORING
chopper memory whilst the RESTORE routine is ACCELER. DELAY
happening
MAIN MENU
When finished, the Console shows : RESTORE PARAM.
' ' '

4 NOTE: in reality the SAVE and RESTORE function requires the Windows PC-
Console.
11.3 Description of console “PROGRAM VACC” function

This enables adjustment of the minimum and maximum useful signal level, in either
direction. This function is unique when it is necessary to compensate for asymmetry
with the mechanical elements associated with the potentiometer, especially relating
to the minimum level.
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.
This function looks for and remembers the minimum and maximum potentiometer
wiper voltage over the full mechanical range of the pedal. It enables compensation
for non symmetry of the mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM
VACC function.

Flow Chart showing how to use the PROGRAM VACC function of the Digital
Console.
ADXZ2A ZP1.00
' % '
MAIN MENU
Press ROLL UP or ROLL DOWN button until % ' '

PROGRAM VACC the display % ' '
MAIN MENU
The Display will show : PROGRAM VACC
Press ENTER to go into the PROGRAM VACC ' % '

function ' ' '
The Display will show the minimum and maximum

VACC SETTING
values of potentiometer wiper output. 4.8 4.8
Both directions can be shown
Press ENTER to clear these values. ' % '

Display will show 0.0 ' ' '
Select Forward Direction, close any interlock MIN VACC MAX

switches that may be in the system 0.0 - 0.0
Slowly depress the accelerator pedal (or tiller

butterfly) to its maximum value. The new minimum
and maximum voltages will be displayed on the
Console plus an arrow indicating the direction.
MIN VACC MAX

Select the Reverse Direction and repeat Item 10 0.6 ↑ 4.4
' ' '

When finished , press OUT ' % '
ARE YOU SURE

The Display will ask : ARE YOU SURE ? YES=ENTER NO=OUT
' % '
Press ENTER for yes, or OUT for NO ' % '
MAIN MENU
When finished, the Console shows : PROGRAM VACC
' ' '


11.4 Description of the throttle regulation
This regulation applies a not linear relationship between the position of the
accelerator and the speed of the truck. The main goal is to increase the resolution
for the speed modulation when the truck is slowly moving.
Three adjustments are used for the throttle regulation:
1) THROTTLE 0 ZONE
2) THROTTLE X POINT
3) THROTTLE Y POINT
THROTTLE 0 ZONE: the speed of the truck remains at frequency creep meanwhile
the voltage from the accelerator potentiometer is lower than this percentage of the
MAX VACC setting. This adjustment define the width of a dead zone close to the
neutral position.
THROTTLE X POINT & THROTTLE Y POINT: the speed of the truck grows up with
a fixed slope (linear relationship) from the THROTTLE 0 ZONE up to THROTTLE X
POINT. This slope is defined by the matching between the X point percentage of the
MAX VACC setting with the Y point percentage of the full truck speed.
From the X point up to the MAX VACC point, the slope of the relationship between
the truck speed and the accelerator position is different (see figure below) to match
the full speed in the truck with the MAX VACC voltage in the accelerator position.

11.5 Description of the battery charge detection setting
The Battery Charge detection uses two setting that specify the Full Charge Voltage
Level (100%) and the Discharge Voltage Level (10%). These two settings are the
Bat.Max.Adj and the Bat.Min.Adj. It is possible to adapt the Battery Charge
Detection to your specific battery, by changing the above two settings (e.g. if the
Battery Discharged Detection occurs when the battery is not totally discharged, it is
necessary to reduce the Bat.Min.Adj setting as indicated in the figure below).
48V NOMINAL BATTERY VOLTAGE
24V NOMINAL BATTERY VOLTAGE

The Battery Charge detection follows this algorithm:
1) Battery voltages is read when the Battery current is zero, that is when the output
power stage is not driven.
2) Vbatt is the mean of the least samples measured by the microcontroller
converter (the samples are took on key input).
3) Vbatt is compared with a threshold value (function of the actual charge
percentage) in a table and with comparison is found a new charge percentage.
4) Thresholds value can be changed with parameters Bat. Max. Adj. and Bat. Min.
Adj.
5) After key on battery charge can be only increased if the battery charge
computed after key on is greater than the last value stored in Eeprom the
battery charge value is updated otherwise the Battery charge is not updated.

12 COMBIACX /ACEX ALARMS LIST
The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It
has a FIFO (First Input First Output) structure that means the oldest alarm is lost
when the database is full and a new alarm occurs. The logbook is composed of five
locations getting possible to stack five different type of alarms with the following
information:
1) The alarm code
2) The times that each alarm occurs consecutively
3) The Hour Meter value when the first event of every alarm occurred
4) And the inverter temperature when the first event of every alarm occurred.
This function permits a deeper diagnosis of problems as the recent history can be
revised.
4 NOTE: if the same alarm is continuously happening, the controller does not use new
memory of the logbook, but only updates the last memory cell increasing the related
counter (point 2) of previous list). Nevertheless, the hourmeter indicated in this
memory refers to the first time the alarm occurred. In this way, comparing this
hourmeter with the controller hourmeter, it is possible to determine:
- When this alarm occurred the first time.
- How many hours are elapsed from the first occurrence to now.
- How many times it has occurred in said period.
12.1 Faults diagnostic system

The fault diagnostic system of COMBIACX / ACEX controller is divided into 2 main
groups of faults:
ALARMS: these are the faults which open the power section, which means the
power bridge is opened and, when possible, the LC is opened and EB
is applied.
These are faults related to:
- failures in the motor/controller that the power system is not
anymore able to drive the truck
- safety related failures
WARNINGS: these are faults which do not stop the truck or stop it by a controlled
regen braking. In other words, the controller is working well, but it has
detected conditions to reduce the performances or to stop the truck
without opening the power devices.
These warnings are related to:
- wrong operator sequences
- conditions which require performance reduction (like high
temperatures, ….)

12.2 Alarms overview
Machine status
Restart
Error Code Description Effect when the test is
procedure
done
Capacitor Power capacitors voltage does not increase Valve, pump, traction start-up Valve or pump or
charge - MDI stopped, Lc opened, Eb traction request
CAN 60 applied
Vmn low - MDI Motor output voltage lower than expected Valve, pump, traction start-up, traction Valve or pump or
CAN 72 stopped, Lc opened, Eb traction request
applied
Vmn high - Motor output voltage higher than expected Valve, pump, traction start-up, traction Valve or pump or
MDI CAN 31 stopped, Lc opened, Eb traction request
applied
Power mos Short circuit on the power mosfets Valve, pump, traction start-up Valve or pump or
short - MDI stopped, Lc opened, Eb traction request
CAN 89 applied
Coil short. MC- Shortcircuit on LC or EB coil Valve, pump, traction stby, traction Valve or pump or
EB - MDI CAN stopped, Lc opened, Eb traction request
76 applied
Driver shorted - Driver of LC coil is shorted, so it is not able to open Valve, pump, traction start-up Valve or pump or
MDI CAN 74 the LC, or LC coil is disconnected stopped, Lc opened, Eb traction request
applied
Contactor Driver of LC coil is damaged (not able to close) Valve, pump, traction stby, traction Valve or pump or
Driver - MDI stopped, Lc opened, Eb traction request
CAN 75 applied
Contactor The LC coil has been driven but LC does not close Valve, pump, traction stby, traction Valve or pump or
Open - MDI stopped, Lc opened, Eb traction request
CAN 77 applied
Contactor LC contact is stuck Valve, pump, traction start-up Valve or pump or
closed - MDI stopped, Lc opened, Eb traction request
CAN 75 applied
Aux driv. Shrt. - When the mos of EB is shorted Valve, pump, traction start-up,stby,marcia Valve or pump or
applied
Aux driver Driver of EB coil is damaged (not able to close) Valve, pump, traction stby, traction Valve or pump or
open - MDI stopped, Lc opened, Eb traction request
CAN 42 applied
Pos. EB Output of built in Smart Driver, which supplies Eb coil Valve, pump, traction start-up Valve or pump or
shorted - MDI positive, is high (= +batt) when the tiller switch is stopped, Lc opened, Eb traction request
CAN 86 opened. applied
Logic Failure Overvoltage/Undervoltage condition has been Valve, pump, traction start-up Valve or pump or
#1 - MDI CAN detected stopped, Lc opened, Eb traction request
54 applied
Logic Failure Motor voltage feedback circuits are damaged Valve, pump, traction stby, immediately Valve or pump or
#2 - MDI CAN stopped, Lc opened, Eb after Lc closing traction request
55 applied
Logic failure Failure in the high current HW protection circuit valve, pump, traction start-up, stby Valve or pump or
#3 - MDI CAN stopped, Lc opened, Eb traction request
17 applied
Stby i high - In stby condition (no current applied to the traction Valve, pump, traction start-up, stby Valve or pump or
MDI CAN 53 motor) the current feedbacks are aout of permitted stopped, Lc opened, Eb traction request
stby range applied
Wrong Battery -The battery voltage is too low or too high (< 0,8 Vbatt Valve, pump, traction start-up, stand-by Valve or pump or
MDI CAN 41 OR > 1,2 Vbatt) stopped, Lc opened, Eb (only immediately traction request
applied after Lc closing)
Analog input - Problem on the A/D conversion of uC Valve, pump, traction traction Valve or pump or
applied
Encoder Error - Problem on the encoder Valve, pump, traction traction Valve or pump or
applied
Tiller error - Input mismatch between hard&soft switch input and Traction stopped, Eb applied start-up, stby, Valve or pump or
MDI CAN 64 tiller input traction traction request
Watchdog - One of two (or both) Watchdog circuit outputs Valve, pump, traction start-up, stby, Key re-cycle
MDI CAN 08 becomes high due to an HW or SW problem stopped, Lc opened, Eb traction
applied

Smart driver KO - MDI Smart driver is open, not able to valve, pump, traction stopped,
start-up Key re-cycle
CAN 68 provide EB positive Lc opened
Key-off shorted - MDI CAN valve, pump, traction stopped,

Key-off signal is low at Key-on start-up Key re-cycle
76 Lc opened
Evp driv. short - MDI CAN Evp driver is failed shorted (always valve, pump, traction stopped, start-up, stby valve or pump or
50 ON) mismatch between the valve Lc opened, Eb applied traction request
set-point and its feedback
Pump Vmn Low - MDI Pump motor output is too low, with valve, pump, traction stopped, start-up, stby, valve or pump or
CAN 28 respect to pwm applied Lc opened, Eb applied during pump traction request
function
Pump Vmn High - MDI Pump motor output is too high, valve, pump, traction stopped, during pump valve or pump or
CAN 29 with respect to pwm applied Lc opened, Eb applied function traction request
Wrong Zero - MDI CAN The outputs of the amplifiers (used valve, pump, traction stopped, init valve or pump or
code alarm 53 to measure the motor voltage) are Lc opened, Eb applied traction request
cheked this alarm occurs when
voltage signals >3V or <2V at the
init
Evp coil The Evp1 coil is not connected valve, pump, traction stopped, start-up, stby, valve or pump or
open - MDI CAN 50 between PAUX and EVP output, Lc opened, Eb applied traction traction request
and the parameter EVP TYPE in
the set-option menu is set Analog
or Digital
Aux Batt. Short - MDI CAN When the positive of the AUX valve, pump, traction stopped, start-up, stby
code alarm 74 OUTPUT is driven by the tiller, the Lc opened, Eb applied
positive is high and the tiller is
released.
Pev not OK - MDI CAN The PEV connector (B2) is not valve stopped, (eventually) continuous
code alarm 98 connected to the battery or the pump stopped, (eventually)
voltage is different. traction stopped, (eventually)
Lc opened and MC applied
Flash Checksum - MDI The software is corrupted or the valve, pump, traction stopped, continuous
CAN 08 flash on the inverter is damaged. Lc opened, Eb applied
Controller Mism - MDI The software is not compatible with valve, pump, traction stopped, start-up key-recycle
CAN 12 the controller. Lc opened, Eb applied
valve, pump, traction stopped, start-up key-recycle

Motor output voltage lower than Lc opened, Eb applied
Init vmn low - MDI CAN 72
expected, before driving the bridge.

Init vmn high - Motor output voltage higher than Lc opened, Eb applied
MDI CAN 31 expected, before driving the bridge.

Pump vmn not ok - Pump motor output voltage is
Lc opened, Eb applied
MDI CAN 32 different than expected

Analysis and troubleshooting of microcontroller alarms
To Enter the MAIN MENU’ push the Enter button at the Home Page of the hand set
display and Roll for the ALARMS item. Here is the ALARMS list:
1) “CAPACITOR CHARGE”
Follows the charging capacitor system:
When the key is switched ON, the inverter tries to charge the power capacitors
through a power resistance, and check if the capacitor are charged within a
timeout. If they do not charge, an alarm is signalled; the main contactor is not
closed.
Troubleshooting:
A) There is an external load in parallel to capacitor bank, which sinks current
from the controller capacitors precharging circuit, thus preventing the caps
from charging. Check if a lamp or a dc/dc converter or a auxiliary load is
placed in // to capacitor bank.
B) The charging resistance is opened; insert a power resistance across line
contactor power terminals; if the alarm disappears, it means the controller
internal charging resistance is damaged.
C) The charging circuit has a failure, inside the controller.
D) There is a problem in the controller power section.
2) “VMN LOW”
Cause 1: start-up test.
Before switching the LC on, the software checks the power bridge: it turns on
alternating the High side Power Mosfets and expects the phases voltage to
increase toward the rail capacitor value. If the phases voltage does not
increase, this alarm occurs.
Cause 2:
Motor running test. When the motor is running, power bridge is ON, the motor
voltage feedback is tested; if it is lower than commanded value, fault status is
entered.
Troubleshooting:
A) If the problem occurs at start up (the LC does not close at all), check:
- Motor internal connections (ohmic continuity)
- Motor power cables connections
- Motor leakage to truck frame
- If the motor connections are OK, the problem is inside the controller
B) If the alarm occurs during motor running, check:

- Motor connections
- If motor phases windings/cables have leakages towards truck frame
- That the LC power contact closer properly, with a good contact

- If no problem are found on the motors, the problem is inside the
controller.
3) “VMN HIGH”
Cause 1:
Before switching the LC on, the software checks the power bridge: it turns on
alternating the Low side Power Mosfets and expects the phases voltage to
decrease down to -Batt. If the phases voltage do not decrease, this alarm
occurs.
Cause 2:
This alarm may occur also when the start up diagnosis is overcome, and so the
LC is closed. In this condition, the phases’ voltages are expected to be lower
than 1/2 Vbatt. If it is higher than that value, fault status is entered.
Troubleshooting:
- If the motor connection are OK, the problem is inside the controller
B) If the problem occurs after closing the LC (the LC closed and then opens
back again), check:
- Motor connections
- If motor phases windings/cables have leakages towards truck frame
controller
4) “POWER MOS SHORT”

Cause: Before switching the LC on, the software checks the power bridge: it
turns on alternating the Low side and High side Power Mosfets and expects the
phases voltage to decrease down to –BATT (increase up to +Batt). If the phases
voltage do not follow the comands, this alarm occurs.
Troubleshooting:
This type of fault is not related to external components; replace the controller.
5) “COIL SHOR MC-EB”

Cause:
This alarm occurs when there is a short circuit of one of the coils connected to
outputs of the COMBIACX / ACEX (LC coil or EB coil). After the overload
condition has been removed, the alarm exits automatically by releasing and
then enabling a travel demand.
Troubleshooting:
A) The typical root cause for this error code to be displayed is in the harness or
in the load coil. So the very first check to carry out concerns connections
between controller outputs and loads.
B) In case no failures/problems have been found externally, the problem is in
the controller, which has to be replaced.
6) “DRIVER SHORTED”
Cause:
The driver of the main contactor coil is shorted or the coil is disconnected.
Troubleshooting:
A) Check if there is a short or a low impedance pull-down between NLC
CNB#6 and –BATT.
B) The driver circuit is damaged in the controller, which has to be replaced.
C) The wires to the LC coil are interrupted or not connected, so check the coil
related harness.

7) “CONTACTOR DRIVER”
Cause:
The LC coil driver is not able to drive the load. The device itself or its driving
circuit is damaged.
Troubleshooting:
8) “CONTACTOR OPEN”
Cause:
The main contactor coil has been driven by the controller, but the contactor
does not close.
Troubleshooting:
It could be also a problem of the contact in the LC that is not working (does not
pull-in), try replacing the LC.
9) “CONTACTOR CLOSED”
Cause:
Before driving the LC coil, the controller checks if the contactor is stuck. The
controller drives the bridge for some tens milliseconds, trying to discharge the
capacitors bank. If they don’t discharge the fault condition is entered.
Troubleshooting:
It is suggested to verify the power contacts of LC; to replace the LC is
necessary.
10) “AUX DRIV. SHRT.”

Cause:
The driver of the electromechanical brake coil is shorted.
Troubleshooting:
A) Check if there is a short or a low impedance pull-down between NEB
CNA#4 and –BATT.
B) The driver circuit is damaged in the controller, which has to be replaced.
11) “AUX DRIV. OPEN”

Cause:
The driver of the electromechanical brake coil is not able to drive the load.
Troubleshooting:
Replace the controller.
12) “POS EB SHORTED”

Cause:
The output of the built in Smart Driver, which supplies the positive to the
Electromechanical brake coil is high when the Tiller and the H&S switch are
open.
Troubleshooting:
A) It is suggested to check the harness, in order to verify if a positive is
connected to the Smart driver output CNB#1.
B) If, even disconnecting the wire from the connector pin, the output stays at
high value, the problem is inside the controller and the Smart Driver is
probably shorted.
13) “LOGIC FAILURE #1”

This fault is displayed when the controller detects an overvoltage or
undervoltage condition. Overvoltage threshold is 35V, undervoltage threshold is
9,5V in the 24V controller. In 36/48V controller overvoltage threshold is 65V,

undervoltage threshold is 9,5V.
Troubleshooting of fault displayed at startup or in standby; in these cases it is
very likely the fault is due to an undervoltage, so it is suggested to check:
A) Key input signal down-going pulses (below undervoltage threshold) due to
external loads, like DC/DC converters starting-up, relays or contactor
switching, solenoids energizing / de-energizing.
B) If no voltage transient is detected on the supply line and the alarm is present
every time the key is switched ON, the failure is probably in the controller
hardware, so it is necessary to replace the controller.
Troubleshooting of fault displayed during motor driving; in this case it can be an

undervoltage or a overvoltage condition.
A) If the alarm happens during traction acceleration or driving hydraulic
functions, it is very likely it is an undervoltage condition; check battery
charge condition, power cable connection.
B) If the alarm happens during release braking, it is very likely it is due to
overvoltage condition; check line contactor contact, battery power cable
connection.

Cause:
Fault in the hardware section of the logic board which manages the phase’s
voltage feedback.
Troubleshooting:
This type of fault is not related to external components, so when it happens it is
necessary to replace the Controller.

Cause:
Hardware problem in the logic card circuit for high current (overload) protection.
Troubleshooting:
This type of fault is not related to external components, so, when it is present it
is necessary to replace the controller.
16) “STBY I HIGH”

Cause:
The current transducer or the current feedback circuit is damaged in the
controller.
Troubleshooting:
This type of fault is not related to external components so, when it is present, it
is necessary to replace the controller.
17) “WRONG BATTERY”

Cause:
At start-up, the controller checks the battery voltage and verify it is within a
window around the nominal value.
Troubleshooting:
A) Check that the controller SET BATTERY parameter value matches the
battery nominal voltage.
B) Check that the TESTER MENU / BATTERY VOLTAGE parameter shows
same value as the battery voltage measured with a voltmeter. If it is does
not match, then do a “ADJUST BATTERY” function.
C) Replace the battery.
18) “ANALOG INPUT”

Cause:
This alarm occurs when the A/D conversion of the analog inputs gives frozen
value, on all of the converted signals, for more than 400msec. The goal of this
diagnosis is to detect a failure of the A/D converter or a problem in the code flow
that omits the refreshing of the analog signal conversion.
Troubleshooting:
If the problem occurs permanently it is necessary to substitute the controller.
19) “ENCODER ERROR”

Cause:
This fault is signalled in following conditions: the frequency supplied to the motor
is higher than 40 Hz and the signal feedback from the encoder has a jump
higher than 40 Hz in few tens mSec. This condition is related to a malfunctioning
of the encoder.
Troubleshooting:
A) Check both the electric and the mechanical encoder functionality, the wires
crimping.
B) Check the encoder mechanical installation, if the encoder slips inside its
compartment raising this alarm condition.
C) Also the electromagnetic noise on the sensor bearing can be a cause for the
alarm. In these cases try to replace the encoder.
D) If the problem is still present after replacing the encoder, the failure is in the
controller.
20) “TILLER ERROR”

Cause:
Mismatch between the H&S input and the tiller input.
Troubleshooting:
Check the harness related to CAN#1 and CAN#29 with a voltmeter. If the state
of these inputs is right, then it could be a problem inside the controller, which
has to be changed.
21) “WATCHDOG”
Cause:
This is a safety related test. It is a self diagnosis test within the logic. The watch
dog circuit is composed by two monostable multivibrators so there is a double
check of software execution.
Troubleshooting:
This alarm could be caused by an hardware failure in one of two (or both)
multivibrator or due to a software execution problem. For both cases it is an
internal fault of the controller which must be replaced.
22) “SMART DRIVER KO”

Cause:
The built in smart driver is open, not able to provide the electro mechanic brake
positive.
Troubleshooting:
A) It is suggested to check the harness, in order to verify if the Smart driver
output CNB#1 is shorted to –Batt.
B) If, even disconnecting the wire from the connector pin, the output stays at
low value, the problem is inside the controller and the Smart Driver is
probably damaged.
23) “KEYOFF SHORTED”

Cause:

This fault is displayed when the controller detects a low logic level of Key-Off
signal during Start-Up diagnosis.
Troubleshooting:
It is very likely the fault is due to an under voltage, so it is suggested to check:
A) Key input signal down-going pulses (below under voltage threshold) due to
external loads, like DC/DC converters starting-up, relays or contactor
switching, solenoids energizing / de-energizing.
B) Check the connection of power cables to the battery terminal, positive and
negative, to MC and to controller +Batt and –Batt, which must be screwed
with a torque comprised in the range 5,6Nm÷8,4Nm.
C) If no voltage transient is detected on the supply line and the alarm is present
every time the key is switched ON, the failure is probably in the controller
hardware, so it is necessary to replace the logic board.
24) “EVP DRIV. SHORT.”

Cause:
A) The EVP driver is shorted.
B) The microcontroller detects a mismatch between the valve set-point and the
diver voltage measured on the LOWER EVP output.
Troubleshooting:
Check if there is a short or a low impedance between the negative of the coil
and -BATT. Otherwise the driver circuit is damaged and the controller must be
replaced.
25) “PUMP VMN LOW”

Cause:
The pump motor output is lower than expected, considering the pwm applied.
Troubleshooting:
- If the motor connection are OK, the problem is inside the controller
B) If the problem occurs after closing the LC (the LC closed and then opens
back again), check:
- Motor connections
- If motor windings/cables have leakages towards truck frame
controller
C) If the alarm occurs during motor running, check:
- Motor connections
- If motor windings/cables have leakages towards truck frame
- That the LC power contact closer properly, with a good contact
controller.
26) “PUMP VMN HIGH”

Cause:
This test is carried out when the pump motor is turning (pwm applied). The
pump motor output is higher than expected, considering the pwm applied.
Troubleshooting:
It is suggested to check:
A) Motor connections
B) If motor windings/cables have leakages towards truck frame
C) If no problem are found on the motors, the problem is inside the controller

27) “WRONG ZERO”
Cause:
The outputs of the amplifiers (used to measure the traction motor voltage) are
checked to be included into a range . This alarm occurs when the voltage
signals >3V or <2V at the init.
Troubleshooting:
28) ”EVP COIL OPEN”

Cause:
This fault appears when the LOWER EVP output is used (parameter “EVP
TYPE” in “SET OPTION” menu is set ANALOG or DIGITAL) but no load is
connected between the output and PAUX positive.
Troubleshooting:
A) It is suggested to check the harness, in order to verify if EVP coil is
connected to the right connector pin and if it is not interrupted.
B) If, even connecting the coil to the right pin or replacing it, the alarm is still
present than the problem is inside the controller logic board, replace it.
29) “AUX BATT. SHORT”

Cause:
A) The coil on the aux output is not correctly connected.
B) The smartdriver inside the controller is damaged.
Troubleshooting:
- It is suggested to check that the coil is correctly connected between B1 and
B5.
- If no problem is found on the coil, the problem is inside the controller.
30) “PEV NOT OK”

Cause:
The PEV connector (B2) is not connected to the battery or the voltage is
different. This alarm occours if one output between EV1, EV2, EV3, HORN is
present or AUX OUT FUNCTION is PRESENT (if POSITIVE EB= 0 or 2). In
other words, one of the output load is connected to PEV.
All the valves (EVP, EV1, EV2, EV3) are stopped. Horn is stopped.
Traction is stopped if the AUXOUT is used for an electrobrake and PEV is
indispensable for it (AUX OUT FUNCTION = PRESENT, POSITIVE EB 0 or 2).
Pump is stopped if EV1, EV2 or EV3 are used (PRESENT).
Troubleshooting:
Check B2 connector: it must be connected to the battery voltage (after the main
contactor)
31) “FLASH CHECKSUM”

Cause:
The software was not correctly written into the flash memory or the flash
memory is damaged.
Troubleshooting:
This type of fault is not related to external components, replace the controller.
32) “INIT VMN LOW”

Cause:
Before switching the LC on, the software checks the power bridge voltage
without driving it.
The software expects the voltage to be at a “steady state” value.

If it is too low, this alarm occours.
Troubleshooting:
Please check
33) “INIT VMN HIGH”

Cause:
Before switching the LC on, the software checks the power bridge voltage
without driving it.
The software expects the voltage to be at a “steady state” value.
If it is too high, this alarm occours.
Troubleshooting:
Please check
- Motor internal connections
34) “PUMP VMN NOT OK”

Cause:
Before switching the LC on, the software checks the output voltage on –P
connector, and expects it to be at a “steady state” value (if TRUCK TYPE
options is set to LEVEL=1).
If the voltage is too low, this alarm occours.
Troubleshooting:
Please check
- The motor connected to –P must be completely still before this alarm
occours. The software waits 30 seconds before showing this alarm. During
this time it shows the “WAIT MOTOR STILL” warning (see in the warnings
chapter)
- Motor internal connections
- If the motor connections are ok, the problem is inside the controller

12.3 Warnings overview
Machine status
Restart
Error code Description Effect when the test is
procedure
done
Slip profile - Error on the parameters of the slip Traction is stopped start-up, stand-by Traction
MDI CAN 99 profile setting. request
Forw+backwa The travel demands are active in both Traction is stopped start-up, stand-by, Traction
rd - MDI CAN directions at the same time traction request
80
Incorrect start - Incorrect starting sequence Traction is stopped start-up, stand-by Traction
MDI CAN 79 request
Vacc not ok - The acceleretor value is higher than Traction is stopped start-up, stand-by, Traction
MDI CAN 78 the minimum value recorded, and the traction request
direction/enable switches are opened.
Th. Protection -The controller has reached the Traction controller continuous
MDI CAN 62 thermal cutback temperature 85°C reduces the maximum
current linearly from
Imax (85°C) down to
0A (105°C)
Battery low Battery is <= 10% when the The maximum current continuous
parameter BATTERY CHECK is set is reduced to half and
>0 speed is reduced (if
CHECK OPTION = 1)
Eeprom ko - Error is detected in eeprom or in Controller works using continuous
MDI CAN 71 eeprom management Deafult parameters
Motor Traction motor temperature sensor is The maximum current continuous
temperat - opened (if digital) or has overtaken is reduced to half and
MDI CAN 65 the threshold of 150°C (if analog) speed is reduced
Thermic sens The output of the controller thermal The maximum current continuous
ko - MDI CAN sensor is out of range. is reduced to half and
61 speed is reduced
Check up Maintenance time is reached
needed
Data Maximum current adjustment Traction is stopped stand-by Traction
acquisition procedure is in progress (NOTE: this request
procedure has to be done only by
Zapi test department)
Tiller open - The truck is in stby with tiller switch LC opens standby Valve or pump
MDI CAN 51 opened for more than 30s or traction
request
Current gain - The Maximum current gain Controller works, but start-up, stanby
MDI CAN 92 parameters are the default values, with low maximum
which means the maximum current current
adjustment procedure has not been
carried out yet
Waiting for A Canbus network node is in alarm continuous
node - MDI condition. uC is waiting for it to
CAN 68 resolve its error condition.

Machine status
Restart
Error code Description Effect when the test is
procedure
done
Drv. Shor. EV1 dri - EV1 on/off valve drivers shorted On/off valves stopped start-up, stby valve on/off request
MDI CAN 74 (always ON)
Drv. Shor. EV2 - EV2 on/off valve driver shorted On/off valves stopped start-up, stby valve on/off request
Drv. Shor. EV3 - EV3 on/off valve driver shorted On/off valves stopped start-up, stby valve on/off request
Pump I NO zero - Pump chopper current sensor Pump motor stopped start-up, stby pump request
MDI CAN 56 feedback is out of permitted stby
range
Pump I=0 ever - Pump current feedback is always Pump motor stopped pump function pump request
MDI CAN 52 0A even when pump motor is
running
Cont. Drv. Ev1 - MDI Driver of Ev1 is open, not able to Ev1 stopped during Ev1 valve Ev1 request
CAN 75 close function
Pump Vacc not OK - The pump accelerator value is Pump stopped Continuous Pump request
MDI CAN 89 higher than the minimum value
recorded, and the lift/lower
switches are open
Sens. Mot. Temp. The motor temperature sensor is Performance highly Continuous Key-on recycle
KO - MDI CAN 67 damaged reduced
Vacc out range - The voltage on CNC#4 is out of the Traction stopped Continuous Program VACC
MDI CAN 85 parameters range
Stall rotor - MDI The traction rotor is stuck or the Traction stopped Continuous Key-on recycle
CAN 11 encoder is not working
EVP driver open - The EVP driver isdamaged or the EVP stopped Continuous Key-on recycle
MDI CAN 48 EVP coil impedance is too low
Many pump reqs - There are too many pump requests Pump stopped Continuous Remove request
MDI CAN 49 at the same time
Pump inc start - MDI Incorrect pump starting sequence Pump stopped start-up, stand- Pump request
CAN 79 by
Pump Vacc range - The voltage on CNC#9 is out of the Pump stopped, EVP Continuous Pump request
MDI CAN 90 parameters range stopped
Param. Restore - A parameters set restore was No effect start-up Traction, pump or
MDI CAN 13 made since the last keyoff EVP request
Wait mot. P. still - The software waits for the motor Valve, pump, traction start-up None
MDI CAN 63 pump to stop stopped, LC opened,
Eb applied

12.4 Analysis and troubleshooting of warnings
1) “SLIP PROFILE”
Cause:
There is an error on the choice of the parameters of the slip profile.
Troubleshooting:
Check in the hardware setting menu the value of those parameters.
2) “FORW+BACK”
Cause:
This alarm occurs when both the travel demands (Fwd and Bwd) are active at
the same time.
Troubleshooting:
Check the wiring of the Fwd and Rev travel demand inputs (use the readings in
the TESTER to facilitate the troubleshooting). Check the microswitches for
failures.
A failure in the logic is possible too. So, when you have verified the travel
demand switches are fine working and the wiring is right, it is necessary to
replace the controller.
3) “INCORRECT START”
Cause:
This is a warning for an incorrect starting sequence.
Troubleshooting:
The possible reasons for this alarm are (use the readings in the TESTER to
facilitate the troubleshooting):
A) A travel demand active at key on
B) Presence man sensor active at key on
Check the wirings. Check the micro-switches. It could be also an error
sequence made by the operator. A failure in the logic is possible too; so when
all of the above conditions were checked and nothing was found, replace the
controller.
4) “VACC NOT OK”

Cause:
The test is made at key-on and after 20sec that both the travel demands have
been turned off. This alarm occurs if the ACCELERATOR reading in the
TESTER menu’ is 1,0V higher than PROGRAM VACC min acquisition when
the accelerator is released.
Troubleshooting:
Check the mechanical calibration and the functionality of the potentiometer.
5) “TH. PROTECTION”
Cause:
This alarm occurs when the temperature of the base plate is higher than 85°.
Then the maximum current decreases proportionally with the temperature
increases from 85° up to 105°. At 105° the Current is limited to 0 Amps.
Troubleshooting:
Improve the air cooling of the controller. If the alarm is signalled when the
controller is cold, the possible reasons are a thermal sensor failure or a failure in
the logic card. In this case, it is necessary to replace the controller.

6) “BATTERY LOW”
Cause:
It occurs when the battery charge is calculated being less than or equal to 10%
of the full charge and the BATTERY CHECK setting is other than 0 (refer to SET
OPTION menu).
Troubleshooting:
Get the battery charged. If it doesn’t work, measure with a voltmeter the battery
voltage and compare it with the value in the BATTERY VOLTAGE parameter. If
they are different adjust the value of the ADJUST BATTERY function.
7) “EEPROM KO”
Cause:
It’s due to a HW or SW defect of the non-volatile embedded memory supporting
the controller parameters. This alarm does not inhibit the machine operations,
but the truck will work with the default values.
Troubleshooting:
Try to execute a CLEAR EEPROM operation (refer to Console manual). Switch
the key off and on to check the result. If the alarm occurs permanently, it is
necessary to replace the controller. If the alarm disappears, the previously
stored parameters will have been replaced by the default parameters.
8) “MOTOR TEMPERATURE”
Cause:
This warning occurs when the temperature sensor is opened (if digital) or has
overtaken the threshold of 150°C (if analog).
Troubleshooting:
Check the thermal sensor inside the motor (use the MOTOR TEMPERATURE
reading in the TESTER menu); check the sensor ohmic value and the sensor
wiring. If the sensor is OK, improve the air cooling of the motor. If the warning is
present when the motor is cool, then the problem is inside the controller.
9) “THERMIC SENS. KO”

Cause:
The output of the controller thermal sensor is out of range.
Troubleshooting:
10) “CHECK UP NEEDED”

Cause:
This is just a warning to call for the time programmed maintenance.
Troubleshooting:
It is just enough to turn the CHECK UP DONE option to level ON after the
maintenance is executed.
11) “DATA ACQUISITION”

Cause:
Acquisition of the current gains.
Troubleshooting:
The alarm ends when the acquisition is done.
12) “TILLER OPEN”

Cause:
Warning: when the tiller is released, after a fixed period of time of standby (30
seconds) the main contactor open.
Troubleshooting:

At the next travel request the warning disappear.
13) “CURRENT GAIN”

Cause:
The Maximum current gain parameters are at the default values, which means
the maximum current adjustment procedure has not been carried out yet.
Troubleshooting:
Ask the assistance of a Zapi technician to do the correct adjustment procedure
of the current gain parameters.
14) “WAITING FOR NODE”

Cause:
The controller receives from the CAN the message that another controller in the
net is in fault condition; as a consequence the ACEX / COMBIACX controller
itself cannot enter an operative status, but has to WAIT for the other controller
coming out from the fault status.
15) “COIL SHOR. EV”

Cause:
One of the electrovalves EV coil is shorted.
Troubleshooting:
Check if there is a short or low impedance between the negative of the EV coil
and +BATT. Otherwise the controller is damaged and it must be replaced.
16) “DRV. SHOR. EV1”

Cause:
Electrovalve EV1 driver is shorted.
Troubleshooting:
Check if there is a short or a low impedence between the negative of one of
those coils and –BATT. Otherwise the driver circuit is damaged and the
controller must be replaced.

Cause:
Troubleshooting:
Check if there is a short or a low impedance between the negative of this coil
and –BATT. This warning occurs also if the external load is not present and the
parameter EV2 in the “Set Options” menu is set “PRESENT”, in this case the
warning disappears setting the EV2 parameter “ABSENT”. Otherwise the driver
circuit is damaged and the controller must be replaced.

Cause:
Troubleshooting:
Check if there is a short or a low impedance between the negative of this coil
and –BATT. This warning occurs also if the external load is not present and the
parameter EV3 in the “Set Options” menu is set “PRESENT”, in this case the
warning disappears setting the EV3 parameter “ABSENT”. Otherwise the driver
circuit is damaged and the controller must be replaced.
19) “CONT. DRV. EV”

Cause:
One or more on/off valve drivers is not able to drive the load (cannot close).

Troubleshooting:
The device or its driving circuit is damaged, replace the controller.
20) “PUMP I NO ZERO”

Cause:
In standby condition (pump motor not driven), the feedback coming from the
current sensor in the pump chopper gives a value out of a permitted range,
because the pump current is not zero.
Troubleshooting:
21) “PUMP I=0 EVER”

Cause:
This test is carried out when the pump motor is running, and it verifies that the
current feedback sensor is not constantly stuck to 0.
Troubleshooting:
A) Check the motor connection, that there is continuity. If the motor connection
is opened, the current cannot flow, so the test fails and the error code is
displayed.
B) If everything is ok for what it concerns the motor, the problem could be in
the current sensor or in the related circuit.
22) “CONT. DRV. EV1”

Cause:
The EV1 valve driver is not able to drive the load (cannot close).
Troubleshooting:

Cause:
Troubleshooting:

Cause:
Troubleshooting:
25) “PUMP VACC NOT OK”

Cause:
The minimum of the lift potentiometer is not correctly set.
Troubleshooting:
It is suggested to repeat a “PROGRAM VACC” procedure.
26) “SENS. MOT. TEMP. KO”

Cause:
A) The motor temperature sensor is not correctly connected to D3.
B) The motor temperature sensor is damaged.
Troubleshooting:
- Check the correct connection of the motor temperature sensor.
- If the current sensor is correctly connected, replace it.
- If the problem persist, it is due to the controller.

27) “VACC OUT RANGE”
Cause:
The voltage on CNC#4 is outside of the parameters’ range.
Troubleshooting:
Please re-acquire the VACC parameters with a PROGRAM VACC procedure.
28) “STALL ROTOR”

Cause:
The traction rotor is stuck or the encoder signal is not correctly received by the
controller.
Troubleshooting:
Please check if the sign of FREQUENCY and ENCODER on the tester menu
are the same and different than zero during a traction request.
29) “EVP DRIVER OPEN”

Cause:
The EVP driver is damaged or the EVP coil impedance is too law.
Troubleshooting:
Please check the EVP coil impedance.
If the EVP impedance is OK, the problem is inside the controller.
30) “MANY PUMP REQS”

Cause:
More than one pump functions were requested at the same time.
Troubleshooting:
Just one pump function at a time can be requested. Please reset all the
requests and try again.
31) “PUMP INC START”

Cause:
This is a warning for a pump incorrect starting sequence.
Troubleshooting:
The possible reasons for this alarm are:
A) Pump request active at keyon.
B) Pump request active without man presence.
Check the wirings. Check the micro-switches. It could also be an error
sequence made by the operator. A failurw logic is possible too. When all of the
above conditions were checked and nothing was found, replace the controller.
32) “PUMP VACC RANGE”

Cause:
The voltage on CNC#9 is outside of the parameters range.
Troubleshooting:
If the EVP TYPE parameter is set to ANALOG, please acquire again the values
of MIN LOWER and MAX LOWER.
If the controller is in Combiacx configuration and the PROPORTION. LIFT
parameter is set to ON, please acquire again also the values of MIN LIFT and
MAX LIFT.
33) “PARAM RESTORE”

Cause:
This warning appears when the controller restored the default values.
Troubleshooting:
If a CLEAR EEPROM was mode before the last keyon-recycle, this warning just
means that the EEPROM was correctly cleared. A travel demand or a pump

request cancel the alarm.
If this alarm appears at keyon without any CLEAR EEPROM request by the
operator, there could be a problem inside the controller.
34) “WAIT MOT.P. STILL”

Cause:
If TRUCK TYPE option is set to LEVEL = 1, the software expects the voltage on
–P output to be at a “steady state” value, before switching the LC on.
If the voltage is different, it could be due to the fact that the motor connected to
–P is not still. For this reason, the software waits 30 seconds for the voltage to
be at the “steady state” value (and for the pump motor to be still).
After this time, the software assumes that the problem is not due to the fact that
the pump motor is not still, and show the “PUMP VMN NOT OK” alarm (see in
the alarms chapter).
Troubleshooting:
If the motor connected to –P is still moving, just wait for it to be still.
If not, in 30 seconds the alarm “PUMP VMN NOT OK” will appear. Please see
the alarms chapter.

13 RECOMMENDED SPARE PARTS
Part number Description
C29508 SW 180 24V Single Pole Contactor
C29522 SW 180 48V Single Pole Contactor
C12359 Connector Minifit 6 pins Female
Part number Description Version
C16604 Protected 100A strip fuse ACEX 36/48V
C16529 Protected 125A strip fuse ACEX 24V
C16502 Protected 160A strip fuse

ACEX PW 24/36/48V
C16591 Protected 175A strip UL fuse

COMBIACX 24/36/48V

COMBIACX PW 24/36/48V
C16520 10A 20mm control circuit fuse All

14 PERIODIC MAINTENANCE TO BE
REPEATED AT TIMES INDICATED
Check the wear and condition of the Contactors’ moving and fixed contacts.
Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that
there is no electrical resistance between the contacts by measuring the volt drop
between the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the inverter, and cables to the motor. Ensure the
insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller. Are the return springs ok. Do
the potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be free
to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement parts
used should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the
diagrams included in this Manual. Any variations or special requirements should be
made after consulting a Zapi Agent. The supplier is not responsible for any problem
that arises from wiring methods that differ from information included in this Manual.
During periodic checks, if a technician finds any situation that could cause damage
or compromise safety, the matter should be bought to the attention of a Zapi Agent
immediately. The Agent will then take the decision regarding operational safety of
the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
U IMPORTANT NOTE ABOUT WASTE MANAGEMENT:

This controller has both mechanical parts and high-density electronic parts
(printed circuit boards and integrated circuits). If not properly handled during
waste processing, this material may become a relevant source of pollution.
The disposal and recycling of this controller has to follow the local laws for
these types of waste materials.
Zapi commits itself to update its technology in order to reduce the presence of
polluting substances in its product.

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ELECTRONIC • OLEODYNAMIC • INDUSTRIAL

is a registered trademark property of Zapi S.p.A.

4 The symbol aboard is used inside this publication to indicate an annotation or a

U The symbol aboard is used inside this publication to indicate an action or a

Page - 2/81 AFCZP0BB- COMBIACX & ACEX - User Manual

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 3/81

COMPANY FUNCTION INIZIALS SIGN

SALES MANAGER VISA

Publication N°: AFCZP0BB

Page - 4/81 AFCZP0BB- COMBIACX & ACEX - User Manual

- Controller for AC 600W to 2 kW AC motors;

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 5/81

2.1 Technical specifications COMBIACX / ACEX

4 Note(1): The DC chopper specifications are related to COMBIACX only

2.2 Technical specifications COMBIACX Power / ACEX Power

4 Note(1): The DC chopper specifications are related to COMBIACX only

Page - 6/81 AFCZP0BB- COMBIACX & ACEX - User Manual

2.3.2 Pump control

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 7/81

3.1 Digital inputs

3.2 Analog unit

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3.3 Other analogue control unit

3.4 Analog motor thermal sensor input

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 9/81

Page - 10/81 AFCZP0BB- COMBIACX & ACEX - User Manual

U These are Warning boxes, they describe:

4.1 Material overview

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 11/81

4.2 Installation of the hardware

4.2.1 Positioning and cooling of the controller

CONTROLLER WITH FINNED HEATSINK: Sometimes the base plate installation

4.2.3 Wirings: CAN connections and possible interferences

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 13/81

The red lines are can wires.

Note: Module 1 power > Module 2 power > Module 3 power

Page - 14/81 AFCZP0BB- COMBIACX & ACEX - User Manual

Note: Module 1 power ≈ Module 2 power > Module 3 power

4.2.4 Wirings: I/O connections

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 15/81

D2 +5V / +12V positive of encoder power supply.

Page - 16/81 AFCZP0BB- COMBIACX & ACEX - User Manual

4.2.7 Insulation of truck frame

U As stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7,

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 17/81

Page - 18/81 AFCZP0BB- COMBIACX & ACEX - User Manual

U ZAPI controllers are designed according to the EN13849-1 specifications for

U EMC and ESD performances of an electronic system are strongly influenced

AFCZP0BB – COMBIACX & ACEX - User Manual Page - 19/81

4) EMISSIONS. Three ways can be followed to reduce the emissions:

A) SOURCE OF EMISSIONS: finding the main source of disturb and work on

5) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are

6) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent

A) PREVENTION: when handling ESD-sensitive electronic parts, ensure the

Page - 20/81 AFCZP0BB- COMBIACX & ACEX - User Manual

4.5 Various suggestions