Cat NSP10 1214 16N2 NSP12 14 16N2R NSP12 14 16NI NSP12 14 16NIR NSP16NS NSP16NSR O&M Manual

EN

Operation & Maintenance Manual NSP10/12/14/16N2 NSP12/14/16N2R NSP12/14/16NI NSP12/14/16NIR NSP16NS NSP16NSR

MCFE Hefbrugweg 77, 1332 AM Almere, The Netherlands

SWHSU - 00310

Copyright © 2007 MCFE. All rights reserved.

Printed in Finland

SWHSU - 00310

614743 EN 06/2013 - Original instructions

1. Truck ................................................................................. 3 2. Safety instructions ............................................................ 4 3. Operating environment ..................................................... 7 4. Operating devices ............................................................. 9 5. Driving instructions ......................................................... 18 6. Load handling ................................................................. 24 7. Batteries ......................................................................... 26 8. Maintenance ................................................................... 30 9. Service ............................................................................ 32 10. Transportation and storage ............................................. 35 11. Troubleshooting and alarms ........................................... 37 12. Technical specifications .................................................. 38 13. EC Declaration Of Conformity ........................................ 61

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1. Truck General Information Warehouse trucks are designed and manufactured to lift and transport materials indoors. Please read this manual before operating or performing maintenance on the truck. After reading this manual, store it in a safe, dry place for later use.

The truck conforms to the EN ISO 3691-1 standard, ensuring its safety according to the EU machine directive 2006/42/EC. The most important regulations and guidelines are mentioned in these instructions. As regulations vary from country to country, we expect you to familiarize yourself with the regulations and standards valid in your country.

For further information on trucks or training, please contact our sales organization.

A truck may cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions. To order more copies of the instruction book, contact your dealer.

Electromagnetic compatibility The truck conforms to the EN 12895 standard, ensuring its safety according to the EMC directive 2004/108/EC. The truck is designed for light and heavy industry use (EN 50081-1 and EN 50082-2).

WARNING! Do not make any modifications to the electric devices in the truck without the manufacturer's expressed permission. Modifications to electric devices may affect the electromagnetic compatibility and, therefore, reduce operational safety.

Non-ionising radiation The truck itself does not emit non-ionising radiation. Auxiliary devices like radio transmitter, RFID reader and data collection system may produce non-ionising radiation which can cause harm to persons, in particular persons with active or non-active implantable medical devices. If those auxiliary devices are installed by the user, the user itself shall ensure that the supplier's instructions are fulfilled and no harm for the persons has risen.

NOTE Where trucks are fitted with non-ionising radiation devices, warning signs shall be installed to the truck and supplier's instructions attached to the instruction manual.

Delivery Before shipping, each truck is inspected carefully to make sure that the truck you receive is flawless and fully equipped. Nevertheless, check the truck immediately after receiving it for any damages that may have occurred during shipping.

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2. Safety instructions Instructions for site supervision • • •

Familiarise yourself with the operating instructions and their contents Train the operator on the use, safety and maintenance aspects of the truck Control that the operating and maintenance instructions, and safety regulations are observed

Occupational safety • • • • • • •

Keep the truck clean and in good working order. Carry out the daily and weekly maintenance checks in accordance with the maintenance instructions and schedule to avoid faults and operational errors.

If you notice any faults or deficiencies that may effect the safe operation of the truck, take the truck out of operation until the faults or deficiencies have been remedied In the event of a malfunction, switch off the power and notify the site supervision.

Do not repair anything on the truck without the permission from the site supervision When using the truck, you are responsible for both your own and your environment's safety Immediately notify the site supervision of any accidents or injuries. In such a case, leave the truck at the place of the accident The truck can only be used for purposes corresponding with its equipment.

Truck operator Requirements: • • • • •

At least 18 years old Sufficient physical (e.g. good hearing and sight) and mental abilities for operating the truck without risks Appropriately trained; familiar with operating, safety and maintenance instructions Has permission from the site supervision to operate the truck Knows and masters the drive and operational features of the truck.

Emergency procedures If the truck falls over, hold onto the steering wheel and warn others. If the machine malfunctions, brake and switch off the power. The truck must not be used again, until a person authorised by the supervisor has repaired the truck.

Noise The average noise level (LpA) to which the driver may be subjected has been measured at the driver’s ear as per standards EN 12053:2001 and EN ISO 4871. The measured values are listed in Chapter 12, Technical Specifications, section 8.4 in this manual.

NOTE Higher sound pressure levels may occur during the truck’s operation, caused by different method of operation, environmental effects and other sources of noise.

Vibration The level of vibration to which the driver is subjected (aw,z ) has been measured as per standard EN 13059:2002.

The measured values are listed in Chapter 12, Technical Specifications, section 8.4 in this manual.

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Work at dangerous premises A standard truck may not be used in an explosive atmosphere. There are specially manufactured trucks for such premises. Contact your truck dealer for a specially designed and equipped trucks for hazardous conditions.

Repairs and structural modifications Do not modify the truck without the manufacturer's express permission. Do not add or remove, weld or bend any parts, as the modifications could affect the operation of the truck and might weaken its construction.

NOTE Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: • • • •

arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; maintain a permanent record of the design, test(s) and implementation of the modification or alteration; approve and make appropriate changes to the capacity plate(s), decals, tags and instruction handbook; affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

Overhead guard and load support (applies only to trucks with mast) Trucks driven sitting or standing that are capable of lifting a load higher than 1.8 m must be equipped with an overhead guard. Modifications to the overhead guard that could possibly weaken its structure are not allowed. If it is possible for objects to fall through the openings in the overhead guard, the size of the openings must be reduced. Trucks used for transporting small objects or unstable loads must be equipped with a load support.

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Legend for warning symbols attached to the truck and used in this manual Note! A truck may cause serious accidents unless you are sufficiently familiar with its operation and unless you know its operating and maintenance instructions.

For more information, see the truck manual.

Familiarise yourself with the truck manual and its contents before operating or servicing the truck.

Do not touch moving parts.

Do not use the truck to lift persons.

Do not walk or stand underneath the truck's raised forks.

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3. Operating environment General Information Use the truck in dry, indoor facilities with substantially firm, smooth, level and prepared surfaces according to standard DIN 15185-1. The truck may be continuously operated at a temperature of +5...+25°C and for short periods at a temperature of 0...+45°C. The recommended humidity is 30...95% (non-condensing). If the operating temperatures differ from those mentioned above, contact your truck dealer and acquire a truck specifically designed for cold and freezing or extremely high temperatures. A special machine for freezing conditions can be used in temperatures down to -35°C. A special machine for hot conditions can be continuously used in temperatures up to + 45 °C. This truck conforms to the requirements of the EU machine safety directive (2006/42/EC) and thus has the CE marking.

Never use the truck: • • • • • • • • •

To transport or lift people At premises with risk of fire (ATEX premises) In explosive atmospheres At premises with insufficient floor load capacity If it is damaged As a mounting surface As an access board or a ladder To tow another truck Under the influence of intoxicating substances.

Free space Make sure that the truck has sufficient moving space with respect to overhead structures. Before driving through aisles or door openings, ensure that there is enough space for the truck, the load and yourself.

NOTE Always drive at a safe distance from the edge of loading platforms or bridges.

Bearing capacity of the floor Make sure that the combined weight of the truck and the load does not exceed the bearing capacity of the floor.

Using elevators You need a permission from the site supervision to use an elevator to transport the truck between floors. Make sure that the combined weight of the truck, the load and yourself does not exceed the maximum load capacity of the elevator. Always drive the truck into elevators and any other narrow spaces with the load in front.

NOTE Do not let other people enter the elevator while driving the truck in or out. The parking brake of the truck must be engaged and power switched off before the elevator starts moving.

Driving on ramps You need a permission from the site supervision to drive on a slope or ramp. The inclination of the ramp should not exceed 10%. We recommend using warning signs in places where this is exceeded.

NOTE All truck types are not suitable for driving on ramps. Make sure that the truck you are using is suitable for this purpose.

WARNING!

Driving trucks with a gradeability of 0% is forbidden on the ramp. RISK OF OVERTURNING!

Observe extreme caution when driving on a ramp. When the truck is loaded, travel with the load pointing uphill.

To ensure steerability and braking, the grip of the ramp must be equivalent to a standard floor.

NOTE Do not turn the tiller arm abruptly on a ramp; the truck might overturn.

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Driving on loading bridges Always check the bearing capacity and the fastening of the bridge before loading or unloading. If you need to drive the truck onto another vehicle, ensure that the vehicle cannot move during this procedure. Do not drive to the edges of a loading bridge because there is always the risk of overturning.

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4. Operating devices General information and intended use The truck is a four wheel pedestrian operated electric stacker, equipped with a multifunctional tiller control for driving, steering and load handling. It is designed to transport and stack pallets on level surfaces.

Identification plates on the truck

Type plate (1) The truck's type plate is marked with: • • • • • • • • • •

Manufacturer Truck type Year of manufacture Serial number Truck weight in operating condition without battery or accessories Battery minimum weight Battery terminal voltage Truck's nominal lifting capacity Nominal power in kW CE mark

Check that the plates are legible and securely attached.

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Capacity plate The capacity plate states the maximum lifting capacity at the maximum lifting height, and the lifting height with the nominal lifting capacity. In addition, the plate states the load centre distance for the relevant lifting capacity.

WARNING! Do not overload!

Safety devices • • • •

Emergency stop button Start button/key switch Parking brake for emergency braking Audible signal horn

See detailed descriptions below.

Operating devices (pedestrian stacker)

• • • • •

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Tiller arm (1) Truck display (2) Emergency stop button and key switch (3) Recharging plug (under the battery cover) (4) Battery locking device (under the battery cover) (5)

Operating devices (platform stacker)

• • • • • •

Tiller arm (1) Truck display (2) Emergency stop button and key switch (3) Operator's stand on platform (4) Recharging plug (under the battery cover) (5) Battery locking device (under the battery cover) (6)

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Control Panel

Emergency stop button (1) Disconnect the truck's power supply by pressing the emergency stop button. Release the button by turning it clockwise. Use the emergency stop button in the following cases: • •

if there is a short circuit or other electrical malfunction, for example, the pump motor will not stop running or if an accident happens.

Key switch (2)

The key switch switches on the truck's electrical system: • • •

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1 = Power off (power may be still connected to certain electronic devices) 2 = Power on, economy mode (lower energy comsumption and deceleration) The "ECO" symbol is shown in the multi-function display (alternative).

3 = Power on, standard mode

Truck display (3) There are two display versions available: Led display

The device displays: •

Level of battery charge

Green: 70—100% (1) Yellow: 40 —70% (2) Red: 20—40% (3) Slowly flashing red: 0—20% (battery empty, recharge immediately) (4) •

Fault codes Fashing red: alarm Flashing yellow: warning If a fault code is displayed, contact maintenance personnel for assistance.

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Multi-function display (alternative)

The device displays: • • •

•

•

Level of battery charge (1) Indication of operational hours (2) System messages (2) ECO = Economy mode selected. For further information, see chapter "Key switch".

Lo SPd = Low speed mode selected. For further information, see chapter "Tiller arm".

Fault codes (2) Numeric code: alarm/warning If a fault code is displayed, contact maintenance personnel for assistance.

LED (3) Flashing red: alarm If a fault code is displayed, contact maintenance personnel for assistance.

WARNING!

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Do not step on the truck! FALLING HAZARD!

PIN code entry device (optional)

PIN code entry device can be used to activate the truck. For more information, see section "Using the PIN code entry device" in chapter 5, "Driving instructions".

Brakes Service brake The truck has an electric service brake for reducing the driving speed. Braking is carried out by the truck's speed control system. During braking the driving motor runs as a generator which output energy is restored into the battery.

To brake turn the accelerator to the opposite direction or release it to neutral.

• •

When you change the driving direction, the braking level is adjustable. Use the accelerator to set it suitable.

When you release the accelerator, the braking level is not adjustable. Contact service man to set the release braking level suitable.

NOTE

Practice braking with and without load in a safe area before you start working with the truck.

WARNING!

Do not left your foot under the truck while the truck is moving. It may get trapped between the moving truck and the floor. CRUSHING HAZARD!

Parking brake The truck has a parking brake which holds the truck in place. The brake is an on/off-type magnetic brake.

To release the parking brake: •

tilt the tiller arm to driving position and turn the accelerator.

To apply the parking brake: • •

bring the truck to a standstill and the brake will switch on automatically or release the tiller arm to the up position and the truck will stop immediately.

NOTE

Make sure that the brake has been applied before leaving the truck.

Emergency braking While the truck is moving, press the tiller arm to the down position or release it to the up position.

NOTE Emergency braking makes the truck uncontrollable and can cause the drive wheel to wear unevenly.

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Tiller arm

Safety button (1) The safety button prevents you from getting squeezed between the truck and an obstacle.

When you push the safety button, the truck reverses its travelling direction and stops when the button is released.

NOTE Never use the safety button for normal driving. The safety button is disabled when driving on the platform (if available).

Check the operation of the safety button daily before you start working with the forklift truck.

Push buttons for lifting and lowering (2) Push button "up" to lift forks. Push button "down" to lower forks.

Horn (3) Press the button to give an audible warning signal.

Steering (4) The tiller arm turns ± 100 degrees.

Accelerator (5) The accelerator is used for controlling the driving speed and for braking. Use the accelerator with your right or left hand. The more you turn the accelerator, the higher the speed. The accelerator returns automatically to the central position when it is released. Brake smoothly by turning the accelerator to the opposite direction.

NOTE Handle the accelerator gently.

Brake release / slow speed button (6) The button has two functions: •

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Brake release When the tiller arm is in up position, hold the button down to release the parking brake and turn the accelerator to drive the truck in the slow speed mode. Release the button to apply the parking brake.

Tip Use this feature in very narrow places where there is no room to tilt the tiller arm •

Slow speed mode When the tiller arm is in driving position, activate the slow speed mode by pressing the button once. The "Lo SPd" symbol is shown in the multi-function display (optional). Deactivate the slow speed mode by pressing the button once again.

Lever for lifting and lowering (optional) (7) Pull lever "up" to lift forks. Push lever "down" to lower forks.

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5. Driving instructions Daily checks before operation Carry out the daily maintenance check before using the truck. Neglecting daily maintenance may decrease the safety and reliability of the truck. Notify the site supervisor immediately if you notice an error or deficiency during the check.

• • • • • • • • • • • • • •

Check the truck externally to see that there are no oil leaks.

Check all wheels for damage or wear.

Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be about 15 mm above the plates. (Does not apply to maintenance-free batteries.)

Check the gearbox for leaks. Also check the hydraulic pipes, hoses, and connectors. No leaks or damage should be found.

Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks.

Check the operation of the accelerator and steering by driving slowly forward and backward.

Also check the operation of the other electrical functions.

Check that the batteries are charged and locked in place.

Check the operation of the horn.

Check that the emergency stop operates properly.

Check that the safety button works.

Make sure that the tiller arm returns to the up position.

Check that the service brake and the parking brake functions properly.

Check the fastenings of the lifting chain (if available).

Before you start •

Make sure that the daily maintenance has been carried out.

Using the PIN code entry device (optional) The truck may be equipped with an optional PIN code entry device. It can have three different user codes and one master code. The factory pre-programmed code is 2341. Contact service person to program new codes.

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NOTE

It is recommended to program one general code to the unit, so that, in the event of emergency, the truck can be activated and moved also by persons who do not have a PIN code of their own.

To activate the truck, turn the key switch on, enter the PIN code by pressing the number keys (1,2,3,4) and finally press the Enter key (6). If an error occurs, press the Esc key (5) and re-enter the code. After use, turn the key switch off.

The truck display The PIN code device utilizes the truck display. In normal operation, it signals the following: Led display • • •

Yellow flashing: waiting for the PIN code after key switch on.

Red flashing for 2 seconds: incorrect PIN code, re-enter it.

Green flashing for 2 seconds: correct PIN code, truck activated.

Multi-function display • • •

"PIn" flashing: waiting for the PIN code after key switch on.

"888888" flashing for 2 seconds: incorrect PIN code, re-enter it.

"SLOt #" flashing for 2 seconds: correct PIN code, truck activated.

Driver present mode (optional) The PIN code system has an optional feature to prevent unauthorised use. It will automatically switch off the power after a pre-adjustable time (1...30 minutes), if the truck has been left unattended. The factory pre-programmed time is 30 minutes. Contact service person to set the switch off time suitable.

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Driving

• • • •

Tilt the tiller arm to the driving position (tiller arm in position 1, see the picture above).

Turn the accelerator lightly in the driving direction.

To brake, turn the accelerator in the opposite direction to the driving direction.

Steer the truck smoothly because abrupt movements may cause a dangerous situation, especially when driving at high speed.

NOTE

Due to safety reasons, the truck may be adjusted to travel slower to the direction of the forks.

General driving instructions • • • • • • • •

Practice steering and controlling the truck carefully in a safe area.

Drive slowly at intersections and when turning.

Handle the truck responsibly and always keep it under control.

Avoid sudden starts and stops.

Steer and brake smoothly.

Decrease the speed if the floor is slippery, for example, because of humidity.

Take great care when driving on a slanted surface.

Do not drive over any loose objects on the floor.

When driving, keep the load lowered and, if possible, tilted backwards. Do not lift the load except when stacking.

This does not apply to trucks designed to be driven with the load raised.

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Be especially careful: • • •

When there are other people or objects in the working area.

When the load reduces visibility.

When driving in narrow aisles, make sure that there is enough space for the truck and the load.

Driving position Pedestrian mode To drive the truck in the direction of the forks, walk behind the truck and keep both hands on the tiller arm (see the picture below).

To drive in the opposite direction, walk beside the truck and keep one hand on the tiller arm (see the picture below).

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Riding mode (platform stacker) The truck may be equipped with a reversible platform. It can be driven either walking behind the truck (pedestrian mode) or standing on the platform (riding mode).

To drive the truck standing on the platform, lower the platform to the horizontal position. Step on the platform and keep both hands on the tiller arm (see picture above).

When driving, always keep your body completely within the outlines of the truck.

When you step off the platform, it will stay in the horizontal position. To return to pedestrian mode, lift the platform slightly and let the gas spring fold it up.

Speed Control the speed according to the situation. Take into consideration the load, visibility, and people in the working area and the working environment. Slow down at cross aisles and whenever the vision is obstructed. If the visibility is inadequate, use an assistant to help guide you.

Uncontrolled acceleration or braking, excessive speed at turning points, and fast and sudden turning may overturn the load and cause an accident. In all conditions, drive the truck at a speed that enables you to stop it safely.

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Stopping the truck Brake the truck smoothly by turning the accelerator against the direction of travel (tiller arm in position 1). When you release the accelerator, the truck decelerates, and when the truck is completely stopped, the brake is engaged.

You should anticipate a situation when you must brake and decrease the speed well ahead.

When you release the tiller arm to the up position or press it to the down position, the driving circuit breaks and the brake is engaged (tiller arm in position 2).

Parking Park the truck in a reserved parking place. When parking the truck, the forks must be lowered and the parking brake must be on. Ensure that the truck cannot move by itself or that an inexperienced person cannot start driving it under any circumstances.

NOTE Never park or stack goods in front of fire doors, fire extinguishers, emergency exits and the like. Do not park on a slanted surface.

Traffic rules Maintain good visibility in the driving direction and keep sufficient safety distances. Follow the traffic regulations and speed limits.

Do not drive the truck outside a private area without an order or permission from the site supervisor. Outside a private area, the truck is subject to general traffic rules and regulations.

If a door opening is so narrow that two trucks cannot possibly pass through it at the same time, drive in the middle of the opening. When two trucks meet in a narrow or cross aisle, the loaded truck has the right of way.

NOTE When driving, you should sound the horn when necessary to warn others in the same area.

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6. Load handling Only transport a load when it has been loaded safely.

• • • • • • •

Always drive the truck with its forks lowered.

When the load is raised, steer and brake carefully.

Operate all hydraulic functions from the operator's position only. Operation outside of the operator's position is prohibited.

If the truck has side stabilizers, use them when loading and unloading. Raise them when driving.

Do not let anyone, under any circumstances, walk or stand under the forks.

Never place any part of your body between the mast structures or any moving parts of the truck.

When carrying a load larger than the outlines of the truck, take into account the extra space it requires.

Only handle undamaged loads.

Place the load correctly.

When driving the truck on slopes and ramps, • Observe extreme caution.

• Keep the forks and load down.

• Drive straight with the load pointing uphill.

• Drive at a low speed and anticipate other traffic.

•

Do not overload.

• • •

Lifting capacity The lifting capacity of the truck is printed on the capacity plate. Obey the maximum values for load weight and load center information in the different loading situations. Take into account the effect of any attachments on the lifting capacity.

WARNING! Do not exceed the truck's maximum loading capacity under any circumstances, because there is always a risk of overturning.

Pallet handling To load: • • •

Drive towards the pallet with the forks lowered.

Move forward until the forks are completely under the pallet.

Raise the pallet so that it is clearly above the floor level.

To unload: • • •

Stop the truck.

Lower the forks so that they disengage.

Reverse from the unloading location.

WARNING!

Do not overload! CRUSHING HAZARD!

WARNING!

Do not climb onto the truck or racking! FALLING HAZARD!

Stacking and unloading To stack: • • • •

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Drive towards the shelf or stacking level with the load lowered.

Lower the side stabilizers (if available).

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Move forward until the forks and load are on top of the shelf.

• •

Lower the forks so that they disengage, and then reverse from the stacking location. Make sure that the forks are clear of both the stacking level and the pallet. Lower them to the driving position.

Raise the side stabilizers (if available).

To unload: • • • • • • •

Drive towards the shelf or stacking level with the forks lowered.

Lower the side stabilizers (if available).

Raise the forks high enough so that they can freely go underneath the pallet when you drive forward.

Move forward until the pallet is completely on top of the forks.

Raise the load so that it is clearly above the stacking height or shelf level. Note the height of the upper horizontal beam of the shelf.

Reverse from the stacking location so that the load can be freely lowered. Lower the forks.

Raise the side stabilizers (if available).

WARNING!

Do not overload! CRUSHING HAZARD!

WARNING!

Do not climb onto the truck or racking! FALLING HAZARD!

Handling of broken pallets

WARNING!

A broken pallet or an unstable load must never be left on a shelf or stack, but must always be removed.

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7. Batteries Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries must have sufficient protective clothing and eye gear. Battery charging and maintenance areas shall be arranged according to the standard EN 50272-3 Safety requirements for secondary batteries and battery installations. Part 3: Traction batteries.

WARNING! During battery charging gases are evolved from all battery cells that are using aqueous electrolytes. When emitted into the ambient atmosphere an explosive mixture may be created if the hydrogen concentration exceeds 4 % hydrogen by volume in air (lower explosion limit).

• • • • •

•

Do not handle a naked flame in the vicinity of batteries because of a risk of explosion.

Do not smoke when working with batteries.

Do not leave tools or other metal implements on top of the battery. Sparking or a short-circuit may cause the battery to explode.

When batteries are recharged, the cell plugs must be closed firmly to prevent splashing of battery fluid.

Battery fluid is a corrosive acid solution; avoid getting it on your skin or in your eyes. The battery fluid develops explosive gas at the end phase of recharging. Therefore, make sure that the battery has sufficient ventilation (this does not apply to maintenance-free batteries).

Always perform a complete battery charging, as repeated partial charging may reduce the battery life.

Furthermore, a low battery charge status may damage the battery during long-time use.

Opening and closing the battery cover

Open the battery cover (1).

Remove the battery plug.

Perform the battery maintenance.

Fasten the battery plug. Make sure that the battery cables remain completely safe within the frame of the truck.

WARNING! Battery cables may get damaged and cause serious burning hazard if they are left outside of the truck! BURNING HAZARD! 1.

2.

3.

4.

5. Close the battery cover.

WARNING! When closing the cover, do not leave your fingers under the cover! CRUSHING HAZARD!

Recharging the battery Make sure that the charger is the appropriate model (correct battery type and voltage) and that the battery has sufficient ventilation.

1.

2.

3.

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Park the truck in a reserved recharging place.

Switch off the power from the key switch.

Make sure that the charger has been switched off.

4.

5.

6.

Open the battery cover.

Disconnect the battery plug and connect it to the charger.

Switch on the charger.

After recharging 1.

2.

3.

4.

5.

Switch off the charger.

Disconnect the battery connector from the charger. Grab the plugs; do not pull the cables.

Check the battery according to the battery manufacturer's maintenance instructions.

Fasten the battery plug. Make sure that the battery cables remain completely safe within the frame of the truck.

Close the battery cover.

Measuring the battery's specific gravity

Measure the specific gravity of the battery fluid according to the manufacturer's instructions. The acid density of a fully charged battery is 1.28 to 1.30 at +30°C. The gravity is ' • • • •

1.24 when the battery is 3/4 charged.

1.20 when the battery is 1/2 charged.

1.16 when the battery is 1/4 charged.

1.15 when the battery is empty. Charge the battery immediately.

Acquiring a new battery When acquiring a battery for the truck, pay attention to the following sections of the standard EN 1175-1: • •

5.1 Traction batteries (includes the requirements for the protective cover of the battery case, ventilation and interior surface treatment) 7.4 Minimum markings (includes the requirements specified on the truck battery plate).

The battery plate should provide at least the following information: • • • • • •

Manufacturer Type Serial number Nominal voltage Capacity (Ah / 5h) Service weight.

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Replacing the battery Replace the battery according to the manufacturer's instructions. When reinstalling batteries, use the appropriate tools for moving, connecting and fastening the battery securely. Do not keep the tools or other metal implements on top of uncovered batteries.

When replacing the battery, use one with similar dimensions and weight so that the stability or braking properties of the truck are not weakened. The minimum weight of the battery is indicated on the identification plate of the truck. Make sure that the capacity of the lifting device is sufficient.

When you use a lifting device for lifting the battery, place a non-conductive plate on top of the battery to avoid the risk of a short circuit. This is not necessary if the lifting device has sufficient insulation and is equipped with a distributor, or if the pole shoes and cell combinations are fully protected.

1.

2.

3.

4.

5.

6.

7.

8.

9.

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Open the battery cover.

Remove the battery plug.

Uninstall the locking device (1) with 6 mm hex key.

Attach self-locking lifting hooks (size 5/6) to the lifting points (2).

Lift up the battery.

Insert a new battery (verify the battery type and voltage).

Install the locking device (1) with the hex key.

Fasten the battery plug. Make sure that the battery cables remain completely safe within the frame of the truck.

Close the battery cover.

Battery charging with an inbuilt charger (optional) Before charging, turn the key switch off. The mains plug of the charger can be found underneath the battery cover. To activate the charger, extract the mains plug and insert it into the correct mains outlet (230 V ±10% / 50 Hz). After activating the charger, charging process starts automatically.

The charging phase is indicated with two indicator lights - yellow (1) and green (2): • • • • •

Solid yellow: power on (3) Flashing yellow: a fault in the charging system (4) Flashing green: charging phase (5) Slowly flashing green: equalizing phase (6) Solid green: fully charged (7)

The charger will stop automatically after the charging is complete and you can unplug the mains plug and put it back into the truck.

If there is a fault in the charging system, the charging process is stopped automatically. Unplug the mains plug and contact maintenance personnel for assistance.

NOTE While the plug is connected to the mains outlet, all electrical functions will remain switched off and the truck cannot be used.

NOTE

If the battery type is changed from lead-acid battery to maintenance-free battery (or vice versa), remember to change the type setting of the battery charger accordingly (0: lead acid, 1:maintenance-free). The type selector can be found in the bottom of the inbuilt charger.

WARNING!

No inflammable materials are allowed within two meters of the truck under charge or the charger. RISK OF FIRE!

29

489465

8. Maintenance Only adequately trained truck operators and servicepersons are allowed to carry out the daily and weekly check-up.

The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

Safety instructions for maintenance • • • • • • • • • •

Keep the service area clean. Oil, grease, and water make the floor slippery.

Remove all rings, watches and other metal jewellery. If a metal object gets into contact with an electrically conductive part, a short-circuit or burn may result.

Switch off the truck's power before opening the cover of the motor or the electrical system.

Release the hydraulic pressure before opening the system.

Dismount the seat for the duration of service work (applies only to sit-on trucks).

Do not use your hands to check for oil leaks.

Remember that the surfaces of the hydraulic system and the motors may be hot.

Only use clean oil in the hydraulic system.

When welding, always disconnect the battery and the electronic devices. Remove paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

The truck must always be supported on jacks if someone needs to work underneath it.

WARNING!

Do not make any alterations or repairs that can weaken the truck’s structure or endanger safety.

Daily checks • • • • • • • • • • • • • •

30

Check the truck externally to see that there are no oil leaks.

Check all wheels for damage or wear.

Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface should be about 15 mm above the plates. (Does not apply to maintenance-free batteries.)

Check the gearbox for leaks. Also check the hydraulic pipes, hoses and connectors. No leaks or damage should be found.

Switch on the power and test the operation of the lifting hydraulics by raising and lowering the forks.

Check the operation of the accelerator and steering by driving slowly forward and backward.

Check also the operation of the other electrical functions.

Check that the batteries are charged and locked in place.

Check the operation of the horn.

Check that the emergency stop operates properly.

Check that the safety button works.

Make sure that the tiller arm returns to the up position.

Check that the service brake and the parking brake functions properly.

Check the fastenings of the lifting chain (if available).

Weekly maintenance • • • • • • • • • • •

Check and clean the battery cable fastenings.

Ensure that the air holes of the battery cell plugs are not plugged up (does not apply to maintenance-free batteries).

Clean the batteries with a dry rag.

Check that the hydraulic system has no leaks.

Check the hydraulic oil level in the oil tank. Add if necessary.

Check that all the screws, nuts, and pipe connections are tight.

Check that the fastening bolts of the driving wheel are tight.

Check that the information plates and labels are fastened securely and are fully legible.

Clean the truck if necessary.

Check the length of the lifting chains. When the carriages are level with the mast, the chains should be slightly loose. Adjust if necessary. (Does not apply to pallet trucks.)

Apply a thin layer of lubrication on the mast's guide surfaces.

NOTE

Do not let water onto the electrical devices.

31

614748

9. Service Only adequately trained servicepersons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.

It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorised and efficient maintenance service.

Opening the covers

Open two mounting screws (1) and remove the machinery shield (2).

Open two mounting screws (3) and remove the instrument panel (4).

Semi-annual inspection service (or 600 h) Check and, if necessary, adjust or repair: • • • • • • • • • •

Connections of the drive motor and pump motor.

Operation of the accelerator.

Operation of the microswitches or inductive sensors.

Operation of the contactors and solenoids.

Cables.

Tiller arm gas spring.

Function of the lift cylinder.

Play of the fork carriage, and the slope of the forks and their condition.

Air gap in the brake: 0.2 mm when new, maximum gap 0.6 mm.

Clean the truck of dirt and debris inside and outside.

Annual maintenance (or 1200 h) •

32

Change the hydraulic oil.

Hydraulic oil recommendations: • • • •

Normal operating conditions: ISO VG 32.

Cold storage: ISO VG 15.

Hot temperatures: ISO VG 46 Fill tank up to the volume of ¾.

Filling hole for hydraulic oil (1)

Transmission lubricant recommendation •

None.

NOTE

There is no need to change the lubricant during the truck's lifetime.

Additional maintenance work for service personnel • • • • • •

Clean the oil filter.

Check the operation of the hydraulics and the pressure relief valves.

Check the fastening of the gearbox.

Check the fastening of the tiller arm.

Check the condition of the side castor wheels and load wheels.

Check the wear of the drive wheel: • Drive wheel diameter is 230 mm when new • Wearing of the drive wheel must be compensated with the adjustment of the caster wheel so that the truck always stands upright.

• Drive wheel has to be replaced when its diameter is 218 mm.

33

Location of fuses in el-panel

1F1

10A

Line contactor fuse (2)

3F1

10A

Control circuit fuse (2)

4F1

10A

Working lights fuse (optional) (2)

5F1

300A

Drive/pump motor fuse (1)

6F1

10A

Power output fuse (optional) (2)

NOTE

The tightening momentum of the fuse (1) terminals is 4.5 ±1 Nm.

Ordering spare parts When ordering spare parts, always contact your dealer or the maintenance centre. Only use original spare parts.

To ensure that you receive the correct parts, include the following information in the order: 1.

2.

3.

4.

5.

Truck type Serial number of the truck Order number of the part Name of the part Number of parts ordered.

The truck's type and serial number are listed on the front page of the manual or on the identification plate of the truck. The order number and name of the parts are listed on the spare part pages of the manual supplied with the truck.

Hazardous waste and disposal Hydraulic and transmission oil, as well as batteries are hazardous waste that must be disposed of accordingly.

The truck itself is not hazardous waste, and can be recycled.

34

614749

10. Transportation and storage Transportation Lifting the truck

The truck can only be lifted from a marked position. Make sure that the capacity of the lifting device is sufficient.

NOTE If the truck has more than one lifting position, all of the positions must be used during lifting the truck.

35

Tying the truck

Tie the truck for transportation as shown in the picture above. Block all the wheels to prevent the truck from moving.

Towing the truck. The truck can only be towed with its drive wheel raised from the floor.

Storage If the truck is not used for a lengthy period of time, it should be stored in a cool (above 0°C) and dry place on an even surface. Before storage, complete the following: • • •

Charge the battery well, and recharge it every 2 or 3 months to prevent damage during storage. At the same time, check the fluid level and add more if necessary.

Change the hydraulic oil if the machine is not used for more than a year.

If the machine is not used for more than a week, support the truck in such a way that the load exerted on the drive wheel becomes lighter.

Returning the truck to operation. If the truck has been stored for several months, it must undergo maintenance as per 600 operational hours. Otherwise normal daily maintenance and inspection are sufficient.

36

492501

11. Troubleshooting and alarms Troubleshooting Symptom

Fault

Action

Truck does not move

Recharging plug is unplugged.

Plug in the recharging plug.

Battery is empty.

Recharge the battery.

Incorrect start.

Release the tiller arm and recycle the key switch.

Emergency stop button is activated. Release the emergency stop button.

Lift pump does not run

Lifting functions improperly

Battery does not charge

Key switch is faulty.

Replace the switch.

Contact maintenance personnel.

Drive motor fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Control circuit fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Accelerator is faulty.

Contact maintenance personnel.

Pump motor fuse has blown.

Check the connections and cables and replace the fuse.

Contact maintenance personnel.

Load handling switch is faulty.

Replace the switch.

Contact maintenance personnel.

Control unit is faulty.

Contact maintenance personnel.

Overload.

Reduce the load.

Battery is empty.

Recharge the battery.

Not enough oil in tank.

Add oil.

Oil leak.

Check the joints and seals.

Contact maintenance personnel.

Pump is faulty.

Contact maintenance personnel.

Dirt or wear in valves.

Contact maintenance personnel.

Charger is incorrectly connected.

Check the connection.

Charger fuse has blown or main voltage is missing.

Check the connections and cables and replace the fuse.

Contact maintenance personnel

Battery cell’s water level or specific gravity is low.

Check the cell voltages and specific gravity. Add water and/or acid when necessary. See section "Recharging the Battery" in chapter 7.

37

614750

12. Technical specifications 1

IDENTIFICATION

1.2 Model

Pedestrian stacker 1000

Pedestrian Pedestrian Pedestrian stacker 1200(i) stacker 1400(i) stacker 1600(i)

1.3 Power source

Battery

Battery

Battery

Battery

Pedestrian

Pedestrian

Pedestrian

Pedestrian

1000

1200

1400

1600

1.4 Operating mode 1.5 Nominal capacity/load

Q [kg]

1.6 Load centre

c [mm] 600

600

600

600

1.8 Load wheel axle to fork face (forks lowered)

x [mm] 625

625 (925)

625 (925)

625 (925)

1.9 Wheelbase (forks lowered)

y [mm] 1141

1141 (1551)

1205 (1615)

1205 (1615)

2.1 Truck weight (without load and battery)

[kg]

1817

2402 (2549)

2618 (2795)

2822 (2993)

2.2 Axle loadings (with load and battery), drive/load side

[kg]

739/1078

826 (1178)/1576 (1371)

807 (1239)/1811 (1556)

811 (1275)/2011 (1718)

607/210

820 (954)/382 834 (982)/384 834 (982)/384 (395) (413) (413)

Vul/Vul

Vul/Vul

Vul/Vul

Vul/Vul

2

WEIGHTS

2.3 Axle loadings (without load/with [kg] battery), drive/load side 3

WHEELS AND TYRES

3.1 Tyres, material (R=rubber, U=Urethan, Vul=Vulkollan, P=Power Thane) Drive / Load side 3.2 Drive wheel dimensions

[mm]

230x70

230x70

230x70

230x70

3.3 Load wheel dimensions

[mm]

85x90

85x90

85x75

85x75

3.4 Castor wheel dimensions

[mm]

125x60

125x60

125x60

125x60

1+1x/2

1+1x/2

1+1x/4

1+1x/4

3.5 Number of the wheels (x=driven) drive/load side 3.6 Track width (centre of tyres), drive side

b10 [mm]

517

517

517

517

3.7 Track width (centre of tyres), load side

b11 [mm]

385

385

385

385

38

4

DIMENSIONS

4.2 Lowered mast height (see tables)

h1 [mm]

2235

2385(2490)

2385(2490)

2385(2490)

4.3 Free lift (see tables)

h2 [mm]

115

-

-

-

4.4 Lift

h3 [mm]

3215

5315(5310)

5315(5310)

5315(5310)

4.5 Raised mast height (see tables) h4 [mm]

3800

5940(6045)

5940(6045)

5940(6045)

4.6 Initial lift

h5 [mm]

-

(115)

(115)

(115)

4.9 Height of the tiller arm in travel position (min./max.)

h14 [mm]

1050/1372

1050/1372

1050/1372

1050/1372

4.15 Fork height, fully lowered

h13 [mm]

85

85(90)

85(90)

85(90)

4.19 Overall length

l1 [mm] 1834

1834 (1943)

1898(2007)

1898(2007)

4.20 Powerhead length to face of forks

l2 [mm] 686

686(795)

750(837)

750(837)

4.21 Chassis (overall width)

b1/b2 [mm]

800

800

800

800

4.22 Fork dimensions (thickness/width/length)

s/e/l [mm]

56/186/1150

56/186/1150

56/186/1150

56/186/1150

4.24 Forkcarriage width

b3 [mm]

752

752

752

752

4.25 Outside width over forks

b5 [mm]

570

570

570

570

4.32 Ground clearance, centre of wheelbase (forks lowered)

m2 [mm]

20

20

20

20

4.33 Working aisle width (Ast3), pallet Ast3 1000x1200, load lengthwise [mm]

2158

2158 (2259)

2222(2323)

2222(2323)

4.33 Working aisle width (Ast), pallet Ast 1000x1200, load lengthwise [mm]

2345

2345 (2555)

2409(2619)

2409(2619)

4.34 Working aisle width (Ast3), pallet Ast3 800x1200, load lengthwise [mm]

2158

2158 (2259)

2222(2323)

2222(2323)

4.34 Working aisle width (Ast), pallet Ast 800x1200, load lengthwise [mm]

2283

2283(2469)

2347(2533)

2347(2533)

4.35 Turning radius (forks lowered)

1383

1383 (1784)

1447(1848)

1447(1848)

Wa [mm]

39

5

PERFORMANCE

5.1 Travel speed, laden/unladen

[km/h]

6.0/6.0

6.0/6.0

6.0/6.0

6.0/6.0

5.2 Lifting speed, laden/unladen

[m/s]

0.12/0.26

0.12/0.26

0.12/0.26

0.14/0.27

5.3 Lowering speed, laden/unladen [m/s]

0.35/0.40

0.35/0.40

0.35/0.40

0.35/0.40

5.8 Maximum gradeability, laden/unladen

8/15

8/15

8/15

8/15

Electrical

Electrical

Electrical

Electrical

[%]

5.10 Service brake 6

MOTORS

6.1 Drive motor S2 60 min

[kW]

1.0

1.0

1.0

1.0

6.2 Lift motor S3 kW/%

[kW/%] 2.2

2.2

2.2

3.2

6.4 Battery voltage/capacity (5 hr. rating)

[V/Ah]

24/150

24/250

24/250

24/250

6.5 Battery weight

[kg]

151

212

212

212

Stepless

Stepless

Stepless

Stepless

55

57

67

60/60/41

60/60/41

70/72/41

8

MISCELLANEOUS

8.1 Speed control type

8.4* Noise level, value at operator's [dB (A)] 57 ear EN 12 053:2001 and EN ISO 4871, work cycle LpA Noise level, value at operator's [dB (A)] 60/60/41 ear EN 12 053:2001 and EN ISO 4871, drive/lift/idle LpA

Manufacturer reserves the right to make technical changes. * Uncertainty of 4 dB(A) in section 8.4 ( ) = With initial lift All values are measured with standard configuration; values can vary with different masts.

Ast3=Wa-x+l6+200 Ast=Wa+R+200

40

Pedestrian stacker 1000 Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1980

1980

1500

D

2500

1775

3000

195

2900

1975

3400

195

3300

2175

3800

195

Pedestrian stacker 1200/1400/1600 Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1950

1950

1500

DS

2500

1835

3000

200

2900

2035

3400

200

3300

2235

3800

200

3600

2385

4100

200

4300

2735

4800

200

2500

1775

2940

1355

2900

1975

3340

1555

3300

2235

3800

1755

3600

2385

4100

1905

4300

2735

4800

2255

4100

1955

4640

-

4300

2020

4840

-

4700

2153

5250

-

5400*

2385

5940

-

4100

1955

4640

1475

4300

2020

4840

1540

4700

2153

5250

1673

5400

2385

5940

1905

DEV

TR

TREV

41

Pedestrian stacker 1200/1400/1600 initial lift Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

2055

2055

1505

DS

2500

1940

1940

200

2900

2140

2140

200

3300

2340

3905

200

3600

2490

4205

200

4300

2840

4905

200

2500

1940

3105

1360

2900

2140

3505

1560

3300

2340

3905

1760

3600

2490

4205

1910

4300

2840

4905

2260

4100

2060

4745

-

4300

2125

4945

-

4700

2153

5345

-

5400*

2490

6045

-

4100

2060

4745

1480

4300

2125

4945

1545

4700

5345

5345

1673

5400*

2490

6045

1910

DEV

TR

TREV

* = only 1400/1600 & 1400i/1600i S=Simplex DS = Duplex with clear view mast DEV = Duplex with full free lift TR = Triplex with clear view mast TREV = Triplex with full free lift h3+h13 = Lifting height h1 = Lowered mast height h4 = Raised mast height h2+h13 = Free lift

42

1

IDENTIFICATION

1.2

Model

Pedestrian stacker 1600 straddle

1.3

Power source

Battery

1.4

Operating mode

Pedestrian

1.5

Nominal capacity/load

Q [kg]

1600

1.6

Load centre

c [mm]

600

1.8

Load wheel axle to fork face (forks lowered)

x [mm]

650

1.9

Wheelbase (forks lowered)

y [mm]

1295

2

WEIGHTS

2.1

Truck weight (without load and battery)

[kg]

2997

2.2

Axle loadings (with load and battery), drive/load side

[kg]

1941/1056

2.3

Axle loadings (without load/with battery), drive/load side

[kg]

945/452

3

WHEELS AND TYRES

3.1

Tyres, material (R=rubber, U=Urethan, Vul=Vulkollan, P=Power Thane) Drive / Load side

3.2

Drive wheel dimensions

[mm]

230x70

3.3

Load wheel dimensions

[mm]

85x75

3.4

Castor wheel dimensions

[mm]

125x60

3.5

Number of the wheels (x=driven) drive/load side

3.6

Track width (centre of tyres), drive side

b10 [mm]

517

3.7

Track width (centre of tyres), load side

b11 [mm]

1025-1425

4

DIMENSIONS

4.2

Lowered mast height (see tables)

h1 [mm]

2385

4.3

Free lift (see tables)

h2 [mm]

-

4.4

Lift

h3 [mm]

5315

4.5

Raised mast height (see tables)

h4 [mm]

5940

4.9

Height of the tiller arm in travel position (min./max.)

h14 [mm]

1150/1350

4.15

Fork height, fully lowered

h13 [mm]

85

4.19

Overall length

l1 [mm]

1967

4.20

Powerhead length (to fork face)

l2 [mm]

817

4.21

Chassis (overall width)

b1/b2 [mm] 800/1140-1575

4.22

Fork dimensions (thickness/width/length)

s/e/l [mm]

40/100/1150

4.24

Forkcarriage width

b3 [mm]

980

4.25

Outside width over forks

b5 [mm]

260-900

4.26

Width between reach legs

b4 [mm]

1015-1450

Vul/Vul

1+1x/4

43

4.32

Ground clearance, centre of wheelbase (forks lowered)

m2 [mm]

20

4.33

Working aisle width (Ast3), pallet 1000x1200, load lengthwise

Ast3 [mm]

2285

4.33

Working aisle width (Ast), pallet 1000x1200 mm, load lengthwise

Ast [mm]

2478

4.34

Working aisle width (Ast3), pallet 800x1200 mm, load lengthwise

Ast3 [mm]

2285

4.34

Working aisle width (Ast), pallet 800x1200 mm, load lengthwise, platform down

Ast [mm]

2415

4.35

Turning radius (forks lowered)

Wa [mm]

1535

5

PERFORMANCE

5.1

Travel speed, laden/unladen

[km/h]

6.0/6.0

5.2

Lifting speed, laden/unladen

[m/s]

0.14/0.27

5.3

Lowering speed, laden/unladen

[m/s]

0.35/0.40

5.8

Maximum gradeability, laden/unladen

[%]

8/15

5.10

Service brake

[s]

Electric

6

MOTORS

6.1

Drive motor S2 60 min

[kW]

1.0

6.2

Lift motor S3 kW/%

[kW/%]

3.2

6.4

Battery voltage/capacity (5 hr. rating)

[V/Ah]

24/250

6.5

Battery weight

[kg]

212

8

MISCELLANEOUS

8.1

Speed control type

8.4*

Noise level, value at operator's ear EN 12 053:2001 and EN ISO 4871, work cycle LpA

[dB (A)]

67

Noise level, value at operator's ear EN 12 053:2001 and EN ISO 4871, drive/lift/idle LpA

[dB (A)]

70/72/41

Stepless

Manufacturer reserves the right to make technical changes. * Uncertainty of 4 dB(A) in section 8.4 ( ) = With initial lift All values are measured with standard configuration; values can vary with different masts.

Ast3=Wa-x+l6+200 Ast=Wa+R+200

44

Pedestrian stacker 1600 straddle Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1950

1950

1500

DS

2500

1835

3000

200

2900

2035

3400

200

3300

2235

3800

200

3600

2385

4100

200

4300

2735

4800

200

2500

1775

2940

1355

2900

1975

3340

1555

3300

2235

3800

1755

3600

2385

4100

1905

4300

2735

4800

2255

4100

1955

4640

-

4300

2020

4840

-

4700

2153

5240

-

5400

2385

5940

-

4100

1955

4640

1475

4300

2020

4840

1540

4700

2153

5240

1673

5400

2385

5940

1905

DEV

TR

TREV

S=Simplex DS = Duplex with clear view mast DEV = Duplex with full free lift TR = Triplex with clear view mast TREV = Triplex with full free lift h3+h13 = Lifting height h1 = Lowered mast height h4 = Raised mast height h2+h13 = Free lift

45

1

IDENTIFICATION

1.2 Model

Platform stacker 1000

Platform Platform Platform stacker 1200(i) stacker 1400(i) stacker 1600(i)

1.3 Power source

Battery

Battery

Battery

Battery

1.4 Operating mode

Pedestrian/ Stand-on

Pedestrian/ Stand-on

Pedestrian/ Stand-on

Pedestrian/ Stand-on

1000

1.5 Nominal capacity/load

Q [kg]

1200

1400

1600

1.6 Load centre

c [mm] 600

600

600

600

1.8 Load wheel axle to fork face (forks lowered)

x [mm] 625

625 (925)

625 (925)

625 (925)

1.9 Wheelbase (forks lowered)

y [mm] 1141

1141 (1551)

1205 (1615)

1205 (1615)

2.1 Truck weight (without load and battery)

[kg]

1817

2442 (2589)

2658 (2835)

2862 (3033)

2.2 Axle loadings (with load and battery), drive/load side

[kg]

779/1078

866 (1218)/1576 (1371)

847 851 (1279)/1811(1556) (1315)/2011 (1718)

647/210

860 (994)/382 874 (395) (1002)/384 (413)

874 (1022)/384 (413)

Vul/Vul

Vul/Vul

Vul/Vul

Vul/Vul

2

WEIGHTS

2.3 Axle loadings (without load/with [kg] battery), drive/load side 3

WHEELS AND TYRES

3.1 Tyres, material (R=rubber, U=Urethan, Vul=Vulkollan, P=Power Thane) Drive / Load side 3.2 Drive wheel dimensions

[mm]

230x70

230x70

230x70

230x70

3.3 Load wheel dimensions

[mm]

85x90

85x90

85x75

85x75

3.4 Castor wheel dimensions

[mm]

125x60

125x60

125x60

125x60

1+1x/2

1+1x/2

1+1x/4

1+1x/4

3.5 Number of the wheels (x=driven) drive/load side 3.6 Track width (centre of tyres), drive side

b10 [mm]

517

517

517

517

3.7 Track width (centre of tyres), load side

b11 [mm]

385

385

385

385

46

4

DIMENSIONS

4.2 Lowered mast height (see tables)

h1 [mm]

2235

2385(2490)

2385(2490)

2385(2490)

4.3 Free lift (see tables)

h2 [mm]

115

-

-

-

4.4 Lift

h3 [mm]

3215

5315(5310)

5315(5310)

5315(5310)

4.5 Raised mast height (see tables) h4 [mm]

3800

5940(6045)

5940(6045)

5940(6045)

4.6 Initial lift

h5 [mm]

-

(115)

(115)

(115)

4.9 Height of the tiller arm in travel position (min./max.)

h14 [mm]

1150/1350

1150/1350

1150/1350

1150/1350

4.15 Fork height, fully lowered

h13 [mm]

85

85(90)

85(90)

85(90)

4.19 Overall length, platform up/down l1 [mm] 1954/2434

1954/2434 (2063/2543)

2018/2498 (2127/2607)

2018/2498 (2127/2607)

4.20 Powerhead length to face of forks

l2 [mm] 806/1286

806/1286 (915/1395)

870/1350 (957/1437)

870/1350 (957/1437) )

4.21 Chassis (overall width)

b1/b2 [mm]

800

800

800

800

4.22 Fork dimensions (thickness/width/length)

s/e/l [mm]

56/186/1150

56/186/1150

56/186/1150

56/186/1150

4.24 Forkcarriage width

b3 [mm]

752

752

752

752

4.25 Outside width over forks

b5 [mm]

570

570

570

570

4.32 Ground clearance, centre of wheelbase (forks lowered)

m2 [mm]

20

20

20

20

4.33 Working aisle width (Ast3), pallet Ast3 1000x1200, load lengthwise, [mm] platform up

2278

2278 (2379)

2342 (2443)

2343 (2443)

4.33 Working aisle width (Ast), pallet Ast 1000x1200, load lengthwise, [mm] platform up

2465

2465

2529 (2739)

2530 (2739)

4.33 Working aisle width (Ast3), pallet Ast3 1000x1200, load lengthwise, [mm] platform down

2758

2758 (2859)

2822 (2923)

2823 (2923)

4.33 Working aisle width (Ast), pallet Ast 1000x1200, load lengthwise, [mm] platform down

2945

2945 (3155)

3009 (3219)

3010 (3219)

4.34 Working aisle width (Ast3), pallet Ast3 800x1200, load lengthwise, [mm] platform up

2278

2278 (2379)

2342 (2443)

2342 (2443)

4.34 Working aisle width (Ast), pallet Ast 800x1200, load lengthwise, [mm] platform up

2403

2403 (2589)

2467 (2653)

2467 (2653)

47

4.34 Working aisle width (Ast3), pallet Ast3 800x1200, load lengthwise, [mm] platform down

2758

2758 (2859)

2822 (2923)

2822 (2923)

4.34 Working aisle width (Ast), pallet Ast 800x1200, load lengthwise, [mm] platform down

2883

2883 (3069)

2947 (3133)

2947 (3133)

4.35 Turning radius (forks lowered)

Wa [mm]

1503/1983

1503/1983 (1904/2384)

1567/2047 (1968/2448)

1567/2047 (1968/2448)

5.1 Travel speed, laden/unladen

[km/h]

6.0/6.0

6.0/6.0

6.0/6.0

6.0/6.0

5.2 Lifting speed, laden/unladen

[m/s]

0.12/0.26

0.12/0.26

0.12/0.26

0.14/0.27

5.3 Lowering speed, laden/unladen [m/s]

0.35/0.40

0.35/0.40

0.35/0.40

0.35/0.40

5.8 Maximum gradeability, laden/unladen

8/15

8/15

8/15

8/15

Electric

Electric

Electric

Electric

5

PERFORMANCE

[%]

5.10 Service brake 6

MOTORS

6.1 Drive motor S2 60 min

[kW]

1.0

1.0

1.0

1.0

6.2 Lift motor S3 kW/%

[kW/%] 2.2

2.2

2.2

3.2

6.4 Battery voltage/capacity (5 hr. rating)

[V/Ah]

24/150

24/250

24/250

24/250

6.5 Battery weight

[kg]

151

212

212

212

Stepless

Stepless

Stepless

Stepless

57

57

67

60/60/41

60/60/41

70/72/41

8

MISCELLANEOUS

8.1 Speed control type

8.4* Noise level, value at operator's [dB (A)] 57 ear EN 12 053:2001 and EN ISO 4871, work cycle LpA Noise level, value at operator's [dB (A)] 60/60/41 ear EN 12 053:2001 and EN ISO 4871, drive/lift/idle LpA

Manufacturer reserves the right to make technical changes. * Uncertainty of 4 dB(A) in section 8.4 ( ) = With initial lift All values are measured with standard configuration; values can vary with different masts.

Ast3=Wa-x+l6+200 Ast=Wa+R+200

48

Platform stacker 1000 Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1980

1980

1500

D

2500

1775

1775

195

2900

1975

1975

195

3300

2175

3800

195

Platform stacker 1200/1400/1600 Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1950

1950

1500

DS

2500

1775

1835

200

2900

1975

2035

200

3300

2085

3800

200

3600

2385

4100

200

4300

2735

4800

200

2500

1775

2940

1355

2900

1975

3340

1555

3300

2235

3800

1755

3600

2385

4100

1905

4300

2735

4800

2255

4100

1955

4640

-

4300

2020

4840

-

4700

2153

5250

-

5400

2385

5940

-

4100

1955

4640

1475

4300

2020

4840

1540

4700

2153

5250

1673

5400

2385

5940

1905

DEV

TR

TREV

49

Platform stacker 1200/1400/1600 initial lift Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

2055

2055

1505

DS

2500

1775

1940

200

2900

1975

2140

200

3300

2340

3905

200

3600

2490

4205

200

4300

2840

4905

200

2500

1940

3105

1360

2900

2140

3505

1560

3300

2340

3905

1760

3600

2490

4205

1910

4300

2840

4905

2260

4100

2060

4745

-

4300

2125

4945

-

4700

2153

5345

-

5400

2490

6045

-

4100

2060

4745

1480

4300

2125

4945

1545

4700

5345

5345

1673

5400*

2490

6045

1910

DEV

TR

TREV

* = only 1400/1600 & 1400i/1600i S=Simplex DS = Duplex with clear view mast DEV = Duplex with full free lift TR = Triplex with clear view mast TREV = Triplex with full free lift h3+h13 = Lifting height h1 = Lowered mast height h4 = Raised mast height h2+h13 = Free lift

50

1

IDENTIFICATION

1.2

Model

Platform stacker 1600 straddle

1.3

Power source

Battery

1.4

Operating mode

Pedestrian/Stand-on

1.5

Nominal capacity/load

Q [kg]

1600

1.6

Load centre

c [mm]

600

1.8

Load wheel axle to fork face (forks lowered)

x [mm]

650

1.9

Wheelbase (forks lowered)

y [mm]

1295

2

WEIGHTS

2.1

Truck weight (without load and battery)

[kg]

3037

2.2

Axle loadings (with load and battery), drive/load side

[kg]

1981/1056

2.3

Axle loadings (without load/with battery), drive/load side

[kg]

985/452

3

WHEELS AND TYRES

3.1

Tyres, material (R=rubber, U=Urethan, Vul=Vulkollan, P=Power Thane) Drive / Load side

3.2

Drive wheel dimensions

[mm]

230x70

3.3

Load wheel dimensions

[mm]

85x75

3.4

Castor wheel dimensions

[mm]

125x60

3.5

Number of the wheels (x=driven) drive/load side

3.6

Track width (centre of tyres), drive side

b10 [mm]

517

3.7

Track width (centre of tyres), load side

b11 [mm]

1025-1425

4

DIMENSIONS

4.2

Lowered mast height (see tables)

h1 [mm]

2385

4.3

Free lift (see tables)

h2 [mm]

-

4.4

Lift

h3 [mm]

5315

4.5

Raised mast height (see tables)

h4 [mm]

5940

4.9

Height of the tiller arm in travel position (min./max.)

h14 [mm]

1050/1350

4.15

Fork height, fully lowered

h13 [mm]

85

4.19

Overall length, platform up/down

l1 [mm]

2087/2567

4.20

Powerhead length (to fork face), platform up/down

l2 [mm]

937/1417

4.21

Chassis (overall width)

b1/b2 [mm] 800/1140-1575

4.22

Fork dimensions (thickness/width/length)

s/e/l [mm]

40/100/1150

4.24

Forkcarriage width

b3 [mm]

980

4.25

Outside width over forks

b5 [mm]

260-900

4.26

Width between reach legs

b4 [mm]

1015-1450

Vul/Vul

1+1x/4

51

4.32

Ground clearance, centre of wheelbase (forks lowered)

m2 [mm]

20

4.33

Working aisle width (Ast3), pallet 1000x1200, load lengthwise, platform up

Ast3 [mm]

2405

4.33

Working aisle width (Ast), pallet 1000x1200 mm, load lengthwise, Ast [mm] platform up

2598

4.33

Working aisle width (Ast3), pallet 1000x1200 mm, load lengthwise, Ast3 [mm] platform down

2885

4.33

Working aisle width (Ast), pallet 1000x1200 mm, load lengthwise, Ast [mm] platform down

3078

4.34

Working aisle width (Ast3), pallet 800x1200, load lengthwise, platform up

Ast3 [mm]

2405

4.34

Working aisle width (Ast), pallet 800x1200 mm, load lengthwise, platform up

Ast [mm]

2535

4.34

Working aisle width (Ast3), pallet 800x1200 mm, load lengthwise, Ast3 [mm] platform down

2885

4.34

Working aisle width (Ast), pallet 800x1200 mm, load lengthwise, platform down

Ast [mm]

3015

4.35

Turning radius (forks lowered), platform up/down

Wa [mm]

1655/2135

5

PERFORMANCE

5.1

Travel speed, laden/unladen

[km/h]

6.0/6.0

5.2

Lifting speed, laden/unladen

[m/s]

0.14/0.27

5.3

Lowering speed, laden/unladen

[m/s]

0.35/0.40

5.8

Maximum gradeability, laden/unladen

[%]

8/15

5.10

Service brake

[s]

Electric

6

MOTORS

6.1

Drive motor S2 60 min

[kW]

1.0

6.2

Lift motor S3 kW/%

[kW/%]

3.2

6.4

Battery voltage/capacity (5 hr. rating)

[V/Ah]

24/250

6.5

Battery weight

[kg]

212

52

8

MISCELLANEOUS

8.1

Speed control type

8.4*

Noise level, value at operator's ear EN 12 053:2001 and EN ISO 4871, work cycle LpA

[dB (A)]

67

Noise level, value at operator's ear EN 12 053:2001 and EN ISO 4871, drive/lift/idle LpA

[dB (A)]

70/72/41

Stepless

Manufacturer reserves the right to make technical changes. * Uncertainty of 4 dB(A) in section 8.4 ( ) = With initial lift All values are measured with standard configuration; values can vary with different masts.

Ast3=Wa-x+l6+200 Ast=Wa+R+200

53

Platform stacker 1600 straddle Lifting mast

h3+h13

h1

h4

h2+h13

S

1500

1950

1950

1500

DS

2500

1835

3000

200

2900

2035

3400

200

3300

2235

3800

200

3600

2385

4100

200

4300

2735

4800

200

2500

1775

2940

1355

2900

1975

3340

1555

3300

2235

3800

1755

3600

2385

4100

1905

4300

2735

4800

2255

4100

1955

4640

-

4300

2020

4840

-

4700

2153

5240

-

5400

2385

5940

-

4100

1955

4640

1475

4300

2020

4840

1540

4700

2153

5240

1673

5400

2385

5940

1905

DEV

TR

TREV

S=Simplex DS = Duplex with clear view mast DEV = Duplex with full free lift TR = Triplex with clear view mast TREV = Triplex with full free lift h3+h13 = Lifting height h1 = Lowered mast height h4 = Raised mast height h2+h13 = Free lift

54

1376 h14 max. h14 min.

h2

h1

h3

h4

Pedestrian stacker 1000/1200/1400/1600

l

m2

12

171

h13

30

s

x

y l1

Wa

a/2

b12

b11 b5

b10

b1

e

l6

a/2 Ast3

55

1376 h14 max. h14 min.

h2

h1

h3

h4

Pedestrian stacker 1200/1400/1600 initial lift

l

171

l2

h13

m2

30

s

x

y l1

Wa

a/2

a/2 Ast3

56

b12

b11 b5

b10

b1

e

l6

1376 h14 max. h14 min.

h2

h1

h3

h4

Pedestrian stacker 1600 straddle

l

m2

12

171

h13

30

s

x

y l1

l6

b4

b11 b2

b5 a/2

b12

b10

b1

e

Wa

a/2 Ast3

57

1390 h14 max. h14 min.

h2

h1

h3

h4

Platform stacker 1000/1200/1400/1600

l

m2

l2

h13

30

h7

s

x

y l1

l6

b11 b5 b12

b10

b1

e

Wa

a/2

a/2 Ast3

58

1390 h14 max. h14 min.

h2

h1

h3

h4

Platform stacker 1200/1400/1600 initial lift

l

h13

l2

m2

30

h7

s

x

y l1

l6

b11 b5 b12

b10

b1

e

Wa

a/2

a/2 Ast3

59

60

b1

a/2

a/2

Ast3 b4

Wa

b11 b2

e

30

h13

m2

l2

b12

b5

b10 h7

s

1390 h14 max. h14 min.

h2

h1

h3 h4

Platform stacker 1600 straddle

l

x

y l1

l6

614751

13. EC Declaration Of Conformity (Directive 2006/42/EC, Annex II A)

Rocla Oy declares that this machine; which has been launched onto the market, meets the requirements set to this machine in the Directive on the Approximation of the laws of the Member States Relating to Machinery (2006/42/EC) and EMC Directive (2004/108/EC); and furthermore declares that the following harmonized standards have been followed: • •

EN ISO 3691-1 - Industrial trucks - Safety requirements and verification.

EN 12895 Industrial trucks - Electromagnetic compatibility.

For the name and address of the person authorized to compile the technical file, see the end of this document.

2012-09-03 Järvenpää, Finland

Tapio Rummukainen Acting Managing Director

Technical Information: ROCLA OY / Henry Tekoniemi P.O. Box 88 FIN-04401 JÄRVENPÄÄ FINLAND

61

12

13

14

SAFETY SWITCH (BELLY)

15

16

19

BW

POT LOW

FW

20

21

22

23

TILLER SWITCH

B2

0-5V B-

B+

com

COLD STORAGE

25

26

27

28

29

30

HORN

BRAKE RELEASE

LIFT / INITIAL LIFT

LOWER / INITIAL LOWER

R2

-

no

COM

S6

R1 WH/

NC

24

R1 + R2 for stacker trucks R1 for pallet trucks.

ACCELERATOR

NO

S3

COM

S4

NO COM

S5

NO COM

COM NO

COM S2.2

XB1/8

3

WH 4

OR 5

BK 6

BN 7

RED/ GRN 1

BN 2

XB2/1

BK 2

X20

BU 3

XT3/

2

1

XT5/

3

4

2

12

11

10

DATE: 2008-09-29

XB4.1/ 2

4

X21 6

5

1

XB4.1/ 1

WH/ BK

XB4.1/ 5

NC GRY

NAME: IR

CHANGE: TILLER SWITCH CONNECTIONS

18

RD B1

S2.1

17

XB4.1/ 3

c ROCLA OYJ 2006

11

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV E

X22

XT1/7

6

5

4

3

2

1

9

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ DESIGN. 2006-09-14 FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

8

15

NAME: JL

14

13

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

XT2/2

NEW TILLER LAVANSIIRTÄJÄT JA PINOAJAT PALLET AND STACKER TRUCKS

3

1

1/2

REV

3-6969

E

c ROCLA OYJ 2006

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

1 SPEED LIFT / 2 SPEED LOWER OR PROPORTIONAL LIFT / LOWER, NOT BOTH IN SAME TRUCK B4

B3 1 SPEED LIFT, 2 SPEED LOWER

2 SPEED LOWER

1 SPEED LOWER

LIFT

B-

LIFT/LOWER

B+

0-2.5-5V B-

B+

BK OR WH/ BK

WH

WH/ BR

GR

XB4/ 5

4

3

2

1

XT4/5

4

3

2

1

GR

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE: 2006-09-14

NAME:

CHANGE:

GRY

DATE: P.O. BOX 88 04401 JÄRVENPÄÄ 2006-09-14 DESIGN. FINLAND CHECK. Tel +358-0-271 471 Fax +358-0-271 47430 APPROV.

NAME: JL

ROCLA OYJ PIIRIKAAVIO CIRCUIT DIAGRAM

TS1150908

NEW TILLER PINOAJAT STACKER TRUCKS

2/2

REV

3-6969

E

ROCLA OYJ 2011

11

12

13

14

15

16

17

18

21

22

23

24

25

26

27

28

29

30

HYDRAULIC COLD STORAGE VALVES & WORKING LIGHT

18

BF

2

1

5F1

c

1

20

A1

K1

POWER OUTPUT

X1/B+

19

300A 2

PUMP MOTOR

2

2

2

1

10A

3F1

1

10A

4F1

1

10A

10A

1F1

1

6F1

+B DRIVE MOTOR

2

M2

V

3

A

J14 7-14

W

M1 W

+

V

U

V1

U

-

C

3

5

4

6

IR 2016-05-11

Capacitor added

XS1/1 XS1.1/1

1 11 EM.STOP

12

XX1

24V G1

XS1.1/ 4 XS1/ 4

X9/

4F1.2 2

S9

KEY

2

1

J6

J8

2-17

4-26

S1

XM1/ 1

XA1_D/6

XM1/ 2

XA1_D/3

XM1/3

XA1_B/1

XM1/4

XA1_B/5

0V TEMP. SENSOR

R31 6

4 5

J16

1 3

2 A2

7-16

Y31 XS1.1/ 2 XS1.1/ XS1/ 2 XS1/

L

NAME: REV

DATE:

CHANGE:

K3

A1

3 3

-P

7-17

X22/ 1

CHARGER CONTROL

J34

X22.1/1

XA1_B/2 XA1_A/12

DI-8 SLOW MODE

XA1_B/6 K3 added when cold storage or work lights installed to the truck

8 K3 1

A2

K1 A1

J2

J4 J18 J20 J26 J27 J28 J32

4-30

4-23

2-16

4-17

4-11

5-28

4-20

2-28

XX3

XA1_C/1 A1 -B 47uF 63V

_

X1/ B-

+

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

XX2

XX25 C1 XX26 DATE: DESIGN. 2011-01-10 CHECK. APPROV.

J33 J29 J25 J21 J7 7-15

2-30

4-21

4-18

NAME: JL

PIIRIKAAVIO CIRCUIT DIAGRAM

TS1340000

2-26

J5

J3

J1

2-17

2-14

4-24

COMBI AC-X CONTROLLER

NSP12-16N2I, NSP12-16N2R AJOPIIRIT DRIVE CIRCUIT

1/9

REV

3-7506

N

A1

CHECK.

APPROV. DATE:

DESIGN. 2010-12-23 RH

PIIRIKAAVIO CIRCUIT DIAGRAM

NAME:

TS1340000

20

A1

H1 A2

PNP

1-24

J7

NSP12-16N2I, NSP12-16N2R AISA JA TULOT 1 TILLER AND INPUTS 1

OPTION: FOR POSSIBLE FUTURE USE

1

BU

28

XS12/ 3

XT2/

BK

27

XS12/ 4

BN

26

XA1_C/ 6

INITIAL LIFT LIMIT

XS12/ 1

25

DI-0 TILLER

J17 3

2

24

XA1_A/7

1

23

DI11

XA1_A/10

4

XT1/

XA1_C/ 9

22

GND

24

10

9

21

CPOTL

J17

XA1_A/11

XS7/ 4

S7

20

DI6

1-16

19

XS7.1/1

XS7.1/4

18

XA1_A/ 5 XS7/1

XS7/3

J6

1-24

BLU

J5

1-21

XS7.2/3

J18 WHT

J3

1-25

XS7.2/1

17

BRN

ROCLA OYJ 2011

16

8

7

6

5

4

2

3

1

Init. lift limit sensor type & pins

c

15

XS7.2/4

IR

2012-08-27

CHANGE:

14

DI7

XA1_C/4

XA1_B/8

NAME:

DATE:

13

CPOTTR

DI4

XA1_B/4

E

REV

12

DI3

DI1

XA1_C/2

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

11 29 30

TILLER

S12 PNP

4 3

A

V8 K

1-24 1-22

J32 J29

+24V 0V

XX14

ZAPI COMBI-AC X PW CONTROLLER

2/9 REV

3-7506

N

ROCLA OYJ 2011

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

c

INITIAL INITIAL LIFT LOWER

26

BRAKE RELEASE

27

28

29

30

HORN

FW

0-5V

B-

B+

24R R1

B3

24R

ENABLE 0-2.5-5V

B-

B+

S4

S5

S3

S6

NO

COM

NO

NO

COM

NO

COM

COM

4

3

S2.1 COM NC S2.2 COM

X20

VT

WH

BN

3

4

BU

BK

OR

6

7

1

XB1/ 8

X21

RD

XT3/ 5

2

BU

GN

BK

RD

4

3

2

1

XT5/

XB4/ 1

5

G2 1

6

5

1

2

XX17

NC

XX16

2

100nF 100V

M

J11 J9 20

14

J9

J24

J13

J11

J22

J24

J13

14

24

27

13

15

15

20

J22 21

XT1/

4

3

2

1

9

8

7

6

XX5

5

4

2

3

1

XX4

10

Accelerator & Lift/lower wiring corrected IR

BW

POT LOW

PROPORTIONAL LIFT/LOWER

R2

ACCELERATOR

2016-08-10

CHANGE:

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE:

NAME:

COLD STORAGE

B1

SAFETY SWITCH (BELLY)

XT2/

DATE: DESIGN. 2011-10-19 CHECK. APPROV.

NAME: EP

PIIRIKAAVIO CIRCUIT DIAGRAM

TS1340000

NSP12-16N2I, NSP12-16N2R AISA JA TULOT 2 TILLER AND INPUTS 2

3/9

REV

3-7506

N

ZAPI COMBI-AC X CONTROLLER

DATE:

DESIGN. 2011-02-02

CHECK.

APPROV. JL

PIIRIKAAVIO CIRCUIT DIAGRAM

0V

NAME:

TS1340000

X30/4

X30.1/ 4

X30.1/ 3

XA10/

XA10/

4

3

2

GND

IN2

IN1

GREEN

YELLOW

RED

LOWER

615689

3

XY1/A1 (M1) A1

A2

Y1

1-21 1-25

J4 J1

+24V 0V

XY1/A2

LIFT/LOWER ENABLE

XY2/A1 (M2) A1

A2

Y2

XY2/A2

NSP12-16N2I, NSP12-16N2R TULOT & LÄHDÖT INPUTS & OUTPUTS

28

XA1_A/2

J25

+24V

XA10/

A10

27

EV3

J28

0V

V+

LED INDICATOR (STANDARD)

26

XA1_A/8

J21

+24V

5-19

25

EV2

J20

+24V

24

XA1_A/ 1

J26

23

EV1

1-23

XA1_B/ 3

1-23

NEVP

1-23

X30/3

XX18

NAUX1

1-22

22

XA1_A/ 9

1-22

J30

X30.1/ 2

+24V

X30/2

2 1

S14

XA10/

1

BU

BATTERY LOCK (OPTION)

XA1_A/ 3

XX21 X30.1/ 1

3

NAUX2

XX20

NPN

21

X30/1

4

20

A10 absent if optional display A7 is installed in the system

1

BK

614785

XS14/ 3

3

19

XS14/ 2

PNP

XA1_A/ 14

S11

DI-12 BATTERY LOCK

PLATFORM DOWN (OPTION)

BN

614785

18

XS14/ 1

17

BU

S10

PLATFORM UP (OPTION)

XS11/ 3

16

BK

BN

15

XS11/ 4

4

XS11/ 1

1

BU

ROCLA OYJ 2011

PNP

XS10/ 3

4 BK

BN

c

609813 NO reed-switch

XS10/ 4

XS10/ 1

XS18.1/ 4

XS18.1/ 1

XS18/ 4

XS18/ 1

XX16->XX18, XX17->XX19, XX20 & XX21 added

CHANGE:

CUTBACK

XA1_A/ 13

IR

NAME:

S18

14

DI-10 PLATFORM DOWN

2013-03-14

DATE:

1

13

XA1_A/ 4

XA1_A/ 6

G

REV

12

DI-5 PLATFORM UP

DI-9 CUTBACK

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

11 29 30

INITIAL LIFT/LOWER ENABLE CONTROLLER

+24V

J8

FAN

1-20 1-20

J2

XX8

5-20

0V

J31 XY3/A1 (M3) A1

A2

Y3

XX19 XY3/A2

X6/1 +

M6

-

X6/2

A1

4/9 REV

3-7506

N

CHECK.

APPROV. DATE:

DESIGN. 2011-02-01 IR

PIIRIKAAVIO CIRCUIT DIAGRAM

NAME:

TS1340000 A1

26

XX10

27

MULTIPURPOSE DISPLAY (OPTION)

1 120R

NSP12-16N2I, NSP12-16N2R CAN-VÄYLÄ, NÄYTTÖ CAN BUS, DISPLAY

XS21/ 2

25

XA1_C/ 7

24

DI-2 CUTBACK

CAN-BUS OUTPUT TO ABBOT2

XS21/ 1

23

XA1_C/5

22

XA1_C/10

21

CANH

CANL

1-23

XAB1.1/8

0V

XAB1/ 8

4-25

+24V

XAB1.1/7

J31

4-22

XAB1/ 7

J30 XAB1.1/6

XA7.1/ 1

XA7.1/ 2

20

XAB1/ 6

120R

19

XAB1.1/5

R3 2 XA7.1/ 3

18

XAB1/ 5

XA7.1/ 4 1

XA7/1

ROCLA OYJ 2011

17

XA7/2

XA7/3

Display unit A10 (refer to page 4) and jumper XA7.1/ are removed if display A7 is installed

X30.1/ 5

1 B-

OR

X30/ 5

2 B+

c

DISPLAY

XA7/4

3 CANH

+

16

X30.1/6

4 CANL

-

X30/ 6

Lift Cut off option

CHANGE:

15

CANL

IR

NAME:

14

X10/ 2

2017-03-30

DATE:

A7

13

CANH

N

REV

12

X10/ 1

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

11 28 29

1

5/9

30

LIFT CUT OFF OPTION

S21 469342 NO reed-switch

2

J27 +24V

XX9 R1 2

ZAPI COMBI-AC X CONTROLLER

CAN-BUS OUTPUT

REV

3-7506

N

ROCLA OYJ 2011

11

12

13

14

15

c

SISÄINEN VARAAJA ON-BOARD CHARGER (OPTION)

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

WORKING LIGHTS (OPTION)

LED INDICATOR

MAINS SOCKET

X9/

1

S20 BRN

RED

SECURITY RELAY

CHARGE STATUS

NO COM

IR

+

+24Vdc 30A -

POWER ON

RED

BLK

2

1 0

2 3

0: 1: 2: 3:

Open lead acid Maitenance free 120-380 Ah Maitenance free 42 Ah Fixed 24 V output

X1

E1

X1

E2 X2

X2

BLK

WHT

A1-B

X22.1/1

A1-B

RED

K1/1

J

2013-06-06

GRN

X22/ 1

L1

Power takeout to page 1

N

85-265Vac 10A-4A

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE:

NAME:

CHANGE:

PE

YEL

1

DATE: DESIGN. 2011-01-28 CHECK. APPROV.

NAME: IR

PIIRIKAAVIO CIRCUIT DIAGRAM

TS1340000

NSP12-16N2I, NSP12-16N2R LISÄVARUSTEET OPTIONAL DEVICES

6/9

REV

3-7506

N

CHECK.

APPROV. DATE:

DESIGN. 2011-10-19 EP

PIIRIKAAVIO CIRCUIT DIAGRAM

NAME:

TS1340000

GRN

X1D1/ 4 XJ1/ 12

GRN

RED

23 24

iBUTTON LED1

BRN

X1D1/ 3

CAN BUS CONNECTION (ON PAGE 5)

XJ1/ 11

ABBOT2 (OPTION)

WHT

GRY

YEL

22

iBUTTON LED2

X1D1/ 2

XJ1/ 4

XX15

X1D1/ 1

XX13

XJ1/ 5

21

iBUTTON 1-WIRE

XX12

iBUTTON GND

XX11

20

XAB1.2/7

1-12

19

XAB1.2/8

1-13

XAB1.2/6

J34

1-22

18

XJ1/ 20

17

CANL

J16

1-13

XAB1.2/5

0V

J33

XJ1/ 19

ENABLE RELAY OUT

XAB1/4

XAB1.2/4

+24V

J14

CANH

XJ1/ 3

XJ1/ 7

ENABLE RELAY IN

XAB1/3

XAB1.2/3

16

ENABLE OUT

KEY SWITCH

XJ1/ 1

XJ1/ 15

0V

XAB1/2

XAB1.2/2

ROCLA OYJ 2011

15

ENABLE IN

SAFETY CHAIN

ABBOT2 XJ1/ 9

c

14

0V

PWR IN 10,8-96V

ABBOT 2

XAB1/1

EP

2011-10-19

CHANGE:

XAB1.2/1

NAME:

DATE:

13

XJ1/ 16

B

REV

12

PWR IN

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

11 25 26 27

NSP12-16N2I, NSP12-16N2R ABBOT 2 ABBOT 2

28 29

7/9

30

OPTION OPERATOR IDENTIFICATION (489349)

iBUTTON

REV

3-7506

N

ROCLA OYJ 2011

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

PIN CODE LOCK (OPTION) Keypad unit

c

VIRRANULOSOTTO 12V / 12,5A AUX. DEVICES SUPPLY 12V / 12,5A

S8 4

XA7.2/

3

4

3

2

1

4F1.2 2

X22 X23

J38

ENTER

J35

9-22

4

J36

+Vin

24V

12V/12,5A

-Vout

XB5/ 1

2

3

XA11_C/ 5

XA11_C/ 8

XA11_C/ 1

XA11_C/ 2

XA11_C/ 3

XA11_C/ 7

XA11_C/ 6

CANL-OUT

CANH-OUT

+KEY

GND

GND

CANH

CANL

XA11_A/ 3 Pin3

XA11_A/ 4 Pin2

XA11_A/ 5 Pin1

XA11_A/ 12 +12V

A1 -B

A11

2

9-23

1

J37 9-20

If truck is equipped with PIN-code lock the connector XA7.3/ is connected with XA7/. Display or jumper is connected to XA7.2/ (refer to page 5/7)

4

H

-Vin

+Vout

3

XA7.3/

9-19

LISÄLAITTEET AUX. DEVICES

EP 2013-04-04

Additions. Layout change

NAME:

1 ESC

G1

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

REV

DATE:

CHANGE:

2

Zapi CAN-encoder card

DATE: DESIGN. 2012-06-20 CHECK. APPROV.

NAME: EP

PIIRIKAAVIO CIRCUIT DIAGRAM

TS1340000

NSP12-16N2I, NSP12-16N2R KOODILUKKO PIN CODE LOCK

8/9

REV

3-7506

N

15

16

17

18

29

30

"Legs out" LED

Vin

1

OUT

C

2

3

4

XB6/

XV2/ C

XH2/2 3

1

View from top

J35 8-30

XA11_A/ 7

8-25

XA11_A/ 6

J38

8-30

2

XA10.1/

3

XA10.1/

Legs out

A11

J37

Legs in

8-25

XA11_A/ 8

J36

Aux

XY2

A2

3

M2

XA1_B/

A1

H2

616611

XX6

2

XY3

7

Connected to LED display connector. LED display unavailable with sidesupport legs option.

A

V2

1

XY4

XA10.1/

Pressure sensor 100bar

Optional Beeper 617036

OUT

615872

S17

S16

XH2/1

Vin

gn

XB7/

K

28

XS17/ 2

bn

S15

XY4/A2

XY1

27

"Legs out" sensor

A2

Valve coils

26

XV2/ A

XS13/ 2 XS18.2/ 4

EP

Y4

wh

XS13/ 1 XY4/A1 A1

2015-03-16

25

XS17/ 1

1

XS18.2/ 1

XH2 changed

CHANGE:

24

XS16/ 2

2

(M4) NAME:

23

"Legs in" sensors

619675 (619640) 2*NO reed-switch

bk

DATE:

22

XS16/ 1

Connected between fuse and 3F1:2

REV

21

S13 3F1.1 3F1.2

This document is property of ROCLA OYJ and is not allowed in any condition to be copied, duplicated, shown or handed over to unauthorized person without written permission by ROCLA OYJ.

20

Height cutback sensor

SWS SIDESUPPORT LEGS (OPTION)

c

19

XS15/ 2

14

XS15/ 1

13

XS13/ 4

12

XS13/ 3

ROCLA OYJ 2011

11

Zapi CAN-Encoder card

DATE: DESIGN. 2012-08-22 CHECK. APPROV.

REV

NAME: IR

PIIRIKAAVIO CIRCUIT DIAGRAM

TS1340000

N 9/9 NSP12-16N2I, NSP12-16N2R LISÄVARUSTEET 2: SIVUTUET OPTIONAL DEVICES 2: SIDESUPPORT LEGS3-7506

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259 e-mail: zapi@zapispa.it – 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 U

Page - 2/81

The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention.

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.

AFCZP0BB- COMBIACX & ACEX - User Manual

Contents 1 2

3

4

5 6

7 8

INTRODUCTION ...................................................................................................................5 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 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 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 OPERATIONAL FEATURES .............................................................................................. 22 5.1 Diagnosis.................................................................................................................. 22 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 DESCRIPTION OF POWER CONNECTIONS .................................................................... 26 DRAWINGS......................................................................................................................... 27 8.1 Mechanical drawing COMBIACX.............................................................................. 27 8.2 Mechanical drawing ACEX ....................................................................................... 28

AFCZP0BB – COMBIACX & ACEX - User Manual

Page - 3/81

9 10

11

12

13 14

8.3 Connection drawing COMBIACX.............................................................................. 29 8.4 Connection drawing ACEX ....................................................................................... 30 ONE SHOT INSTALLATION PROCEDURE ...................................................................... 31 9.1 Sequence for Ac Inverter traction setting ................................................................. 32 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 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 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 RECOMMENDED SPARE PARTS ..................................................................................... 80 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

Page - 4/81

AFCZP0BB- COMBIACX & ACEX - User Manual

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 (electrodistributor) 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

AFCZP0BB – COMBIACX & ACEX - User Manual

Page - 5/81

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

Page - 6/81

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

AFCZP0BB- COMBIACX & ACEX - User Manual

2.3 Block diagrams 2.3.1 Traction control

2.3.2 Pump control

AFCZP0BB – COMBIACX & ACEX - User Manual

Page - 7/81

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 Page - 8/81

AFCZP0BB- COMBIACX & ACEX - User Manual

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.

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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

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4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours, they mean:

4 U

These are informations useful for anyone is working on the installation, or a deeper examination of the content

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.

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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

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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 Page - 12/81

The power cables length must be as short as possible to minimize power losses.

AFCZP0BB- COMBIACX & ACEX - User Manual

-

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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.

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

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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:

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-

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.

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Wrong Layout:

Module 1

Module 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.

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Correct Layout:

Module 1

Module 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)

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U

Correct Layout:

Module 1

Module 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.

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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 -

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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

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”

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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 D5 D1 D4

+5V / +12V GND A B

positive of encoder power supply. negative of encoder power supply. phase A of encoder. phase B of encoder.

2) Connection of encoder with open collector output; +5V and +12V power supply.

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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 secondlast letter in the software release name (see 3.5).

AFCZP0BB- COMBIACX & ACEX - User Manual

4.2.6 Main contactor and key connection -

The connection of the main contactor can be carried out following the drawing in the figure.

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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.

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-

4.2.7 Insulation of truck frame

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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.

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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.

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4.3.2 Safety Features

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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

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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

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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.

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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 Page - 20/81

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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.

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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), canbus 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.

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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.

A2

EV3

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 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.

A5

DI7

Input of the switch DI7. The input is activated when it is connected to +Batt. The default function is the controller “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.

A7

DI11

Input of the switch DI11. The input is activated when the 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.

A8

EV2

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 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.

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A10

GND

This is the ground of the logic board.

A11

DI6

Input of the switch DI6. The input is activated when it is connected to +Batt. The default function is the controller “LOWER” enable input.

A12

DI8

Input of the switch DI8. The input is activated when it is connected to +Batt. The default function is the controller “1ST” input: the pump motor turn at a defined speed.

A13

DI10

Input of the switch DI10. The input is activated when it is connected to +Batt. The default function is the controller “2ND” input: the pump motor turn at a defined speed.

A14

DI12

Input of the switch DI12. The input is activated when the 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 connected to +Batt. The default function is the controller “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 maximum continuous current (driving to –Batt). Built-in 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 connected to +Batt. The default function is the controller “REV” request input, closing this input truck moves in backward direction.

6.1.3 CNC external connector

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C1

+KEY

Input of the key switch signal.

C2

DI1

Input of the switch DI1. The input is activated when it is connected to +Batt. The default function is the controller “BELLY” input, closing the switch quick inversion function is activated.

C3

NPOT

Potentiometers negative reference (GND).

AFCZP0BB- COMBIACX & ACEX - User Manual

C4

CPOTTR

Accelerator potentiometer wiper input.

C5

CANH

High level CAN-BUS voltage I/O.

C6

DI0

Input of the switch DI0. The input is activated when it is 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.

C7

DI2

Input of the switch DI7. The input is activated when it is connected to +Batt. The default function is the controller “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.

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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.

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8 DRAWINGS 8.1 Mechanical drawing COMBIACX

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8.2 Mechanical drawing ACEX

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8.3 Connection drawing COMBIACX

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8.4 Connection drawing ACEX

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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.

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9.1 Sequence for Ac Inverter traction setting This section of the manual describes the basic ACEX / COMBIACX set-up procedure.

4 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.

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 recycle the Key Switch if you make any changes to the chopper’s configuration.

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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.

AFCZP0BB- COMBIACX & ACEX - User Manual

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.

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10 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 10.1 Adjustments via console

4 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.

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

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10.3 Description of the console menu 10.3.1 COMBIACX / ACEX Menu

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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 24V 165A 00000

Opening Zapi Display Push ROLL UP + SET UP simultaneously to enter CONFIG MENU

% ' % ' ' ' CONFIG MENU SET MODEL

The Display will show : SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear.

% ' ' ' ' ' CONFIG MENU SET OPTIONS

The Display will show : SET OPTIONS

' % ' ' ' '

Press ENTER to go in the SET OPTIONS MENU

HOURCOUNTER RUNNING

The Display will show the first OPTION Press SET UP or SET DOWN button in order to modify the OPTION

' ' % ' ' % HOURCOUNTER KEYON

The Display will show the new option

' ' ' ' % '

Press OUT to exit the menu The Display will ask “ARE YOU SURE”.

ARE YOU SURE? YES=ENTER NO=OUT

Press ENTER for YES, or OUT for No

' % ' ' ' '

CONFIG MENU SET OPTIONS

The Display will show : SET OPTIONS Press OUT again. Display now will show the opening Zapi menu.

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' ' ' ' % '

' ' ' ' % '

AFCZP0BB- COMBIACX & ACEX - User Manual

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.

- Level 2: BATTERY LOW alarm is raised when the battery level is calculated being less or equal to 10% of the full charge.

- Level 3: BATTERY LOW alarm is raised when the battery level is calculated 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

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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 3phase 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 PRESENT/ABSENT: If set = PRESENT the EV2 output is driven and the diagnosis “EV2 DRIVER SHORTED” relative to the load connected to CNA#8 is activated. When set = ABSENT the diagnosis is not implemented and the EV2 output is NOT driven.

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diagnosis “EV3 DRIVER SHORTED” relative to the load connected to CNA#2 is activated. When set = ABSENT the diagnosis is not implemented and the EV3 output is NOT driven.

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.

1)

Opening Zapi Menu

2)

Press Top Left & Right Buttons to enter CONFIG MENU

3)

The Display will show: SET MODEL

4)

Press ROLL UP button until ADJUSTMENTS MENU appears

5)

ADJUSTMENTS appears on the display

6)

Press ENTER to go into the ADJUSTMENTS MENU

AFCZP0BB – COMBIACX & ACEX - User Manual

ADXT2B ZP1.00 24V 165A 00000 % ' % ' ' ' CONFIG MENU SET MODEL % ' ' ' ' ' CONFIG MENU ADJUSTMENTS ' % ' ' ' '

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7)

The display will show: SET BATTERY TYPE

BATTERY TYPE 24V

8)

Press ROLL UP or ROLL DOWN button until the desired parameter is reached

% ' ' % ' '

9)

The desired parameter appears

TROTTLE 0 ZONE 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 depressed 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).

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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 hourcounter 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.

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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.

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AFCZP0BB- COMBIACX & ACEX - User Manual

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 24V 165A 00000

1)

Opening Zapi Menu

2)

Press ENTER to go into the General Menu

3)

The Display will show: PARAMETER CHANGE

4)

Press ENTER to go into the Parameter Change menu

5)

The Display will show the first parameter

6)

Press either ROLL UP and ROLL DOWN to display the next parameter

% ' ' % ' '

7)

The names of the Parameters appear on the Display

RELEASE BRAKING LEVEL = 5

8)

When the desired Parameter appears, it’s possible to change the Level by pressing either SET UP or SET DOWN buttons.

9)

The Display will show the new level.

10) When you are satisfied with the result of the changes you have made, press OUT. 11) The Display asks: “ARE YOU SURE?” 12) Press ENTER to accept the changes, or press OUT to discard them.

13) The Display will show

' % ' ' ' ' MAIN MENU PARAMETER CHANGE ' % ' ' ' ' ACC DELAY LEVEL = 5

' ' % ' ' % RELEASE BRAKING LEVEL = 2 ' ' ' ' % ' ARE YOU SURE? YES=ENTER NO=OUT ' ' ' ' % ' MAIN MENU 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.

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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 Typically from 10% to 100%. It determines the percentage of the max speed applied when the cutback switch, CNA#14 connector, is active. When set to 100% the speed reduction is ineffective.

13) H&S CUTBACK Typically from 10% to 100%. 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.

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 Page - 44/81

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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.

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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.

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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.

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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 DECEL. BRAKING PEDAL BRAKING

Sec. Sec. Sec.

From 0 to 10 sec., resolution of 0.1 From 0 to 10 sec., resolution of 0.1 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%

Hz

From 0.6 to 4.0 Hz, resolution of 0.1 Hz

%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

Hz

From 3 to 20 Hz, resolution of 1Hz

FREQUENCY CREEP MAXIMUM CURRENT

STOP BRAKE SMOOTH AUXILIARY TIME

Sec.

From 0 to 10 sec., resolution of 0.1

HYDRO TIME

Sec.

From 0 to 10 sec., resolution of 0.1

%

Programmed level from 0 to 9

PU. ACCELER. DEL.

Sec.

From 0 to 10 sec., resolution of 0.1

PU. DECELER. DEL. MAX SPEED LIFT

Sec. %

From 0 to 10 sec., resolution of 0.1 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%

PUMP IMAX

1

ST

PUMP SPEED

%

From 0% to 100%, resolution of 1%

2

ND

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

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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. AFCZP0BB – COMBIACX & ACEX - User Manual

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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.

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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 KTY84130 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.

- OFF GND = When it is not connected to a battery (key) voltage (or it is 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.

- OFF GND = When it is not connected to a battery (key) voltage (or it is 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.

- OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the Forward Travel demand is not active.

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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.

- OFF GND = When it is not connected to a battery (key) voltage (or it is 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.

- OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the Lowering request is not active.

22) DI7/LIFT SWITCH ON/OFF. This is the level of the digital input CNA#5: - 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/OFF. This is the level of the digital input CNA#12: - 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/OFF. This is the level of the digital input CNA#6: - 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/OFF. This is the level of the digital input CNA#13: - 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.

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

27) DI12 CUTBACK 2 ON/OFF. This is the level of the digital input CNA#14: - 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 %).

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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 24V 165A 00000

Opening Zapi Display Press ENTER to go into the General menu

' % ' ' ' ' MAIN MENU PARAMETER CHANGE

The Display will show : Press ROLL UP or ROLL DOWN button until SAVE PARAM. appears on the display

% ' ' % ' ' MAIN MENU SAVE PARAMETERS

The Display will show : Press ENTER to go into the SAVE function If this feature has been used before, the type of controller data stored appears on the top Main with a 2 digit reference Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility

' % ' ' ' ' SELECT: MOD. 00 FREE

% ' ' % ' ' SELECT: MOD. 01 FREE

Press ENTER to commence SAVE routine You can see the items that are being stored whilst the SAVE routine is happening

READING …

ACCEL. DELAY (ECC.) SELECT: MOD. 01 FREE

When finished, the Console shows : Press OUT to return to the Opening Zapi Display Page - 54/81

' % ' ' ' '

' ' ' ' % '

AFCZP0BB- COMBIACX & ACEX - User Manual

4

NOTE: in reality the SAVE and RESTORE function requires the Windows PCConsole.

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.

Opening Zapi Display Press ENTER to go into the General menu The Display will show : Press ROLL UP or ROLL DOWN button until RESTORE PARAM. appears on the display The Display will show : Press ENTER to go into the RESTORE PARAM. function The Display shows the type of Model stored, with a Code Number Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display

ADXT2B ZP1.00 24V 165A 00000 ' % ' ' ' ' MAIN MENU PARAMETER CHANGE % ' ' % ' ' MAIN MENU RESTORE PARAM. ' % ' ' ' ' SELECT : MOD. 00 ACEX ZAPI V1 % ' ' % ' ' SELECT : MOD. 00 ACEX ZAPI V1

Press ENTER to commence the Restore operation The Display will ask “ARE YOU SURE”.

AFCZP0BB – COMBIACX & ACEX - User Manual

' % ' ' ' ' ARE YOU SURE? YES=ENTER NO=OUT

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' % ' ' ' '

Press ENTER for YES, or OUT for No You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening

STORING ACCELER. DELAY

When finished, the Console shows :

MAIN MENU RESTORE PARAM.

Press OUT to return to the Opening Zapi Display

4

' ' ' ' % '

' ' ' ' % '

NOTE: in reality the SAVE and RESTORE function requires the Windows PCConsole.

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.

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Flow Chart showing how to use the PROGRAM VACC function of the Digital Console.

Opening Zapi Display

ADXZ2A ZP1.00 24V 165A 00000 ' % ' ' ' '

Press ENTER to go into the General menu The Display will show :

MAIN MENU PARAMETER CHANGE

Press ROLL UP or ROLL DOWN button until PROGRAM VACC the display The Display will show :

% ' ' % ' ' MAIN MENU PROGRAM VACC

Press ENTER to go into the PROGRAM VACC function The Display will show the minimum and maximum values of potentiometer wiper output.

Both directions can be shown

' % ' ' ' ' VACC SETTING 4.8 4.8

Press ENTER to clear these values.

Display will show 0.0 Select Forward Direction, close any interlock switches that may be in the system

' % ' ' ' ' MIN 0.0

VACC -

MAX 0.0

MIN 0.6

VACC ↑

MAX 4.4

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.

Select the Reverse Direction and repeat Item 10 When finished , press OUT The Display will ask : ARE YOU SURE ?

Press ENTER for yes, or OUT for NO When finished, the Console shows : Press OUT to return to the Opening Zapi Display

AFCZP0BB – COMBIACX & ACEX - User Manual

' ' ' ' % ' ARE YOU SURE YES=ENTER NO=OUT ' % ' ' % ' MAIN MENU PROGRAM VACC ' ' ' ' % '

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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.

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AFCZP0BB- COMBIACX & ACEX - User Manual

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

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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.

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AFCZP0BB- COMBIACX & ACEX - User Manual

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, ….)

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12.2 Alarms overview Error Code

Description

Capacitor Power capacitors voltage does not increase charge - MDI CAN 60 Vmn low - MDI Motor output voltage lower than expected CAN 72 Vmn high MDI CAN 31

Motor output voltage higher than expected

Power mos short - MDI CAN 89

Short circuit on the power mosfets

Effect Valve, pump, traction stopped, Lc opened, Eb applied Valve, pump, traction stopped, Lc opened, Eb applied Valve, pump, traction stopped, Lc opened, Eb applied Valve, pump, traction stopped, Lc opened, Eb applied

Coil short. MC- Shortcircuit on LC or EB coil EB - MDI CAN 76 Driver shorted - Driver of LC coil is shorted, so it is not able to open MDI CAN 74 the LC, or LC coil is disconnected

Valve, pump, traction stopped, Lc opened, Eb applied Valve, pump, traction stopped, Lc opened, Eb applied Contactor Driver of LC coil is damaged (not able to close) Valve, pump, traction Driver - MDI stopped, Lc opened, Eb CAN 75 applied Contactor The LC coil has been driven but LC does not close Valve, pump, traction Open - MDI stopped, Lc opened, Eb CAN 77 applied Contactor LC contact is stuck Valve, pump, traction closed - MDI stopped, Lc opened, Eb CAN 75 applied Valve, pump, traction Aux driv. Shrt. - When the mos of EB is shorted MDI CAN 40 stopped, Lc opened, Eb applied Aux driver Driver of EB coil is damaged (not able to close) Valve, pump, traction open - MDI stopped, Lc opened, Eb CAN 42 applied Pos. EB Output of built in Smart Driver, which supplies Eb coil Valve, pump, traction shorted - MDI positive, is high (= +batt) when the tiller switch is stopped, Lc opened, Eb CAN 86 opened. applied Logic Failure Overvoltage/Undervoltage condition has been Valve, pump, traction #1 - MDI CAN detected stopped, Lc opened, Eb 54 applied Logic Failure Motor voltage feedback circuits are damaged Valve, pump, traction #2 - MDI CAN stopped, Lc opened, Eb 55 applied Logic failure Failure in the high current HW protection circuit valve, pump, traction #3 - MDI CAN stopped, Lc opened, Eb 17 applied Valve, pump, traction Stby i high In stby condition (no current applied to the traction MDI CAN 53 motor) the current feedbacks are aout of permitted stopped, Lc opened, Eb applied stby range Wrong Battery -The battery voltage is too low or too high (< 0,8 Vbatt Valve, pump, traction MDI CAN 41 OR > 1,2 Vbatt) stopped, Lc opened, Eb applied Analog input - Problem on the A/D conversion of uC Valve, pump, traction MDI CAN 96 stopped, Lc opened, Eb applied Valve, pump, traction Encoder Error - Problem on the encoder MDI CAN 82 stopped, Lc opened, Eb applied Tiller error Input mismatch between hard&soft switch input and Traction stopped, Eb applied MDI CAN 64 tiller input Watchdog MDI CAN 08

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One of two (or both) Watchdog circuit outputs becomes high due to an HW or SW problem

Valve, pump, traction stopped, Lc opened, Eb applied

Machine status when the test is done start-up

Restart procedure Valve or pump or traction request

start-up, traction

Valve or pump or traction request

start-up, traction

Valve or pump or traction request

start-up

Valve or pump or traction request

stby, traction

Valve or pump or traction request

start-up

Valve or pump or traction request

stby, traction

Valve or pump or traction request

stby, traction

Valve or pump or traction request

start-up

Valve or pump or traction request

start-up,stby,marcia Valve or pump or traction request stby, traction

Valve or pump or traction request

start-up

Valve or pump or traction request

start-up

Valve or pump or traction request

stby, immediately after Lc closing

Valve or pump or traction request

start-up, stby

Valve or pump or traction request

start-up, stby

Valve or pump or traction request

start-up, stand-by (only immediately after Lc closing) traction

Valve or pump or traction request Valve or pump or traction request

traction

Valve or pump or traction request

start-up, stby, traction

Valve or pump or traction request

start-up, stby, traction

Key re-cycle

AFCZP0BB- COMBIACX & ACEX - User Manual

Smart driver KO - MDI CAN 68

Smart driver is open, not able to provide EB positive

Key-off shorted - MDI CAN Key-off signal is low at Key-on 76 Evp driv. short - MDI CAN Evp driver is failed shorted (always 50 ON) mismatch between the valve set-point and its feedback

valve, pump, traction stopped, start-up Lc opened valve, pump, traction stopped, start-up Lc opened valve, pump, traction stopped, start-up, stby Lc opened, Eb applied

Key re-cycle Key re-cycle valve or pump or traction request

Pump Vmn Low - MDI CAN 28

Pump motor output is too low, with valve, pump, traction stopped, start-up, stby, respect to pwm applied Lc opened, Eb applied during pump function

valve or pump or traction request

Pump Vmn High - MDI CAN 29

Pump motor output is too high, with respect to pwm applied

valve or pump or traction request

Wrong Zero - MDI CAN code alarm 53

The outputs of the amplifiers (used valve, pump, traction stopped, init to measure the motor voltage) are Lc opened, Eb applied cheked this alarm occurs when voltage signals >3V or <2V at the init

valve or pump or traction request

Evp coil open - MDI CAN 50

The Evp1 coil is not connected between PAUX and EVP output, and the parameter EVP TYPE in the set-option menu is set Analog or Digital

valve or pump or traction request

valve, pump, traction stopped, during pump Lc opened, Eb applied function

valve, pump, traction stopped, start-up, stby, Lc opened, Eb applied traction

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 code alarm 98

The PEV connector (B2) is not connected to the battery or the voltage is different.

valve stopped, (eventually) pump stopped, (eventually) traction stopped, (eventually) Lc opened and MC applied

Flash Checksum - MDI CAN 08

The software is corrupted or the flash on the inverter is damaged.

valve, pump, traction stopped, continuous Lc opened, Eb applied

Controller Mism - MDI CAN 12

The software is not compatible with valve, pump, traction stopped, start-up the controller.

Lc opened, Eb applied

key-recycle

valve, pump, traction stopped, start-up Motor output voltage lower than Lc opened, Eb applied expected, before driving the bridge.

key-recycle

Init vmn low - MDI CAN 72

valve, pump, traction stopped, start-up Lc opened, Eb applied Motor output voltage higher than expected, before driving the bridge.

key-recycle

Init vmn high MDI CAN 31 Pump vmn not ok MDI CAN 32

Pump motor output voltage is different than expected

valve, pump, traction stopped, start-up Lc opened, Eb applied

key-recycle

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continuous

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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 Page - 64/81

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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: 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 - 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 - If no problem are found on the motors, the problem is inside the 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.

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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: This type of fault is not related to external components; replace the controller.

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, Page - 66/81

AFCZP0BB- COMBIACX & ACEX - User Manual

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.

14) “LOGIC FAILURE #2” 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.

15) “LOGIC FAILURE #3” 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” AFCZP0BB – COMBIACX & ACEX - User Manual

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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: Page - 68/81

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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: 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 - 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 - If no problem are found on the motors, the problem is inside the 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 - If no problem are found on the motors, the problem is inside the 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

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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: This type of fault is not related to external components; replace the controller.

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.

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If it is too low, this alarm occours.

Troubleshooting: Please 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 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 - Motor power cables connections - Motor leakage to truck frame - If the motor connections are OK, the problem is inside the controller 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 - Motor power cables connections - Motor leakage to truck frame - If the motor connections are ok, the problem is inside the controller

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12.3 Warnings overview

Error code Slip profile MDI CAN 99

Description Error on the parameters of the slip profile setting.

Effect

Machine status when the test is done

Restart procedure

Traction is stopped

start-up, stand-by Traction request

Forw+backwa The travel demands are active in both Traction is stopped rd - MDI CAN directions at the same time 80

start-up, stand-by, Traction traction request

Incorrect start - Incorrect starting sequence MDI CAN 79

Traction is stopped

start-up, stand-by Traction request

Vacc not ok - The acceleretor value is higher than Traction is stopped MDI CAN 78 the minimum value recorded, and the direction/enable switches are opened.

start-up, stand-by, Traction traction request

Th. Protection -The controller has reached the MDI CAN 62 thermal cutback temperature 85°C

Battery low

Eeprom ko MDI CAN 71 Motor temperat MDI CAN 65 Thermic sens ko - MDI CAN 61 Check up needed Data acquisition

Tiller open MDI CAN 51

The maximum current continuous is reduced to half and speed is reduced (if CHECK OPTION = 1) Error is detected in eeprom or in Controller works using continuous eeprom management Deafult parameters Traction motor temperature sensor is The maximum current continuous opened (if digital) or has overtaken is reduced to half and the threshold of 150°C (if analog) speed is reduced

Battery is <= 10% when the parameter BATTERY CHECK is set >0

The output of the controller thermal sensor is out of range.

The maximum current is reduced to half and speed is reduced

continuous

Maintenance time is reached Traction is stopped Maximum current adjustment procedure is in progress (NOTE: this procedure has to be done only by Zapi test department) The truck is in stby with tiller switch LC opens opened for more than 30s

Current gain - The Maximum current gain MDI CAN 92 parameters are the default values, which means the maximum current adjustment procedure has not been carried out yet A Canbus network node is in alarm Waiting for condition. uC is waiting for it to node - MDI CAN 68 resolve its error condition.

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continuous Traction controller reduces the maximum current linearly from Imax (85°C) down to 0A (105°C)

Controller works, but with low maximum current

stand-by

Traction request

standby

Valve or pump or traction request

start-up, stanby

continuous

AFCZP0BB- COMBIACX & ACEX - User Manual

Error code

Description

Drv. Shor. EV1 dri MDI CAN 74 Drv. Shor. EV2 MDI CAN 74 Drv. Shor. EV3 MDI CAN 74 Pump I NO zero MDI CAN 56

Effect

Machine status when the test is done

Restart procedure

EV1 on/off valve drivers shorted (always ON) EV2 on/off valve driver shorted (always ON) EV3 on/off valve driver shorted (always ON) Pump chopper current sensor feedback is out of permitted stby range Pump I=0 ever Pump current feedback is always MDI CAN 52 0A even when pump motor is running Cont. Drv. Ev1 - MDI Driver of Ev1 is open, not able to CAN 75 close Cont. Drv. Ev2 - MDI Driver of Ev2 is open, not able to CAN 75 close Cont. Drv. Ev3 - MDI Driver of Ev3 is open, not able to CAN 75 close Pump Vacc not OK - The pump accelerator value is MDI CAN 89 higher than the minimum value recorded, and the lift/lower switches are open

On/off valves stopped

start-up, stby

valve on/off request

On/off valves stopped

start-up, stby

valve on/off request

On/off valves stopped

start-up, stby

valve on/off request

Pump motor stopped

start-up, stby

pump request

Pump motor stopped

pump function

pump request

Ev1 stopped

during Ev1 function during Ev2 function during Ev3 function Continuous

valve Ev1 request

Pump request

Sens. Mot. Temp.

KO - MDI CAN 67

The motor temperature sensor is damaged

Performance highly reduced

Continuous

Key-on recycle

Vacc out range MDI CAN 85

The voltage on CNC#4 is out of the Traction stopped parameters range

Continuous

Program VACC

Stall rotor - MDI CAN 11

The traction rotor is stuck or the encoder is not working

Traction stopped

Continuous

Key-on recycle

EVP driver open MDI CAN 48

The EVP driver isdamaged or the EVP coil impedance is too low

EVP stopped

Continuous

Key-on recycle

Many pump reqs MDI CAN 49

There are too many pump requests Pump stopped at the same time

Continuous

Remove request

start-up, standby

Pump request

Pump Vacc range - The voltage on CNC#9 is out of the Pump stopped, EVP MDI CAN 90 parameters range stopped

Continuous

Pump request

Param. Restore MDI CAN 13

A parameters set restore was made since the last keyoff

No effect

start-up

Traction, pump or EVP request

Wait mot. P. still MDI CAN 63

The software waits for the motor pump to stop

Valve, pump, traction stopped, LC opened, Eb applied

start-up

None

Pump inc start - MDI Incorrect pump starting sequence CAN 79

AFCZP0BB – COMBIACX & ACEX - User Manual

Ev2 stopped Ev3 stopped Pump stopped

Pump stopped

valve Ev2 request valve Ev3 request

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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.

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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: This type of fault is not related to external components; replace the controller.

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.

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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.

17) “DRV. SHOR. EV2” Cause: Electrovalve EV2 driver is shorted.

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.

18) “DRV. SHOR. EV3” Cause: Electrovalve EV3 driver is shorted.

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).

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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: This type of fault is not related to external components; replace the controller.

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: The device or its driving circuit is damaged, replace the controller.

23) “CONT. DRV. EV2” Cause: The EV2 valve driver is not able to drive the load (cannot close).

Troubleshooting: The device or its driving circuit is damaged, replace the controller.

24) “CONT. DRV. EV3” Cause: The EV3 valve driver is not able to drive the load (cannot close).

Troubleshooting: The device or its driving circuit is damaged, replace the controller.

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.

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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 Page - 78/81

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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.

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13 RECOMMENDED SPARE PARTS

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Part number

Description

C29508

SW 180 24V Single Pole Contactor

C29522

SW 180 48V Single Pole Contactor

C12359

Connector Minifit 6 pins Female

C12414

Connector Minifit 8 pins Female

C12500

Connector Minifit 10 pins Female

C12403

Connector Minifit 14 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

C16591

Protected 175A strip UL fuse

C16504

Protected 300A strip fuse

C16587

Protected 300A strip UL fuse

C16505

Protected 355A strip fuse

C16588

Protected 350A strip UL fuse

C16520

10A 20mm control circuit fuse

ACEX PW 24/36/48V

COMBIACX 24/36/48V

COMBIACX PW 24/36/48V

All

AFCZP0BB- COMBIACX & ACEX - User Manual

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.

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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.

AFCZP0BB – COMBIACX & ACEX - User Manual

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