ELECTRONIC • OLEODYNAMIC • INDUSTRIAL

EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: [email protected] – web: www.zapispa.it

EN

User Manual

ACE3
INVERTER

Publication N°: AFFZP0BB

Edition: 08 May 2017
 Copyright © 1975-2017 Zapi S.p.A.
All rights reserved

Contents of this publication are 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 DEFINITIONS

4 This symbol is used in this publication to indicate an annotation or a suggestion you

should pay attention to.

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

characteristic very important for security. Pay special attention to the
annotations pointed out with this symbol.

Page – 2/139 AFFZP0BB – ACE3 – User Manual

 Contents
1  INTRODUCTION ................................................................................................................... 7 
1.1  About this document ................................................................................................... 7 
1.1.1  Scope of this manual .................................................................................... 7 
1.1.2  Manual revision ............................................................................................ 7 
1.1.3  Warnings and notes...................................................................................... 7 
1.2  About the Controller ................................................................................................... 8 
1.2.1  Safety ........................................................................................................... 8 
1.2.2  OEM’s Responsibility.................................................................................... 8 
1.2.3  Technical Support......................................................................................... 8 
2  SPECIFICATIONS ................................................................................................................ 9 
2.1  General features ......................................................................................................... 9 
2.2  Technical specifications of ACE3 ............................................................................. 10 
2.3  Technical specifications of ACE3 Power .................................................................. 10 
2.4  Functional features ................................................................................................... 11 
2.5  Diagnoses ................................................................................................................ 12 
3  DRAWINGS ......................................................................................................................... 13 
3.1  Mechanical drawing – ACE3 / ACE3 Power ............................................................. 13 
3.2  Connection drawing – ACE3 Traction Standard ....................................................... 14 
3.3  Connection drawing – ACE3 Traction Premium ....................................................... 15 
3.4  Connection drawing – ACE3 Pump Standard .......................................................... 16 
3.5  Connection drawing – ACE3 Pump Premium........................................................... 17 
4  DESCRIPTION OF THE CONNECTORS ........................................................................... 18 
4.1  Power connectors ..................................................................................................... 18 
4.2  Ampseal connectors ................................................................................................. 18 
4.2.1  ACE3 Traction Standard............................................................................. 19 
4.2.2  ACE3 Pump Standard ................................................................................ 20 
4.2.3  ACE3 Traction Premium ............................................................................. 21 
4.2.4  ACE3 Pump Premium ................................................................................ 23 
5  INPUT DEVICES ................................................................................................................. 25 
5.1  Key Input .................................................................................................................. 25 
5.1.1  Function ...................................................................................................... 25 
5.1.2  Protection ................................................................................................... 25 
5.2  Digital Inputs ............................................................................................................. 25 

AFFZP0BB – ACE3 – User Manual Page – 3/139

 5.2.1  Microswitches ............................................................................................. 25 
5.3  Accelerator unit ........................................................................................................ 26 
5.4  Other analog control unit .......................................................................................... 27 
5.4.1  Standard version ........................................................................................ 27 
5.4.2  Premium version......................................................................................... 27 
5.5  Speed feedback ....................................................................................................... 27 
5.5.1  Sin/Cos sensor and Hall sensors ............................................................... 28 
6  INSTALLATION HINTS ...................................................................................................... 29 
6.1  Material overview ..................................................................................................... 29 
6.1.1  Connection cables ...................................................................................... 29 
6.1.2  Contactors .................................................................................................. 29 
6.1.3  Fuses .......................................................................................................... 29 
6.2  Hardware installation ................................................................................................ 30 
6.2.1  Positioning and cooling of the controller ..................................................... 30 
6.2.2  Wirings: power cables ................................................................................ 30 
6.2.3  Wirings: CAN bus connections and possible interferences ........................ 31 
6.2.4  Wirings: I/O connections ............................................................................. 33 
6.2.5  Connection of the encoder ......................................................................... 33 
6.2.6  Connection of a Sin/Cos sensor ................................................................. 34 
6.2.7  Connection of Hall sensors......................................................................... 35 
6.2.8  Main-contactor and key connection ............................................................ 35 
6.2.9  Insulation of truck frame ............................................................................. 36 
6.3  Protection and safety features .................................................................................. 36 
6.3.1  Protection features ..................................................................................... 36 
6.3.2  Safety Features .......................................................................................... 37 
6.4  EMC ......................................................................................................................... 37 
6.5  Various suggestions ................................................................................................. 39 
7  INVERTER SETTINGS ....................................................................................................... 40 
7.1  Settings overview ..................................................................................................... 40 
7.2  Settings description .................................................................................................. 41 
7.2.1  PARAMETER CHANGE ............................................................................. 41 
7.2.2  SET OPTIONS ........................................................................................... 45 
7.2.3  ADJUSTMENT ........................................................................................... 53 
7.2.4  SPECIAL ADJUST. .................................................................................... 58 

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 7.2.5  HARDWARE SETTING .............................................................................. 61 
7.2.6  HYDRO SETTING ...................................................................................... 62 
7.3  TESTER function ...................................................................................................... 63 
7.3.1  Master microcontroller ................................................................................ 63 
7.3.2  Supervisor microcontroller .......................................................................... 69 
7.4  Set-up procedure for traction inverter ....................................................................... 70 
7.4.1  Sin/cos-sensored case ............................................................................... 71 
7.5  Set-up procedure for pump inverter ......................................................................... 72 
8  OTHER FUNCTIONS .......................................................................................................... 73 
8.1  PROGRAM VACC function ...................................................................................... 73 
8.2  PROGRAM LIFT / LOWER function ......................................................................... 74 
8.3  PROGRAM STEER function .................................................................................... 74 
8.4  Acceleration time ...................................................................................................... 75 
8.5  Deceleration time .................................................................................................... 76 
8.6  Acceleration smoothness ....................................................................................... 77 
8.7  Steering curve ......................................................................................................... 78 
8.8  Throttle response ..................................................................................................... 79 
8.9  NLC & NEB output ................................................................................................... 80 
8.10  Battery-charge detection .......................................................................................... 81 
8.11  EVP control .............................................................................................................. 82 
8.12  Torque profile ........................................................................................................... 84 
8.13  Steering table ........................................................................................................... 85 
9  FAULTS DIAGNOSTIC SYSTEM ....................................................................................... 86 
9.1  Alarms – Master uC .................................................................................................. 86 
9.1.1  Troubleshooting of master-uC alarms ........................................................ 90 
9.2  Alarms – Supervisor uC.......................................................................................... 103 
9.2.1  Troubleshooting of supervisor-uC alarms ................................................. 104 
9.3  Warnings – Master uC ............................................................................................ 107 
9.3.1  Troubleshooting of master-uC warnings ................................................... 110 
9.4  Warnings overview (supervisor uC)........................................................................ 120 
9.4.1  Troubleshooting of supervisor-uC warnings ............................................. 120 
10  SPARE PARTS ................................................................................................................. 122 
11  PERIODIC MAINTENANCE .............................................................................................. 123 
12  APPENDICES ................................................................................................................... 124 

AFFZP0BB – ACE3 – User Manual Page – 5/139

 12.1  Appendix A: PC CAN Console user guide ............................................................. 124 
12.1.1  PC CAN Console configuration ................................................................ 124 
12.1.2  Parameter download ................................................................................ 126 
12.1.3  How to modify parameters........................................................................ 126 
Program Vacc ......................................................................................................... 127 
12.1.4  Lift & Lower acquisition............................................................................. 128 
12.1.5  Steering acquisition .................................................................................. 128 
12.1.6  TESTER functionality ............................................................................... 129 
12.1.7  Alarm Logbook ......................................................................................... 129 
12.2  Appendix B: Zapi Smart Console user guide.......................................................... 130 
12.2.1  Operational Modes ................................................................................... 130 
12.2.2  The keyboard............................................................................................ 131 
12.2.3  Home Screen............................................................................................ 131 
12.2.4  Connected ................................................................................................ 132 
12.2.5  How to modify parameters........................................................................ 133 
12.2.6  PROGRAM VACC .................................................................................... 134 
12.2.7  Lift and Lower acquisition ......................................................................... 135 
12.2.8  Steer acquisition ....................................................................................... 136 
12.2.9  TESTER ................................................................................................... 136 
12.2.10  Alarms ...................................................................................................... 136 
12.2.11  Download parameter list into a USB stick ................................................ 137 

APPROVAL SIGNS

COMPANY FUNCTION INITIALS SIGN

PROJECT MANAGER

TECHNICAL ELECTRONIC
MANAGER VISA

SALES MANAGER VISA

Page – 6/139 AFFZP0BB – ACE3 – User Manual

1 INTRODUCTION

1.1 About this document

1.1.1 Scope of this manual
This manual provides important information about ACE3 controller: it presents
instructions, guidelines and diagrams related to installation and maintenance of the
controller in an electrically powered vehicle.

1.1.2 Manual revision

This revision replaces all previous revisions of this document. Zapi has put much
effort to ensure that this document is complete and accurate at the time of printing.
In accordance with Zapi policy of continuous product improvement, all data in this
document are subject to change or correction without prior notice.

1.1.3 Warnings and notes

In this manual, special attention must be paid to information presented in warning
and information notices.
Definitions of warning and information notices are the following.

4 This is an information box, useful for anyone is working on the installation, or for a
deeper examination of the content.

U This is a warning box, it can 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

U This is a further warning within the box. Pay special attention to the
annotations pointed out within these boxes.

AFFZP0BB – ACE3 – User Manual Page – 7/139

 1.2 About the Controller
1.2.1 Safety
Zapi provides this and other manuals to assist manufacturers in using the motor
controller in a proper, efficient and safe manner. Manufacturers must ensure that all
people responsible for the design and use of equipment employing the motor
controller have the proper professional skills and equipment knowledge.

U Before doing any operation, ensure that the battery is disconnected and when
the installation is completed start the machine with the drive wheels raised
from the ground to ensure that any installation error does not compromise
safety.

U After the inverter turn-off, even with the key switch open, the internal
capacitors may remain charged for some time. For safe operation onto the
setup, it is recommended to disconnect the battery and to discharge the
capacitors by means of a resistor of about 10 – 100 Ohm between +Batt and
-Batt terminals of the inverter.

1.2.2 OEM’s Responsibility

Zapi motor controllers are intended for controlling motors in electric vehicles.
These controllers are supplied to original equipment manufacturers (OEMs) for
incorporation into their vehicles and vehicle control systems.
Electric vehicles are subject to national and international standards of construction
and operation which must be observed. It is responsibility of the vehicle
manufacturer to identify the correct standards and to ensure that the vehicle meets
these standards. As a major electrical control component, the role of a Zapi motor
controller should be carefully considered and relevant safety precautions taken. It
has several features which can be configured to help the system integrator meeting
vehicle safety standards.
Zapi does not accept responsibility for incorrect application of its products.

1.2.3 Technical Support

For additional information on any topic covered in this document or application
assistance on other Zapi products, contact Zapi sales department.

Page – 8/139 AFFZP0BB – ACE3 – User Manual

2 SPECIFICATIONS

2.1 General features

Within the ZAPIMOS family, the ACE3 inverter (E stands for evolution) is a controller
designed to control AC induction, BLDC and PMAC motors, in the range from 10 kW
to 20 kW continuous power, used in a variety of battery-powered material-handling
trucks.
Typical applications include, but are not limited to: counterbalanced trucks with load
up to 5 tons, HLOP (Vna), GSE, tow tractors and airport ground support vehicles,
aerial-access equipment (telescopic boom and scissor lift).
The main inverter features are:
 16 bits microcontroller for motor control and main functions (master
microcontroller), 384+ Kbytes embedded Flash memory
 16 bits microcontroller for safety functions (supervisor microcontroller), 320+
Kbytes embedded Flash memory
 Field-oriented motor-control algorithm
 Smooth low-speed control
 Zero-speed holding control
 Zapi patented sensorless and sense-coil control
 Driver for line-contactor coil
 Driver for electromechanical brake
 Drivers for PWM-modulated voltage-controlled electrovalves and for one
PWM-modulated current-controlled proportional valve
 Overload, short-circuit and open-load protection
 Thermal cutback, warnings and automatic shutdown provide protection to the
motor and the controller
 Optically isolated and ESD-protected CAN bus interface
 Software downloadable via serial link (internal connector) or CAN bus
interface (external connector)
 Diagnostics provided via CAN bus interface using Zapi CAN Pc Tool
 Rugged sealed housing and connectors meeting IP65 environmental sealing
standards for use in harsh environments
ACE3 controller can be supplied in two I/O configurations and three voltage ratings:
 Standard Version (24V, 36/48V, 80V): with a 23-poles Ampseal connector.
 Premium Version (24V, 36/48V, 80V): with an additional 23-poles Ampseal
connector for enhanced I/O capabilities.
Moreover, two power-rating variants are available (see paragraphs 2.2 and 2.3):
 ACE3: base power ratings.
 ACE3 Power: increased power ratings.

AFFZP0BB – ACE3 – User Manual Page – 9/139

 2.2 Technical specifications of ACE3
Inverter for AC, BLDC and PMAC three-phase motors
Regenerative braking function
Digital control based on microcontroller
Voltage:.................................................................................................36, 48, 80 V
Maximum current ACE3 36-48V: ............................................... 600 A (RMS) for 2'
Maximum current ACE3 80V: .................................................... 450 A (RMS) for 2'
1 hour current rating ACE3 36-48V: ................................................... 300 A (RMS)
1 hour current rating ACE3 80V: ......................................................... 225 A (RMS)
Operating frequency: ...................................................................................... 8 kHz
External temperature range: ............................................................. -40 °C ÷ 40 °C
Maximum inverter temperature (at full power): ............................................... 85 °C

2.3 Technical specifications of ACE3 Power

Inverter for AC, BLDC an PMAC three -phase motors
Regenerative braking functions
Digital control based upon microcontroller
Voltage:...........................................................................................24, 36, 48, 80 V
Maximum current ACE3 PW 24V: ............................................. 700 A (RMS) for 2'
Maximum current ACE3 PW 36-48V: ........................................ 650 A (RMS) for 2'
Maximum current ACE3 PW 80V: ............................................. 550 A (RMS) for 2'
1 hour current rating ACE3 PW 24V: .................................................. 350 A (RMS)
1 hour current rating ACE3 PW 36-48V: ............................................. 325 A (RMS)
1 hour current rating ACE3 PW 80V: .................................................. 275 A (RMS)
Operating frequency: ...................................................................................... 8 kHz
External temperature range: ............................................................. -30 °C ÷ 40 °C
Maximum inverter temperature (at full power): ............................................... 85 °C

4 Internal algorithms automatically reduce maximum current limit when heat sink
temperature is above 85 °C. Heat sink temperature is measured internally near the
power MOSFETs (see paragraph 6.3).

4 Two-minutes ratings refer to the inverter equipped with a base plate. No additional
external heat sink or fans are used for the two-minutes rating tests. Ratings are
based on an initial base-plate temperature of 40 °C and a maximum base-plate
temperature of 85 °C.

4 The inverter is designed to deliver the rated continuous RMS current only if it is
adequately cooled. When it is equipped with its own finned heat sink, 100 m3/h
airflow is recommended. In case the controller is provided with the base plate, it is
customer’s duty to design an adequate cooling system able to dissipate the heat
produced by the inverter, keeping its temperature under 85 °C. Otherwise, the
inverter will deliver a maximum RMS current lower than the rated one.

Page – 10/139 AFFZP0BB – ACE3 – User Manual

 2.4 Functional features
- Speed control (three versions available: sensored, sense coil and sensorless as
explained in the introduction section).
- Optimum behavior on a slope due to the speed feedback: the motor speed
follows the accelerator, starting a regenerative braking if the speed exceeds the
setpoint.
- Electrical stop on a ramp (the machine is electrically hold on a slope) for a
programmable time.
- Stable speed in every position of the accelerator.
- Regenerative release braking based on deceleration ramps: regenerative
braking when the accelerator pedal is partially or fully released.
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the main
contactor is present.
- Release-braking profile modulated by an analog input, as to obtain a
proportional-brake feature.
- Increased resolution of the speed control at low speed.
- Voltage boost at the start and with overload to obtain more torque (with current
control).
- Integrated driver for an electromechanical brake.
- Hydraulic-steering function:
a) Traction inverter:
- The traction inverter sends a "hydraulic-steering function" request to the
pump inverter on the CAN bus line.
- If the pump inverter is not present (for ex: tractor application), the
traction inverter can manage a "hydraulic-steering function" by driving a
hydro contactor which drives an hydraulic-steering motor.
b) Pump inverter:
- The pump inverter manages a "hydraulic-steering function": it drives the
pump motor at the programmed speed for the programmed time.
- High efficiency of motor and battery due to high frequency commutations.
- Double microcontroller for safety functions.
- Self-diagnosis, the faults can be monitored through the Console or through Zapi
MDI/Display.
- Modification of parameters through the programming console.
- Internal hour-meter that can be viewed from the console.
- Memory of the last five alarms with relative hour-meter and temperature
displayed on the console.
- Test function within the Console for checking the inverter parameters.

AFFZP0BB – ACE3 – User Manual Page – 11/139

 2.5 Diagnoses
The microcontroller continually monitors the inverter and carries out a diagnostic
procedure of the main functions. Diagnoses are made of 4 steps:
1) Diagnosis at the key-on that checks: watchdog circuits, current sensors,
charging of capacitors, phase voltages, contactor driver, CAN bus interface, if
the switching sequence of microswitches is correct and if the accelerator unit is
in the correct position.
2) Diagnosis during standby that checks: watchdog circuits, phase voltages,
contactor driver, current sensors and CAN bus interface.
3) Diagnosis during operation that checks: watchdog circuits, contactor driver,
current sensors and CAN bus interface.
4) Continuous diagnoses that check: inverter and motor temperature.
Diagnoses can be provided in two ways: the digital console can be used, which
gives detailed information about failures; as an alternative the failure code is sent on
the CAN bus and can be monitored by means of Zapi PC CAN Console.

Page – 12/139 AFFZP0BB – ACE3 – User Manual

3 DRAWINGS

3.1 Mechanical drawing – ACE3 / ACE3 Power

AS

AFFZP7DA
ACE3 PREMIUM 200X40X230 LONGITUDINAL HEAT SINK WITH POWER FUSE
21/10/11

1/1
/
0.5 X 45°
R 0.5

A3
/

1:2
/
/
/

Other versions (without power fuse, with base-plate and with other heat sinks) exist.

AFFZP0BB – ACE3 – User Manual Page – 13/139

 3.2 Connection drawing – ACE3 Traction Standard

Page – 14/139 AFFZP0BB – ACE3 – User Manual

 3.3 Connection drawing – ACE3 Traction Premium

AFFZP0BB – ACE3 – User Manual Page – 15/139

 3.4 Connection drawing – ACE3 Pump Standard

Page – 16/139 AFFZP0BB – ACE3 – User Manual

 3.5 Connection drawing – ACE3 Pump Premium

AFFZP0BB – ACE3 – User Manual Page – 17/139

4 DESCRIPTION OF THE CONNECTORS

4.1 Power connectors

Power connections are on vertical posts where to bolt power-cables lugs. On the
cover of the converter they are labeled as:
-B * Battery negative terminal.
+B * Battery positive terminal.
U, V, W Motor phases. Match the sequence with that at the motor
terminals.
* Throughout this manual, battery terminals are also addressed as -Batt and +Batt.

4.2 Ampseal connectors

ACE3 Standard is equipped with one 23-poles Ampseal connector like that of the
following figure. Each of the 23 pins is referred to as “A#”, where “A” denotes the
connector name and “#” the pin number, from 1 to 23.

ACE3 Standard 23-poles Ampseal connector.

ACE3 Premium is equipped with two equal 23-poles Ampseal connectors. Each of
the 23+23 pins is referred to as “A#” or “B#”, where “A” and “B” denote the
connector name and “#” the pin number, from 1 to 23.

ACE3 Premium twin 23-poles Ampseal connectors.

The following paragraphs list the functional associations for the pins of Ampseal
connectors, for Standard and Premium versions of ACE3 and for Traction and Pump
configurations.

4 For each I/O pin, the default Zapi function is indicated. The function of each pin can
be changed in the customized software. Also, some I/O pins can have special
functionality depending on the HW configuration of the controller.

Page – 18/139 AFFZP0BB – ACE3 – User Manual

4.2.1 ACE3 Traction Standard
Connector A
A1 KEY Connected to the power supply through a microswitch in
series to a 10 A fuse.
A2 PANIN Positive supply for potentiometers: 12 V / 5 V output; keep
load impedance > 1 kOhm / 0.5 kOhm.
A3 CPOT Accelerator-potentiometer input (from wiper contact).
A4 FW Forward-request input. It must be connected to the
forward-drive microswitch, active high.
A5 BW Backward-request input. It must be connected to the
backward-drive microswitch, active high.
A6 SEAT Seat input. It must be connected to the seat microswitch,
active to -Batt.
A7 CHA Incremental-encoder phase-A input.
A8 PENC Positive supply 12 V / 5 V for encoder.
A9 AGND Negative supply for potentiometers.
A10 CPOT BR Brake-potentiometer input (from wiper contact).
A11 PB/QI Pedal-Brake/Quick-Inversion input, active high.
A12 CAN_T1 CAN termination. If it is connected with A21 (CAN_H1) it
introduces the 120 Ohm termination resistance between
CAN_L1 and CAN_H1.
A13 SR/HB Speed-reduction-request or handbrake-request input.
Active when the microswitch is open, inactive when it is
closed to -Batt.
A14 CHB Incremental-encoder phase-B input.
A15 NENC Negative supply for encoder.
A16 NLC Main-contactor output. The coil is driven to -Batt.
Freewheeling diode to the positive supply is built-in.
A17 PEB Connect the positive supply of electrovalves (EB and
EVP) to this pin. Take the positive supply immediately
after the main contactor.
A18 NEB Electromechanical-brake output. The coil is driven to
-Batt. Freewheeling diode to A17 is built-in.
A19 NEVP Proportional-electrovalve output. The coil is driven to
-Batt. Freewheeling diode to A17 is built-in.
A20 CAN_L1 CAN bus 1 low-level signal.
A21 CAN_H1 CAN bus 1 high-level signal.
A22 NCAN CAN bus negative supply.
A23 PTH Motor-temperature-sensor input. It is possible to use a
digital or analog (PTC) sensor.

AFFZP0BB – ACE3 – User Manual Page – 19/139

4.2.2 ACE3 Pump Standard
Connector A
A1 KEY Connected to the power supply through a microswitch in
series to a 10 A fuse.
A2 PANIN Positive supply for potentiometers: 12 V / 5 V output; keep
load impedance > 1 kOhm / 0.5 kOhm.
A3 CPOT Lift-potentiometer input (from wiper contact).
A4 LIFT Lifting-request input. It must be connected to the
lifting-enable microswitch, active high.
A5 LOWER Lowering-request input. It must be connected to the
lowering-enable microswitch, active high.
A6 SEAT Seat input. It must be connected to the seat microswitch,
active to -Batt.
A7 CHA Incremental-encoder phase-A input.
A8 PENC Positive supply 12 V / 5 V for encoder.
A9 AGND Negative supply for the lifting potentiometer.
A10 ANIN2 Free analog input.
A11 HYDRO Hydraulic-steering request input, active high.
A12 CAN_T1 CAN termination. If it is connected with A21 (CAN_H1) it
introduces the 120 Ohm termination resistance between
CAN_L1 and CAN_H1.
A13 SR Speed-reduction request input. Active when the switch is
open. Not active when it is closed to -Batt.
A14 CHB Incremental-encoder phase-B input.
A15 NENC Negative supply for encoder.
A16 NLC Main-contactor output. The coil is driven to -Batt.
Freewheeling diode to the positive supply is built-in.
A17 PAUX Connect the positive supply of electrovalves (AUX and
EVP) to this pin. Take the positive supply immediately
after the main contactor.
A18 NAUX Auxiliary-coil output. The coil is driven to -Batt.
Freewheeling diode to A17 is built-in.
A19 NEVP Lowering-proportional-electrovalve output. The coil is
driven to the negative reference. Freewheeling diode to
A17 is built-in.
A20 CAN_L1 CAN bus 1 low-level signal.
A21 CAN_H1 CAN bus 1 high-level signal.
A22 NCAN CAN bus negative supply.
A23 PTHERM Motor-temperature-sensor input. It is possible to use a
digital or analog (PTC) sensor.

Page – 20/139 AFFZP0BB – ACE3 – User Manual

4.2.3 ACE3 Traction Premium
Connector A
A1 KEY Connected to the power supply through a microswitch in
series to a 10 A fuse.
A2 PANIN Positive supply for potentiometers: 12 V / 5 V output; keep
load impedance > 1 kOhm / 0.5 kOhm.
A3 CPOT Accelerator-potentiometer input (from wiper contact).
A4 FW Forward-request input. It must be connected to the
forward-drive microswitch, active high.
A5 BW Backward-request input. It must be connected to the
backward-drive microswitch, active high.
A6 SEAT Seat input. It must be connected to the seat microswitch,
active to -Batt.
A7 CHA Incremental-encoder phase-A input.
A8 PENC Positive supply 12 V / 5 V for encoder.
A9 AGND Negative supply for potentiometers.
A10 CPOT BR Brake-potentiometer input (from wiper contact).
A11 PB/QI Pedal-Brake/Quick-Inversion input, active high.
A12 CAN_T1 CAN termination. If it is connected with A21 (CAN_H1) it
introduces the 120 Ohm termination resistance between
CAN_L1 and CAN_H1.
A13 SR/HB Speed-reduction-request or handbrake-request input.
Active when the microswitch is open, inactive when it is
closed to -Batt.
A14 CHB Incremental-encoder phase-B input.
A15 NENC Negative supply for encoder.
A16 NLC Main-contactor output. The coil is driven to -Batt.
Freewheeling diode to the positive supply is built-in.
A17 PEB Connect the positive supply of electrovalves (EB and
EVP) to this pin. Take the positive supply immediately
after the main contactor.
A18 NEB Electromechanical-brake output. The coil is driven to
-Batt. Freewheeling diode to A17 is built-in.
A19 NEVP Proportional-electrovalve output. The coil is driven to
-Batt. Freewheeling diode to A17 is built-in.
A20 CAN_L1 CAN bus 1 low-level signal.
A21 CAN_H1 CAN bus 1 high-level signal.
A22 NCAN CAN bus negative supply.
A23 PTH Motor-temperature-sensor input. It is possible to use a
digital or analog (PTC) sensor.

AFFZP0BB – ACE3 – User Manual Page – 21/139

 Connector B
B1 PEV Connect the positive supply of electrovalves (EV1, EV2,
EV3, EV4, EV5) to this pin. Take the positive supply
immediately after the main contactor.
B2 CPOT EVP Proportional-valve-potentiometer input (wiper contact).
B3 ANIN5 Free analog input.
B4 AUX1 Free digital input, active when connected to -Batt
B5 AUX2 Free digital input, active when connected to -Batt.
B6 BACKING FW Forward-inching-request input. It must be connected to
the forward-inching microswitch, active high.
B7 SH1/SIN First Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the sin
signal of a sin/cos sensor.
B8 PSENS Positive supply 12 V / 5 V for Hall sensors or sin/cos
sensor.
B9 NEV5 Output for the voltage-controlled PWM-modulated EV5
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B10 STEER POT Steering-potentiometer input (from wiper contact).
B11 AUX3 Braking-request input. It must be connected to the brake
pedal microswitch, active high.
B12 CAN_T2 CAN termination. If it is connected to B21 (CAN_H2) it
introduces the 120 Ohm termination resistance between
CAN_L2 and CAN_H2.
B13 BACKING BW Backward-inching-request input. It must be connected to
the backward-inching microswitch, active high.
B14 SH2/COS Second Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the cos
signal of a sin/cos sensor.
B15 NSENS Negative supply for Hall sensors (or sin/cos sensor).
B16 NEV1 Output for the voltage-controlled PWM-modulated EV1
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B17 NEV2 Output for the voltage-controlled PWM-modulated EV2
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B18 NEV3 Output for the voltage-controlled PWM-modulated EV3
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B19 NEV4 Output for the voltage-controlled PWM-modulated EV4
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B20 CAN_L2 CAN bus 2 low-level signal.
B21 CAN_H2 CAN bus 2 high-level signal.
B22 SH3 Third Hall-sensor input, active low.
B23 FREE Free pin.

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4.2.4 ACE3 Pump Premium
Connector A
A1 KEY Connected to the power supply through a microswitch in
series to a 10 A fuse.
A2 PANIN Positive supply for potentiometers: 12 V / 5 V output; keep
load impedance > 1 kOhm / 0.5 kOhm.
A3 CPOT Lift-potentiometer input (from wiper contact).
A4 LIFT Lifting-request input. It must be connected to the
lifting-enable microswitch, active high.
A5 LOWER Lowering-request input. It must be connected to the
lowering-enable microswitch, active high.
A6 SEAT Seat input. It must be connected to the seat microswitch,
active to -Batt.
A7 CHA Incremental-encoder phase-A input.
A8 PENC Positive supply 12 V / 5 V for encoder.
A9 AGND Negative supply for the lifting potentiometer.
A10 ANIN2 Free analog input.
A11 HYDRO Hydraulic-steering request input, active high.
A12 CAN_T1 CAN termination. If it is connected with A21 (CAN_H1) it
introduces the 120 Ohm termination resistance between
CAN_L1 and CAN_H1.
A13 SR Speed-reduction request input. Active when the switch is
open. Not active when it is closed to -Batt.
A14 CHB Incremental-encoder phase-B input.
A15 NENC Negative supply for encoder.
A16 NLC Main-contactor output. The coil is driven to -Batt.
Freewheeling diode to the positive supply is built-in.
A17 PAUX Connect the positive supply of electrovalves (AUX and
EVP) to this pin. Take the positive supply immediately
after the main contactor.
A18 NAUX Auxiliary-coil output. The coil is driven to -Batt.
Freewheeling diode to A17 is built-in.
A19 NEVP Lowering-proportional-electrovalve output. The coil is
driven to the negative reference. Freewheeling diode to
A17 is built-in.
A20 CAN_L1 CAN bus 1 low-level signal.
A21 CAN_H1 CAN bus 1 high-level signal.
A22 NCAN CAN bus negative supply.
A23 PTHERM Motor-temperature-sensor input. It is possible to use a
digital or analog (PTC) sensor.

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 Connector B
B1 PEV Connect the positive supply of electrovalves (EV1, EV2,
EV3, EV4, EV5) to this pin. Take the positive supply
immediately after the main contactor.
B2 ANIN3 Free analog input.
B3 ANIN5 Free analog input.
B4 3RD Third-speed input, to be connected to the 3rd-speed
microswitch, active high.
B5 4TH Fourth-speed input, to be connected to the 4th-speed
microswitch, active high.
B6 2ND Second-speed input, to be connected to the 2nd-speed
microswitch, active high.
B7 SH1/SIN First Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the sin
signal of a sin/cos sensor.
B8 PSENS Positive supply 12 V / 5 V for Hall sensors (or sin/cos
sensor).
B9 NEV5 Output for the voltage-controlled PWM-modulated EV5
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B10 ANIN5 Free analog input.
B11 5TH Fifth-speed input, to be connected to the 5th-speed
microswitch, active high.
B12 CAN_T2 CAN termination. If it is connected to B21 (CAN_H2) it
introduces the 120 Ohm termination resistance between
CAN_L2 and CAN_H2.
B13 1ST First-speed input, to be connected to the 1st-speed
microswitch, active high.
B14 SH2/COS Second Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the cos
signal of a sin/cos sensor.
B15 NSENS Negative supply for Hall sensors (or sin/cos sensor).
B16 NEV1 Output for the voltage-controlled PWM-modulated EV1
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B17 NEV2 Output for the voltage-controlled PWM-modulated EV2
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B18 NEV3 Output for the voltage-controlled PWM-modulated EV3
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B19 NEV4 Output for the voltage-controlled PWM-modulated EV4
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.
B20 CAN_L2 CAN bus 2 low-level signal.
B21 CAN_H2 CAN bus 2 high-level signal.
B22 SH3 Third Hall-sensor input, active low.
B23 FREE Free pin.
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5 INPUT DEVICES
This chapter describes the external devices needed to complete the ACE3
installation kit.

5.1 Key Input

5.1.1 Function
Start key switch of the vehicle, generally connected to the KEY input. It supplies with
the battery voltage the controller logic circuitry and it also pre-charges the DC-link
capacitors at key-on. The KEY voltage is monitored.

4 Note: external loads connected to the +Batt power terminal, such as proximity
switches, load the internal PTC resistor along the key input path, with the
consequence that the pre-charge voltage may be lower than expected.

5.1.2 Protection
The KEY input is protected against reverse polarity with a diode and it has got
approximately a 22 nF capacitance to -Batt for ESD protection and other filtering
elements. This capacitance may give a high current spike at the KEY input
depending on the external circuit.
Fuse FU1 (see functional drawings, chapter 3), should be sized according to the
number of motor controllers connected to it (10 A fuse is recommended) and the
current absorption of the KEY input (input power under 15 W).

5.2 Digital Inputs

Digital inputs are meant to work in the voltage range from -Batt to +Batt. Related
command devices (microswitches) must be connected to +Batt (typically to the key
voltage) or to -Batt, depending on the input configuration (refer to pin description in
chapter 4). Pull-down or pull-up resistors are built-in. Functional devices (like FW,
BW, PB, etc.) must be normally open, so that each associated function becomes
active when the microswitch closes.
Safety-related devices (like CUTBACK) must be normally closed, so that each
associated function becomes active when the microswitch opens.

5.2.1 Microswitches
- It is suggested to adopt microswitches with a contact resistance lower than
0.1 Ohm and a leakage current lower than 100 µA.
- In full-load condition, the voltage between the key-switch contacts must be lower
than 0.1 V.
- If the microswitches to be adopted have different specifications, it is suggested
to discuss them with Zapi technicians prior to employ them.

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 5.3 Accelerator unit
One analog input can be connected to an accelerator unit. The accelerator unit can
consist of a potentiometer or a Hall-effect device. It should be in a three-wire
configuration. The potentiometer is supplied through terminal A2 (positive terminal)
and A9 (negative terminal). Potentiometer output signal (from the wiper contact)
must drive input CPOT (A3) and voltage signal must be in the 0 – 10 V range.
Potentiometer resistance should be in the 0.5 k – 10 k range; generally, current
should be in the 1.5 – 30 mA range. Faults can occur if this limit is exceeded.
The standard connection for the potentiometer is the one on the left of next figure
(potentiometer at rest on one end) in combination with a couple of travel-demand
switches. On request, it is also possible to adopt the configuration on the right
(potentiometer at rest in the middle) in combination with a couple of travel-demand
switches.

The procedure for automatic acquisition of the potentiometer signal is carried out
using the Console, by means of the PROGRAM VACC function. This enables the
adjustment of the minimum and maximum useful levels, in both direction. This
function is particularly useful when it is necessary to compensate for asymmetry of
mechanical elements associated with the potentiometer, especially relating to the
minimum level.
The following two graphs show the output voltage of a potentiometer versus the
mechanical angle of the control lever. Angles MI and MA indicate the points where
the direction switches close, while 0 represents the mechanical zero of the lever, i.e.
its rest position. Also, the relationship between motor voltage (Vmot) and
potentiometer voltage (Vacc) is shown. After the adjustment procedure, Vmot
percentage is mapped over the useful voltage ranges of the potentiometer, for both
directions. On the other hand, before calibration it results mapped over the default
0 – 5 V range.

Before PROGRAM VACC After PROGRAM VACC

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 5.4 Other analog control unit
5.4.1 Standard version
1) Input A10 is an analog input, whose typical application is as reference for
proportional braking. The driving potentiometer should be in a three-wire
configuration, its resistance should be within the 0.5 – 10 k range, the current
within the 1.5 – 30 mA range and the voltage signal from 0 to 10 V.
2) Connections A23 (PTH) is used for a motor thermal sensor. It can be digital
(on/off sensor, normally closed) or analog.

5.4.2 Premium version

Three additional analog inputs are available:
1) Input B2 is an analog input, whose typical application is as reference for the
control of the proportional valve.
2) Input B10 is an analog input, whose typical application is as steering
reference.
3) Input B3 is an analog input, without a predefined function.
Each driving potentiometer should be in a three-wire configuration, its resistance
should be within the 0.5 – 10 k range, the current within the 1.5 – 30 mA range
and the voltage signal from 0 to 10 V.

5.5 Speed feedback

Motor control is based upon the motor speed feedback (sensored control). The
speed transducer is an incremental encoder, with two phases shifted by 90°.
The encoder can have the following features:
- Power supply: 5 V or 12 V.
- Electric output: open collector (NPN) or push-pull.
- Standard output (channel A and channel B, 90° shifted).
For more details about encoder installation also refer to paragraph 6.2.5.

4 Note: encoder resolution and motor poles pair that the controller is set to handle are
displayed in the home page of the PC CAN Console or of the Smart Console, as:

A3MT2B ZP1.13

Where:
A3MT = ACE3 traction controller (M stands for “Master μC”, S for “Slave μC”)
(A3MP = ACE3 pump controller)
2 = poles pair number
B = 64 pulses/rev

Encoder resolution (in pulses/rev ) is given by the last letter as:A = 32, B = 64, C =
80, D = 128

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5.5.1 Sin/Cos sensor and Hall sensors
ACE3 Premium provides a special interface to connect an absolute sin/cos sensor
or three Hall sensors for special applications that use brushless motor. For more
details about sensors installation also refer to paragraphs 6.2.6 and 6.2.7.

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6 INSTALLATION HINTS
Before starting the inverter, it is necessary to have the required material for a correct
installation. Wrong choice additional parts could lead to failures, misbehaviors or
bad performance.

6.1 Material overview

6.1.1 Connection cables
For the auxiliary circuits use cables with 0.5 mm² section.
For power connections, to the motor and from the battery, use cables with section of
50 mm² or more. Screwing torque for the power connections must be in the 13 - 15
Nm range.
For the optimum inverter performance, the cables from the battery should run side
by side and be as short as possible.

6.1.2 Contactors
Main contactor must always be installed. The output driving the coil is modulated
with a 1 kHz PWM basing on the setting of two parameters (MC VOLTAGE and MC
VOLTAGE RED.). After an initial delay of about 1 second, during which the coil is
driven with a percentage of VBATT set by the MC VOLTAGE parameter, the PWM
reduces the mean voltage down to the percentage set by the MC VOLTAGE RED.
parameter. This feature is useful to decrease the power dissipation of the coil and its
heating.

6.1.3 Fuses
- Use a 10 A fuse for protection of the auxiliary circuits.
- For the protection of the power unit, refer to chapter 10. 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 spreading of particles in case the fuse blows.

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 6.2 Hardware installation

U Before doing any operation, ensure that the battery is disconnected and when
the installation is completed start the machine with the drive wheels raised
from the ground to ensure that any installation error do not compromise
safety.

U After the inverter turn-off, even with the key switch open, the internal
capacitors may remain charged for some time. For safe operation onto the
setup, it is recommended to disconnect the battery and to discharge the
capacitors by means of a resistor of about 10 – 100 Ohm between the +Batt
and -Batt terminals of the inverter.

6.2.1 Positioning and cooling of the controller

Install the inverter with the base-plate on a flat metallic surface.
- Ensure that the installation surface is clean and unpainted.
- Apply a thin layer of thermo-conductive grease between the two surfaces to
allow better heat dissipation.
- Ensure that cable terminals and connectors are correctly connected.
- Fit transient suppression devices to the horn, solenoids and contactors not
connected to the controller.
- Ensure the compartment to be ventilated and the heat-sinking materials ample.
- The heat-sinking material and should be sized on the performance requirement
of the machine. Abnormal ambient temperatures should be considered. In
situations where either external ventilation is poor or heat exchange is difficult,
forced ventilation should be used.
- The thermal energy dissipated by the power module varies with the current
drawn and with the duty cycle.

6.2.2 Wirings: power cables

- Power cables must be as short as possible to minimize power losses.
- They must be tightened onto the controller power posts with a torque in the 13
Nm – 15 Nm range.
- The ACE3 module should only be connected to a traction battery. Do not use
converters outputs or power supplies. For special applications please contact
the nearest Zapi Service Centre.

U Do not connect the controller to a battery with a nominal voltage different to

the nominal value, indicated on the controller label. A higher battery voltage
may cause failures in the power section. A lower voltage may not allow the
controller to work.

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6.2.3 Wirings: CAN bus connections and possible interferences

4 CAN stands for Controller Area Network. It is a communication protocol for real time
control applications. CAN operates at data-rate of up to 1 Mbit/s.
It was introduced by the German company Bosch to be used in the automotive
industry to permit communication among the various electronic modules of a
vehicle. The connection scheme is illustrated in the following image.

- The best type of cables 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 shielded cables, where the shield is connected to the frame of the truck.
Sometimes it is sufficient a not shielded two-wire cable or a duplex cable.
- In a system like an industrial truck, where power cables carry currents of
hundreds of Ampere, voltage drops due to the impedance of the cables may be
considerable, and that could cause errors on the data transmitted through the
CAN wires. The following figures show an overview of wrong and right layouts
for the routing of CAN connected systems.

U Wrong Layout:

Power cables

Module Module

Module

The red lines are CAN wires.

The black boxes are different modules, for example a traction controller, a pump
controller and a display connected via CAN bus.

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 The black lines are the power cables.
This is apparently a good layout, but actually it can bring to errors onto the CAN line.
The best solution depends on the type of nodes (modules) connected in the
network.
If the modules are very different in terms of power, then the preferable connection is
the daisy chain.

U Correct Layout:

Module
Module
1
2

Module
3

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

The chain starts from the –BATT post of the controller that deals with the highest
current, while the other ones 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 (for example a steering
controller), the best way to address this configuration is creating a common ground
point (star configuration), as it is in the next figure.

U Correct Layout:

Module
Module
1
2
Center of the Ground connection

Module
3

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

In this case, the power cables of the two similar controllers must be as short as
possible. Of course also the diameter of the cables concurs in the voltage drops
described before (a greater diameter brings to a lower impedance), so in this last
example the cable between negative battery terminal and the center of the ground

Page – 32/139 AFFZP0BB – ACE3 – User Manual

 connection (pointed by the arrow in the image) must be sized taking into account
both thermal and voltage drop problems and considering the current drawn from the
battery by the overall system.

4 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
- simple design (readily available, multi sourced components and tools)
- low costs (less and smaller cables)
- high reliability (fewer connections)
- ease of analysis (easy connection with a pc to sniff the data being transferred onto
the bus).

6.2.4 Wirings: I/O connections

- After crimping the cables, verify that all strands are entrapped in the wire barrel.
- Verify that all the crimped contacts are completely inserted in the connector
cavities.

U A cable connected to the wrong pin can lead to short circuits and failure; so,
before turning on the truck for the first time, verify with a ohmmeter the
continuity between the starting point and the end of signal wires.

- For information about the pin assignment see chapter 4.

6.2.5 Connection of the encoder

ACE3 controller can handle different types of encoder. To control AC motor, it is
necessary to install an incremental encoder with two phases shifted by 90°. The
encoder supply can be 5 V or 12 V.
A8 +5V/+12V positive supply.
A15 GND negative supply.
A7 ENC A phase A.
A14 ENC B phase B.

Connection of encoder with +5 V supply.

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 Connection of encoder with +12 V supply.

U VERY IMPORTANT
It is necessary to specify in the commercial 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.

6.2.6 Connection of a Sin/Cos sensor

When the PMSM is of the BLAC type, must be controlled with sine waves shape. A
PMSM is a BLAC when, by turning its shaft lightened, the electromotive force
between two motor terminals is of the shape sinusoidal.
To control PMAC motor with Zapi inverter, it is necessary to install an absolute
Sin/Cos sensor. The Sin/Cos sensor power supply can be +5 or +12 V. At the first
key an auto-teaching procedure it is necessary to permit to the controller to acquire
the sensor signals.
B8 +5V/+12V positive supply.
B15 GND negative supply.
B7 SIN sine signal.
B14 COS cosine signal.

Connection of sin/cos sensors.

U VERY IMPORTANT
It is necessary to specify in the commercial order the type of sensor used, in
terms of power supply, electronic output and n° of pulses for revolution,
because the logic unit and the software must be set in the correct way by Zapi
lines.

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6.2.7 Connection of Hall sensors
When the PMSM is of the BLDC type, must be controlled with a six steps inverter
(trapezoidal wave shape). A PMSM is a BLDC when, by turning its shaft lightened,
the electromotive force between two motor terminals is of the shape trapezoidal.
To control BLDC motor with Zapi inverter, it is necessary to three Hall sensors. Hall
sensors power supply can be +5 or +12 V.
B8 +5V/+12V positive supply.
B15 GND negative supply.
B7 HS1 Hall sensor 1.
B14 HS2 Hall sensor 2.
B22 HS3 Hall sensor 3.

Connection of Hall sensors.

U VERY IMPORTANT
It is absolutely mandatory to specify in the commercial order the type of
sensor to be used, in terms of supply voltage, electronic output and number
of pulses per revolution, configuration of hall sensors and the sensor
sequence when the rotor is spinning because the logic unit and the software
must be set in the correct way by Zapi lines.

6.2.8 Main-contactor and key connection

- The connection of the main contactor can be carried out as the following figure.

- The connection of the battery line switches must be carried out following
instructions from Zapi.

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 - If a mechanical battery line switch is installed, it is necessary that the key supply
to the inverter is open together with power battery line; if not, the inverter may
be damaged if the switch is opened during a regenerative braking.
- An intrinsic protection is present against battery voltages above 140% of the
nominal one and against the key switching-off before disconnecting the battery
power line.

6.2.9 Insulation of truck frame

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

“there shall be no electrical connection to the truck frame”. So the truck frame
has to be isolated from any electrical potential of the truck power line.

6.3 Protection and safety features

6.3.1 Protection features
The ACE3 inverter is protected against:
- Battery polarity inversion
It is necessary to install a main contactor in order to protect the inverter 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 temperature excess. Also, the temperature can never exceed
105 °C.
- External agents
The inverter is protected against dust and sprays with a degree of protection
meeting IP65.
- Protection against uncontrolled movements
The main contactor will not close if:
- The power unit is not functioning.
- The logic unit is not functioning.
- The output voltage of the accelerator does not fall below the threshold given
by the minimum voltage value stored during the adjustment procedure, plus
1 V.
- One drive microswitch (forward or backward) is closed.
- Low battery charge
When the battery charge is low, the maximum current is reduced to half of the
maximum programmed current.
- Protection against accidental start up
A precise sequence of operations are necessary for the machine to start.
Operation does not begin if they are not correctly carried out.
Requests for drive must be made after closing the key switch.

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6.3.2 Safety Features

U ZAPI controllers are designed according to the prEN954-1 specifications for

safety related parts of the control system and according 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 customers 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.
The machine manufacturer holds the responsibility for the truck safety
features and related approval.

6.4 EMC

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

by the installation. Special attention must be given to lengths, paths and
shielding of the electric connections. These aspects are beyond of Zapi
control. Zapi can offer assistance and suggestions on EMC related problems,
basing on its long experience. However, ZAPI declines any responsibility for
non-compliance, malfunctions and failures, if correct testing is not made. The
machine manufacturer holds the responsibility to carry out machine
validation, based on existing norms (EN12895 for industrial truck; EN50081-2
for other applications).

EMC stands for Electromagnetic Compatibility, and it deals with the electromagnetic
behavior of an electrical device, both in terms of emission and reception of
electromagnetic waves that may cause electromagnetic interference with the
surrounding electronics.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the device
and the possible countermeasures to prevent the propagation of that energy; we
talk about “conduction” issues when guiding structures such as wires and cables
are involved, “radiated emissions” issues when it is studied the propagation of
electromagnetic energy through the open space. In our case the origin of the
disturbances can be found inside the controller with the switching of the
MOSFETs at high frequency which can generate RF energy. However wires
have the key role to propagate disturbs because they work as antennas, so a
good layout of the cables and their shielding can solve the majority of the
emission problems.

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 2) The study of the immunity can be divided in two main branches: protection from
electromagnetic fields and from electrostatic discharge. The electromagnetic
immunity concerns 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
undergo. These tests are carried out at determined levels of electromagnetic
fields, simulating external undesired disturbances and verifying the response.
The second type of immunity, to ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
“electrostatic charge”; ESD happens when there is a rapid transfer from one
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 thus causing malfunctions; this effect is particularly critical in
modern machines, with serial communications (CAN bus) which are spread
everywhere on the truck and which may carry critical information.
- 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 a temporary malfunction to a definitive failure of the
electronic device.

4 IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from being
generated, rather than increasing the level of immunity of the electronic devices.

There are different solutions for EMC issues, depending on level of emissions/
immunity required, the type of controller, materials and position of the wires and
electronic components.
1) EMISSIONS. Three ways can be followed to reduce the emissions:
- SOURCE OF EMISSIONS: finding the main source of disturb and work on
it.
- SHIELDING: enclosing contactor and controller in a shielded box; using
shielded cables;
- LAYOUT: a good layout of the cables can minimize the antenna effect;
cables running nearby the truck frame or in iron channels connected to truck
frames is generally a suggested not expensive solution to reduce the
emission level.
2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are
valid also for immunity. Additionally, further protection can be achieved with
ferrite beads and bypass capacitors.
3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent
damages from ESD:
- 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.
- ISOLATION: use anti-static containers when transferring ESD-sensitive
material.

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 - GROUNDING: when a complete isolation cannot be achieved, a good
grounding can divert the discharge current trough a “safe” path; the frame of
a truck can works like a “local earth ground”, absorbing excess charge. So it
is strongly suggested to connect to truck frame all the parts of the truck
which can be touched by the operator, who is most of the time the source of
ESD.

6.5 Various suggestions

- Never connect SCR low frequency chopper with asynchronous inverter because
the asynchronous filter capacitors alter the functioning of the SCR choppers. If it
is necessary to use two or more control units (traction and lift for ex.), they must
belong to the ZAPIMOS family.
- During battery charge, disconnect asynchronous from the battery.

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7 INVERTER SETTINGS

7.1 Settings overview

Inverter settings are defined by a wide set of parameters, organized as follows.
PARAMETER SPECIAL HARDWARE
SET OPTIONS ADJUSTMENT
CHANGE ADJUST. SETTING
ACC. TORQUE DEL. HM DISPLAY OPT. SET BATTERY ADJUSTMENT #01 TOP MAX SPEED
DEC. TORQUE DEL. HM CUSTOM 1 OPT. ADJUST KEY VOLT. ADJUSTMENT #02 CONF.POSITIVE LC
ACCELER. DELAY HM CUSTOM 2 OPT. ADJUST BATTERY CURR. SENS. COMP FEEDBACK SENSOR
RELEASE BRAKING TILL/SEAT SWITCH SET POSITIVE PEB DIS.CUR.FALLBACK ROTATION CW ENC
TILLER BRAKING EB ON TILLER BRK SET PBRK. MIN SET CURRENT ROTATION CW MOT
INVERS. BRAKING BATTERY CHECK SET PBRK. MAX SET TEMPERATURE ENCODER PULSES 1
DECEL. BRAKING STOP ON RAMP MIN LIFT DC HW BATTERY RANGE ENCODER PULSES 2
PEDAL BRAKING PULL IN BRAKING MAX LIFT DC DUTY PWM CTRAP MOTOR P. PAIRS 1
SPEED LIMIT BRK. SOFT LANDING MIN LOWER HW EXTENSION MOTOR P. PAIRS 2
STEER BRAKING QUICK INVERSION MAX LOWER PWM AT LOW FREQ ***
MAX SPEED FORW PEDAL BRK ANALOG THROTTLE 0 ZONE PWM AT HIGH FREQ
MAX SPEED BACK HARD & SOFT THROTTLE X1 MAP FREQ TO SWITCH
HYDRO SETTINGS
MAX SPEED LIFT MAIN POT. TYPE THROTTLE Y1 MAP DITHER AMPLITUDE
1ST PUMP SPEED AUX POT. TYPE THROTTLE X2 MAP DITHER FREQUENCY HYDRO TIME
2ND PUMP SPEED SET MOT.TEMPERAT THROTTLE Y2 MAP HIGH ADDRESS HYDRO FUNCTION
3RD PUMP SPEED STEERING TYPE THROTTLE X3 MAP CAN BUS SPEED
4TH PUMP SPEED M.C. FUNCTION THROTTLE Y3 MAP EXTENDED FORMAT
5TH PUMP SPEED EBRAKE ON APPL. BAT. MIN ADJ. DEBUG CANMESSAGE
HYD PUMP SPEED AUX OUT FUNCTION BAT. MAX ADJ. CONTROLLER TYPE
CUTBACK SPEED 1 SYNCRO BDI ADJ STARTUP SAFETY LEVEL
CUTBACK SPEED 2 AUTO PARK BRAKE BDI RESET RS232 CONSOLLE
H&S CUTBACK AUTO LINE CONT. BATT.LOW TRESHLD ID CANOPEN OFST
CTB. STEER ALARM ACCEL MODULATION BAT.ENERGY SAVER 2ND SDO ID OFST
CURVE SPEED 1 EVP TYPE STEER RIGHT VOLT VDC START UP LIM
CURVE CUTBACK EV1 STEER LEFT VOLT VDC UP LIMIT
FREQUENCY CREEP EV2 STEER ZERO VOLT VDC START DW LIM
TORQUE CREEP EV3 MAX ANGLE RIGHT VDC DW LIMIT
MAX. CURRENT TRA EV4 MAX ANGLE LEFT
MAX. CURRENT BRK HIGH DYNAMIC STEER DEAD ANGLE
ACC SMOOTH INVERSION MODE STEER ANGLE 1
INV SMOOTH STEER TABLE STEER ANGLE 2
STOP SMOOTH WHEELBASE MM SPEED FACTOR
BRK SMOOTH FIXED AXLE MM SPEED ON MDI
STOP BRK SMOOTH STEERING AXLE MM LOAD HM FROM MDI
BACKING SPEED REAR POT ON LEFT CHECK UP DONE
BACKING TIME DISPLAY TYPE CHECK UP TYPE
EB. ENGAGE DELAY ABS.SENS.ACQUIRE MC VOLTAGE
AUXILIARY TIME MC VOLTAGE RED.
ROLLING DW SPEED EB VOLTAGE
MIN EVP EB VOLTAGE RED.
MAX EVP PWM EV1
EVP OPEN DELAY PWM EV2
EVP CLOSE DELAY PWM EV3
HYDRO TIME PWM EV4
PWM EV5
MAX MOTOR TEMP.
STOP MOTOR TEMP.
A.SENS.MAX SE
A.SENS.MIN SE
A.SENS.MAX CE
A.SENS.MIN CE
MOT.T. T.CUTBACK
VACC SETTING

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 7.2 Settings description
This section provides detailed information about all the inverter settings.
In the following tables, “Parameter” columns also report between brackets lists of
the controller types where each parameter is available.
Controller types are coded as:
A = All controller types
T = Traction controllers (in single motor applications)
TM = Traction master controllers (in multiple motor applications)
TS = Traction supervisor controllers (in multiple motor applications)
P = AC pump controllers
CO = CANopen controllers
N = none

4 The parameters and the functionalities described in the following paragraphs are
referred to ZAPI Standard software. They could be different in any other customized
software releases depending on customer requests.

7.2.1 PARAMETER CHANGE

PARAMETER CHANGE

Parameter Allowable range Description

ACC. TORQUE DEL. 0.1 s ÷ 10 s This parameter defines the acceleration ramp if TORQUE
CONTROL is ON, i.e. the time needed to increase the torque from
(T, TM, P, CO) (by steps of 0.1 s) the minimum value up to the maximum one.

DEC. TORQUE DEL. 0.1 s ÷ 10 s This parameter defines the deceleration ramp if TORQUE
CONTROL is ON, i.e. the time needed to decrease the torque
(T, TM, P, CO) (by steps of 0.1 s) from the maximum value down to the minimum one.

ACCELER. DELAY 0.1 s ÷ 25.5 s This parameter defines the acceleration ramp, i.e. the time needed
to speed up the motor from 0 Hz up to 100 Hz.
(T, TM, P, CO)
(by steps of 0.1 s) A special software feature manages the acceleration ramp
depending on the speed setpoint (see paragraph 8.4).

RELEASE BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed after the
running request is released, i.e. the time needed to decelerate the
(T, TM, P, CO) (by steps of 0.1 s) motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.4).

TILLER BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed after the
tiller/seat switch is released, i.e. the time needed to decelerate the
(T, TM) (by steps of 0.1 s) motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.4).

INVERS. BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed when the
direction switch is toggled during drive, i.e. the time needed to
(T, TM, CO) (by steps of 0.1 s) decelerate the motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.4).

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 PARAMETER CHANGE

Parameter Allowable range Description

DECEL. BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed when the
accelerator is released but not completely, i.e. the time needed to
(T, TM, CO) (by steps of 0.1 s) decelerate the motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.5).

PEDAL BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed when the
braking pedal is pressed, i.e. the time needed to decelerate the
(T, TM, CO) (by steps of 0.1 s) motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.5).

SPEED LIMIT BRK. 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed upon a
speed-reduction request, i.e. the time needed to decelerate the
(T, TM) (by steps of 0.1 s) motor from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.5).

STEER BRAKING 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp related to the
steering angle, i.e. the time needed to decelerate the motor from
(T, TM) (by steps of 0.1 s) 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp
depending on the starting speed (see paragraph 8.5).

MAX SPEED FORW 0% ÷ 100% This parameter defines the maximum speed in forward direction
as a percentage of TOP MAX SPEED.
(T, TM) (by 1% steps)

MAX SPEED BACK 0% ÷ 100% This parameter defines the maximum speed in backward direction
as a percentage of TOP MAX SPEED.
(T, TM) (by 1% steps)

MAX SPEED LIFT 0% ÷ 100% This parameter defines the maximum speed of the pump motor
during lift, as a percentage of the maximum voltage applied to the
(P) (by 1% steps) pump motor.

st
1ST PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor when 1
speed is requested. It represents a percentage of the maximum
(P) (by 1% steps) pump speed.

nd
2ND PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor when 2
speed is requested. It represents a percentage of the maximum
(P) (by 1% steps) pump speed.

rd
3RD PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor when 3
speed is requested. It represents a percentage of the maximum
(P) (by 1% steps) pump speed.

th
4TH PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor when 4
speed is requested. It represents a percentage of the maximum
(P) (by 1% steps) pump speed.

th
5TH PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor when 5
speed is requested. It represents a percentage of the maximum
(P) (by 1% steps) pump speed.

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 PARAMETER CHANGE

Parameter Allowable range Description

HYD PUMP SPEED 0% ÷ 100% This parameter defines the speed of the pump motor used for the
steering, when HYDRO FUNCTION is ON. It represents a
(P) (by 1% steps) percentage of the maximum pump speed.

CUTBACK SPEED 1 10% ÷ 100% This parameter defines the maximum speed performed when
cutback input 1 is active. It represents a percentage of TOP MAX
(T, TM, P) (by 1% steps) SPEED.

CUTBACK SPEED 2 10% ÷ 100% This parameter defines the maximum speed performed when
cutback input 2 is active. It represents a percentage of TOP MAX
(T, TM, P) (by 1% steps) SPEED.

H&S CUTBACK 10% ÷ 100% This parameter defines the maximum speed performed when the
Hard-and-Soft function is active. It represents a percentage of
(T, TM) (by 1% steps) TOP MAX SPEED.
Note: by default H&S function is not present on ACE3.

CTB. STEER ALARM 0% ÷ 100% This parameter defines the maximum traction speed when an
alarm from the EPS is read by the microcontroller, if the alarm is
(T, TM) (by 1% steps) not safety-related. The parameter represents a percentage of TOP
MAX SPEED.

CURVE SPEED 1 0% ÷ 100% This parameter defines the maximum traction speed when the
steering angle is equal to the STEER ANGLE 1 angle. The
(T, TM) (by 1% steps) parameter represents a percentage of TOP MAX SPEED.

CURVE CUTBACK 1% ÷ 100% This parameter defines the maximum traction speed when the
steering angle is equal to the STEER ANGLE 2 angle. The
(T, TM) (by 1% steps) parameter represents a percentage of TOP MAX SPEED.

FREQUENCY CREEP 0.6 Hz ÷ 25 Hz This parameter defines the minimum speed when the forward- or
reverse-request switch is closed, but the accelerator is at its
(T, TM, P) (by steps of 0.1 Hz) minimum.

TORQUE CREEP 0% ÷ 100% This parameter defines the minimum torque applied when torque
control is enabled and the forward- or reverse-request switch is
(T, TM, P, CO) (255 steps) closed, but the accelerator is at its minimum.

MAX. CURRENT TRA 0% ÷ 100% This parameter defines the maximum current applied to the motor
during acceleration, as a percentage of the factory-calibrated
(T, TM, P, CO) (by 1% steps) maximum current.

MAX. CURRENT BRK 0% ÷ 100% This parameter defines the maximum current applied to the motor
during deceleration, as a percentage of the factory-calibrated
(T, TM, P, CO) (by 1% steps) maximum current.

ACC SMOOTH 1÷5 This parameter defines the acceleration profile: 1 results in a
linear ramp, higher values result in smoother parabolic profiles.
(T, TM, P, CO) (by steps of 0.1)

INV SMOOTH 1÷5 This parameter defines the acceleration profile performed when
the truck changes direction: 1 results in a linear ramp, higher
(T, TM, CO) (by steps of 0.1) values result in smoother parabolic profiles.

STOP SMOOTH 3 Hz ÷ 100 Hz This parameter defines the frequency at which the smoothing
effect of the acceleration profile ends.
(T, TM, P, CO) (by steps of 1 Hz)

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 PARAMETER CHANGE

Parameter Allowable range Description

BRK SMOOTH 1÷5 This parameter defines the deceleration profile: 1 results in a
linear ramp, higher values result in smoother parabolic profiles.
(T, TM, CO) (by steps of 0.1)

STOP BRK SMOOTH 3 Hz ÷ 100 Hz This parameter defines the frequency at which the smoothing
effect of the deceleration profile ends.
(T, TM, CO) (by steps of 1Hz)

BACKING SPEED 0% ÷ 100% This parameter defines maximum speed performed when the
inching function is active. The parameter represents a percentage
(T, TM) (by 1% steps) of TOP MAX SPEED.

BACKING TIME 0 s ÷ 10 s This parameter defines the duration of the inching function.
(T, TM) (by steps of 0.1 s)

EB. ENGAGE DELAY 0 s ÷ 12.75 s This parameter defines the delay introduced between the traction
request and the actual activation of the traction motor. This takes
(T, TM, P, CO) (by steps of 0.05 s) into account the delay occurring between the activation of the EB
output (i.e. after a traction request) and the effective EB release,
so to keep the motor stationary until the electromechanical brake
is actually released. The releasing delay of the brake can be
measured or it can be found in the datasheet.

AUXILIARY TIME 0 s ÷ 10 s For the encoder version, this parameter defines how long the truck
is hold in place if the STOP ON RAMP option is ON.
(T, TM, P, CO) (by steps of 0.1 s)

ROLLING DW SPEED 1 Hz ÷ 50 Hz This parameter defines the maximum speed for the rolling-down
function.
(T, TM, P, CO) (by steps of 1Hz)

MIN EVP 0% ÷ 100% This parameter defines the minimum current applied to EVP when
the relative potentiometer is at minimum. This parameter is not
(A) (255 steps) effective if the EVP is programmed like an on/off valve.

MAX EVP 0% ÷ 100% This parameter defines the maximum current applied to EVP when
the relative potentiometer is at maximum. This parameter also
(A) (255 steps) determines the current value when the EVP is programmed like an
ON/OFF valve.

EVP OPEN DELAY 0 s ÷ 12.75 s This parameter defines the time needed to increase the EVP
current from zero up to the maximum.
(A) (by steps of 0.05 s)

EVP CLOSE DELAY 0 s ÷ 12.75 s This parameter defines the time needed to decrease the EVP
current from the maximum down to zero.
(A) (by steps of 0.05 s)

HYDRO TIME 0 s ÷ 20 s This parameter defines how long the hydraulic steering remains
active after the traction request is released.
(P) (by steps of 0.1 s)

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7.2.2 SET OPTIONS

SET OPTIONS

Parameter Allowable range Description

HM DISPLAY OPT. 0÷6 This parameter decides the configuration for the hour meter
shown on a display (i.e. MDI). The possible settings are the
(T, TM, P, CO) same of HM CUSTOM 1 OPT. parameter.

HM CUSTOM 1 OPT. 0÷6 This parameter decides the configuration for the hour meter
number 1 accessible to the customer.
(T, TM, P, CO)
The possible settings are:
0: The hour meter counts since the controller is on.
1: The hour meter counts when the three-phase power
bridge is active
2: The hour meter counts when the DC motor power
bridge is active
3: The hour meter counts when one of the valve outputs
is active
4: The hour meter counts when the three-phase power
bridge is active or the DC motor power bridge is active
5: The hour meter counts when the DC motor power
bridge is active or one of the valve outputs is active
6: The hour meter counts when the three-phase power
bridge is active or the DC motor power bridge is active or
one of the valve outputs is active
Note: options 2, 4, 5 and 6 are not effective on ACE3

HM CUSTOM 2 OPT. This parameter decides the configuration for the hour meter
0÷6 number 2 accessible to the customer. The possible settings
(T, TM, P, CO) are the same of HM CUSTOM 1 OPT. parameter.

TILL/SEAT SWITCH HANDLE ÷ SEAT This option handles the input A6. This input opens when the
operator leaves the truck. It is connected to a key voltage
(T, TM, P) when the operator is present.
HANDLE = input A6 is managed as tiller input (no delay
when released).
DEADMAN = input A6 is managed as dead-man input
(no delay when released).
SEAT = input A6 is managed as seat input (with a delay
when released and the de-bouncing function).

EB ON TILLER BRK OFF, ON This option defines how the electromechanical brake is
managed depending on the status of tiller/seat input:
(T)
ON = the electromechanical brake is engaged as soon
as the tiller input goes into OFF state. The deceleration
ramp defined by “tiller braking” parameter has no effect.
OFF = when the tiller input goes into OFF state, the “tiller
braking” ramp is applied before engaging the
electromechanical brake.

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 SET OPTIONS

Parameter Allowable range Description

BATTERY CHECK 0÷3 This option specifies the management of the low battery
charge situation. There are four levels of intervention:
(T, TM, P, CO)
0 = nothing happens; the battery charge level is
evaluated but ignored, meaning that no action is taken
when the battery runs out.
1 = the BATTERY LOW alarm occurs when the battery
level is evaluated to be lower or equal to 10% of the full
charge. With the BATTERY LOW alarm, the control
reduces the maximum speed down to 24% of the full
speed and it also reduces the maximum current down to
50% of the full current.
2 = the BATTERY LOW alarm occurs when the battery
level is evaluated to be lower or equal to 10% of the full
charge.
3 = the BATTERY LOW alarm occurs when the battery
level is evaluated to be lower or equal to 10% of the full
charge. With the BATTERY LOW alarm, the control
reduces the maximum speed down to 24% of the full
speed.

STOP ON RAMP OFF, ON This parameter enables or disables the stop-on-ramp feature
(the truck is electrically held in place on a slope for a defined
(T, TM, P, CO) time).
ON = the stop-on-ramp feature (truck electrically held on a
ramp) is performed for a time set in the "AUXILIARY TIME"
parameter. After this interval, the behavior depends on the
"AUX OUT FUNCTION" option.
OFF = the stop-on-ramp feature is not performed. A
controlled slowing down is performed for a minimum
duration set in the "AUXILIARY TIME" parameter. After this
time, the behavior depends on the “AUX OUT FUNCTION"
option.
For more details, see “Behavior on a slope” table at the end of
the paragraph.

PULL IN BRAKING OFF, ON This parameter enables or disables the functionality that
continues to give torque even if the traction (or lift) request has
(A) been released.
ON = when the operator releases the traction request, the
inverter keeps running the truck, as to oppose the friction
that tends to stop it. Similarly, in pump applications, when
the operator releases the lift request, the inverter keeps
running the pump avoiding the unwanted descent of the
forks.
OFF = when the operator releases the traction (or lift)
request, the inverter does not power anymore the motor.
This setting is useful especially for traction application.
When the truck is travelling over a ramp and the driver
wants to stop it by gravity, the motor must not be powered
anymore, until the truck stops.

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 SET OPTIONS

Parameter Allowable range Description

SOFT LANDING OFF, ON This parameter enables or disables the control of the
deceleration rate of the truck when the accelerator is released.
(A)
ON = when the accelerator is released, the inverter
controls the deceleration rate of the truck through the
application of a linearly decreasing torque curve.
This is useful when the operator releases the accelerator
while the truck is going uphill. If the rise is steep, the truck
may stop fast and may also go backwards in short time,
possibly leading to a dangerous situation.
OFF = when the accelerator is released, the inverter does
not control the deceleration rate of the truck, instead it
stops driving the motor.

QUICK INVERSION NONE ÷ BELLY This parameter defines the quick-inversion functionality.
(T, TM, P) NONE = the quick-inversion function is not managed.
BRAKE = upon a quick-inversion request, the motor is
braked.
TIMED = the quick-inversion function is timed: upon a QI
request the controller drives the motor in the opposite
direction for a fixed time (1.5 seconds by default).
BELLY = the quick-inversion function is managed but not
timed: upon a QI request the controller drives the motor in
the opposite direction until the request is released.

PEDAL BRK ANALOG OFF, ON This parameter defines the kind of brake pedal adopted.
(T, TM) ON = brake pedal outputs an analog signal, braking is
linear.
OFF = brake pedal outputs a digital signal, braking is
on/off.

HARD & SOFT OFF, ON This parameter enables or disables the Hard-and-Soft
functionality. With H&S, it is possible to start the truck (at
(T, TM) reduced speed) only by activating the H&S switch and the
accelerator, without the tiller input.
ON = H&S function is enabled
OFF = H&S function is disabled
Note: by default this function is not present on ACE3.

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 SET OPTIONS

Parameter Allowable range Description

MAIN POT. TYPE 0 ÷ 11 This parameter defines the type of the main potentiometer
connected to A3 contact.
(T, TM)
0: V-type pot, low to high value, with direction switches,
without enable switch, without enable dead band.
1: V-type pot, low to high value, with direction switches,
without enable switch, with enable dead band.
2: V-type pot, high to low value, with direction switches,
without enable switch, without enable dead band.
3: V-type pot, high to low value, with direction switches,
without enable switch, with enable dead band.
4: Z-type pot, low to high value, with direction switches,
without enable switch, without enable dead band.
5: Z-type pot, low to high value, with direction switches,
without enable switch, with enable dead band.
6: Z-type pot, low to high value, without direction switches,
with enable switch, with enable dead band
7: Z-type pot, low to high value, without direction switches,
without enable switch, with enable dead band.
8: Z-type pot, high to low value, with direction switches,
without enable switch, without enable dead band.
9: Z-type pot, high to low value, with direction switches,
without enable switch, with enable dead band.
10: Z-type pot, high to low value, without direction
switches, with enable switch, with enable dead band.
11: Z-type pot, high to low value, without direction
switches, without enable switch, with enable dead band.

AUX POT. TYPE 0 ÷ 15 This parameter defines the type of the auxiliary potentiometer
connected to A10 contact.
(T, TM, TS, P)
0 ÷ 11: Same as MAIN POT. TYPE, see prev. parameter.
12: No pot, with direction switches, with enable switch
15: No pot, with direction switches, without enable switch

SET MOT.TEMPERAT NONE ÷ OPTION#3 This parameter defines the type of motor temperature sensor
adopted.
(T, TM, P, CO)
NONE = no motor thermal sensor is connected.
DIGITAL = a digital (ON/OFF) motor thermal sensor is
connected to A23.
OPTION#1 = an analog motor thermal sensor is connected
to A23. The temperature sensor is a KTY 84-130 PTC
(positive thermal coefficient resistance).
OPTION#2 = an analog motor thermal sensor is connected
to A23. The temperature sensor is a KTY 83-130 PTC
(positive thermal coefficient resistance)
OPTION#3 = an analog motor thermal sensor is connected
to A23. The temperature sensor is a PT1000 PTC (positive
thermal coefficient resistance).

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 SET OPTIONS

Parameter Allowable range Description

STEERING TYPE NONE ÷ ANALOG This parameter defines which type of steering unit is
connected to the controller.
(T, TM)
NONE = steering module is not present on the truck; ACE3
does not wait for any CAN message from the EPS and it
does not apply EPS and braking steering cutback.
OPTION#1 = EPS is present and it is configured with
encoder + toggle switches, whose signals are acquired
and related data transmitted to ACE3 via CAN bus.
OPTION#2 = EPS is present and it is configured with
potentiometer + encoder, whose signals are acquired and
related data transmitted to ACE3 via CAN bus.
ANALOG = A hydraulic steering is adopted and ACE3
acquires through one of its analog inputs the signal coming
from a steering potentiometer, as a feedback of the
steering orientation.

M.C. FUNCTION OFF ÷ OPTION#2 This parameter defines the configuration for the main contactor
or line contactor output (A16, NLC: Negative Line Contactor).
(T, TM, P, CO)
OFF = main contactor is not present. Diagnoses are
masked and MC is not driven.
ON = main contactor is in standalone configuration.
Diagnoses are performed and MC is closed after key-on
only if they have passed.
OPTION#1 = for a traction & pump setup, with only one
main contactor for both controllers. Diagnoses are
performed and MC is closed after key-on only if they have
passed.
OPTION#2 = for a traction & pump setup, with two main
contactors. Each controller drives its own MC. Diagnoses
are performed and MCs are closed after key-on only if they
have passed.

EBRAKE ON APPL. ABSENT, PRESENT This parameter enables or disables the management of the
electromechanical brake:
(T, TM, P, CO)
ABSENT = the diagnosis are masked and E.B. is not
driven upon a traction request.
PRESENT = E.B. is driven upon a traction request if all the
related diagnosis pass.

AUX OUT FUNCTION NONE, BRAKE This parameter enables or disables the output A18 (NEB):
(A) NONE = the diagnosis are masked and E.B. is not driven
upon a traction request.
BRAKE = E.B. is driven upon a traction request if all the
related diagnosis pass. The behavior on a slope depends
on the “STOP ON RAMP” setting (see “Behavior on a
slope” table at the end of the paragraph).

SYNCRO OFF, ON This parameter enables or disables the syncro message.

(CO) OFF = the Syncro message is not used.
ON = the Syncro message is enabled.

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 SET OPTIONS

Parameter Allowable range Description

AUTO PARK BRAKE OFF, ON This parameter enables or disables the autonomous
management of the brake.
(CO)
OFF = E.B. is activated or deactivated according to the
signal received via CAN bus.
ON = E.B. is managed by the controller itself ignoring any
activation/deactivation signal received via CAN bus.

AUTO LINE CONT. OFF, ON This parameter enables or disables the autonomous
management of the main contactor.
(CO)
OFF = main contactor is opened or closed according to the
signals received by CAN bus.
ON = main contactor is managed by the controller itself
ignoring any activation/deactivation signal received via
CAN bus.

ACCEL MODULATION OFF, ON This parameter enables or disables the acceleration-

modulation function.
(T, TM, P, CO)
OFF = the acceleration rate is inversely proportional to the
ACCEL DELAY parameter.
ON = the acceleration ramp is inversely proportional to the
ACCEL DELAY parameter only if speed setpoint is greater
than 100 Hz. Below 100 Hz the acceleration ramp is also
proportional to the speed setpoint, so that the acceleration
duration results equal to ACCEL DELAY.
See paragraph 8.4.

EVP TYPE NONE ÷ DIGITAL This parameter defines how the output A19 (EVP) operates.
(A) NONE = output not enabled, no load connected to A19.
ANALOG = A19 manages a current-controlled
PWM-modulated proportional valve.
DIGITAL = A19 manages an on/off valve.
See the EVP-related parameters in PARAMETER CHANGE.

EV1 ABSENT, OPTION#2 This parameter defines how the output B16 (NEV1) operates.
(A – Premium version ABSENT = output not enabled, no on B16.
only)
OPTION#1 = B16 manages an on/off valve. By default it is
controlled by the 1st-speed command.
OPTION#2 = free for future use.

EV2 ABSENT, DIGITAL This parameter defines how the output B17 (NEV2) operates.
(A – Premium version ABSENT = output not enabled, no on B17.
only)
DIGITAL = B17 manages a voltage-controlled PWM-
modulated valve. The PWM frequency is 1kHz and the
duty cycle depends on PWM EV2 (ADJUSTMENT list).

EV3 ABSENT, DIGITAL This parameter defines how the output B18 (NEV3) operates.
(A – Premium version ABSENT = output not enabled, no load on B18.
only)
DIGITAL = B18 manages a voltage-controlled PWM-
modulated valve. The PWM frequency is 1kHz and the
duty cycle depends on PWM EV3 (ADJUSTMENT list).

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 SET OPTIONS

Parameter Allowable range Description

EV4 ABSENT, DIGITAL This parameter defines how the output B19 (NEV4) operates.
(A – Premium version ABSENT = output not enabled, no on B19.
only)
DIGITAL = B19 manages an on/off valve.

EV5 ABSENT, DIGITAL This parameter defines how the output B9 (NEV5) operates.
(A – Premium version ABSENT = output not enabled, no on B9.
only)
DIGITAL = B9 manages an on/off valve.

HIGH DYNAMIC OFF, ON This parameter enables or disables the High-Dynamic function.
(T, TM, P, CO) ON = all acceleration and deceleration profiles set by
dedicated parameters are ignored and the controller works
always with maximum performance.
OFF = standard behavior.

INVERSION MODE OFF, ON This parameter defines the behavior of the Quick-Inversion
input A11.
(T, TM)
ON = the Quick-Inversion switch is normally closed
(function is active when the switch is open).
OFF = the Quick-Inversion switch is normally open
(function is active when the switch is closed).

STEER TABLE NONE ÷ OPTION#2 This parameter defines the steering table.
(TM) NONE = The inverter does not follow any predefined
steering table, but it creates a custom table according to
WHEELBASE MM, FIXED AXLE MM, STEERING AXLE
and REAR POT ON LEFT parameters.
OPTION#1 = Three-wheels predefined steering table.
OPTION#2 = Four-wheels predefined steering table.
The steering table depends on truck geometry. The two
available options by default may not fit the requirements
of your truck. It is advisable to store the dimensions of the
truck in the parameters listed above in order to create a
custom steering table.
It is strongly recommended to consult paragraph 8.7 in
order to properly understand how to fill the mentioned
parameters. If the steering performance of the truck does
not match your requirements even after you have entered
the right truck dimensions, contact a Zapi technician in
order to determine if a custom steering table has to be
created.

WHEELBASE MM 0 ÷ 32000 This parameter must be filled with the wheelbase, i.e. the
distance between the two axles of the truck, expressed in
(TM) millimeters.
See paragraph 8.7.

FIXED AXLE MM 0 ÷ 32000 This parameter must be filled with the axle width at which the
non-steering wheels are connected, expressed in millimeters.
(TM)
See paragraph 8.7

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 SET OPTIONS

Parameter Allowable range Description

STEERING AXLE MM 0 ÷ 32000 This parameter must be filled with the axle length at which the
steering wheels are connected. The length must be expressed
(TM) in millimeters.
See paragraph 8.7

REAR POT ON LEFT OFF, ON This parameter defines the position of the steering
potentiometer.
(TM)
OFF = the steering potentiometer is not placed on the rear-
left wheel.
ON = the steering potentiometer is placed on the rear-left
wheel.

DISPLAY TYPE 0÷9 This parameter defines which type of display is connected to
the inverter.
(T, TM, P)
0 = none.
1 = MDI PRC.
2 = ECO DISPLAY.
3 = SMART DISPLAY.
4 = MDI CAN.
5 ÷ 9 = available for future developments.

ABS.SENS.ACQUIRE OFF, ON This parameter activates the acquisition of motor speed sensor
used for PMSM (Permanent-Magnets Synchronous Motor).
(A – Only custom HW
with sin/cos) Contact Zapi Technicians for a detailed description of the
acquisition procedure.

Behavior on a slope.
AUX STOP-ON- Behavior on a slope
A4 OUTPUT
OUTPUT RAMP (when accelerator is released)
The truck is electrically held in place. After the time set
ON in the "AUXILIARY TIME" parameter has elapsed, brake
It drives the coil of is applied and the three-phase bridge released.
BRAKE
an electromagnetic The truck is not electrically hold in place, instead it
brake. drives down very slowly; when the time set in the
OFF
"AUXILIARY TIME " parameter has elapsed, brake is
applied and the three-phase bridge released.

U Ensure the negative brake is installed and functioning before driving the truck
on any slope.

U Driving the truck on a slope without the brake functioning may lead to serious
accidents for the operators and surrounding people.

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7.2.3 ADJUSTMENT

ADJUSTMENT

Parameter Allowable range Description

SET BATTERY 24V ÷ 80V This parameter defines the nominal battery voltage. The
available options are:
(A)
36V, 48V, 72V, 80V

ADJUST KEY VOLT. Volt Fine adjustment of the key voltage measured by the controller.
Calibrated by Zapi production department during the end of
(A) line test.

ADJUST BATTERY Volt Fine adjustment of the battery voltage measured by the
controller. Calibrated by Zapi production department during the
(A) end of line test.

SET POSITIVE PEB 12V ÷ 80V This parameter defines the supply-voltage value connected to
CNA-3. The available values are:
(A)
12V, 24V, 36V, 40V, 48V, 72V, 80V

SET PBRK. MIN 0V ÷ 25.5V It records the minimum value of brake potentiometer when the
brake is analog.
(T, TM, TS, CO) (by steps of 0.1V)

SET PBRK. MAX 0V ÷ 25.5V It records the maximum value of brake potentiometer when the
brake is analog.
(T, TM, TS, CO) (by steps of 0.1V)

MIN LIFT DC 0V ÷ 25.5V It records the minimum value of lifting potentiometer when the
lift switch is closed.
(Read Only) (by steps of 0.1V)
See paragraph 8.2
(T, TM, TS, P)

MAX LIFT DC 0V ÷ 25.5V It records the maximum value of lifting potentiometer when the
lift switch is closed.
(Read Only) (by steps of 0.1V)
See paragraph 8.2
(T, TM, TS, P)

MIN LOWER 0V ÷ 25.5V It records the minimum value of lower potentiometer when the
lower switch is closed.
(Read Only) (by steps of 0.1V)
See paragraph 8.2
(T, TM, TS, P)

MAX LOWER 0V ÷ 25.5V It records the maximum value of lower potentiometer when the
lower switch is closed.
(Read Only) (by steps of 0.1V)
See paragraph 8.2
(T, TM, TS, P)

THROTTLE 0 ZONE 0% ÷ 100% This parameter defines a dead band in the accelerator input
curve.
(T, TM, P) (by 1% steps)
See paragraph 8.8

THROTTLE X1 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by 1% steps) See paragraph 8.8

THROTTLE Y1 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by 1% steps) See paragraph 8.8

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 ADJUSTMENT

Parameter Allowable range Description

THROTTLE X2 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by 1% steps) See paragraph 8.8

THROTTLE Y2 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by 1% steps) See paragraph 8.8

THROTTLE X3 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by 1% steps) See paragraph 8.8

THROTTLE Y3 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(T, TM, P) (by step of 1%) See paragraph 8.8

BAT. MIN ADJ. -12.8% ÷ 12.7% This parameter defines the minimum level of the
battery-discharge table. It is used to calibrate the discharge
(T, TM, P, CO) (by steps of 0.1%) algorithm for the adopted battery.
See paragraph 8.10

BAT. MAX ADJ. -12.8% ÷ 12.7% This parameter defines the maximum level of the
battery-discharge table. It is used to calibrate the discharge
(T, TM, P, CO) (by steps of 0.1%) algorithm for the adopted battery.
See paragraph 8.10

BDI ADJ STARTUP -12.8% ÷ 12.7% This parameter defines the start-up level of the battery-charge
table, in order to evaluate the battery charge at key-on.
(T, TM, P, CO) (by steps of 0.1%)
See paragraph 8.10

BDI RESET 0% ÷ 100% This parameter defines the minimum variation of the battery-
discharge table to update the battery percentage at start-up. It
(T, TM, P, CO) (by 1% steps) is used to calibrate the discharge algorithm for the adopted
battery.
See paragraph 8.10

BATT.LOW TRESHLD 1% ÷ 50% This parameter defines the minimum charge percentage under
which the BATTERY LOW alarm rises.
(T, TM, P, CO) (by 1% steps)

BAT.ENERGY SAVER OFF, ON When this parameter is ON, the control saves the battery
charge when it is below a certain charge threshold, through a
(A) motor-torque reduction.

STEER RIGHT VOLT 0V ÷ 25.5V This parameter records the maximum steering-control voltage
while turning right.
(T,TM) (by steps of 0.1V)
See paragraph 8.3

STEER LEFT VOLT 0V ÷ 25.5V This parameter records the maximum steering-control voltage
while turning left.
(T,TM) (by steps of 0.1V)
See paragraph 8.3

STEER ZERO VOLT 0V ÷ 25.5V This parameter records the maximum steering-control voltage
when it is in the straight-ahead position
(T,TM) (by steps of 0.1V)
See paragraph 8.3

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 ADJUSTMENT

Parameter Allowable range Description

MAX ANGLE RIGHT 0° ÷ 90° This parameter defines the maximum steering-wheel angle
while turning right.
(T,TM) (by steps of 1°)

MAX ANGLE LEFT 0° ÷ 90° This parameter defines the maximum steering-wheel angle
while turning left.
(T,TM) (by steps of 1°)

STEER DEAD ANGLE 1° ÷ 50° This parameter defines the maximum steering-wheel angle up
to which the permitted traction speed is 100%.
(T, TM) (by steps of 1°)
See paragraph 8.7

STEER ANGLE 1 1° ÷ 90° This parameter defines the steering-wheel angle at which
traction speed is reduced to the value imposed by CURVE
(T, TM) (by steps of 1°) SPEED 1.
For steering-wheel angles between STEER DEAD ANGLE and
STEER ANGLE 1 traction speed is reduced linearly from 100%
to CURVE SPEED 1.
See paragraph 8.7

STEER ANGLE 2 1° ÷ 90° This parameter defines the steering-wheel angle beyond which
traction speed is reduced to CURVE CUTBACK.
(T, TM) (by steps of 1°)
For steering-wheel angles between STEER ANGLE1 and
STEER ANGLE 2 traction speed is reduced linearly from
CURVE SPEED 1 to CURVE CUTBACK.
See paragraph 8.7

SPEED FACTOR 0 ÷ 255 This parameter defines the coefficient used for evaluating the
truck speed (in km/h) from the motor frequency (in Hz),
(T, TM, CO) according to the following formula:

⁄ 10 ∙

SPEED ON MDI OFF, ON This parameter enables or disables the speed visualization on
MDI display:
(T, TM, CO)
ON = MDI shows traction speed when the truck is moving.
In steady-state condition the speed indication is replaced
by the hour-meter indication.
OFF = Standard MDI functionality.

LOAD HM FROM MDI OFF, ON This parameter enables or disables the transfer of the hour-
meter to a MDI unit.
(T, TM, P, CO)
OFF = controller hour meter is not transferred and
recorded on the MDI hour meter.
ON = controller hour meter is transferred and recorded on
the MDI hour meter (connected via the Serial Link).

CHECK UP DONE OFF, ON In order to cancel the CHECK UP NEEDED warning, set this
parameter ON after the required maintenance service.
(T, TM, P, CO)

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 ADJUSTMENT

Parameter Allowable range Description

CHECK UP TYPE NONE ÷ OPTION#3 This parameter defines the CHECK UP NEEDED warning:
(T, TM, P, CO) NONE = no CHECK UP NEEDED warning.
OPTION#1 = CHECK UP NEEDED warning shown on the
hand-set and MDI after 300 hours.
OPTION#2 = like OPTION#1, plus speed reduction
intervenes after 340 hours.
OPTION#3 = like OPTION#2, plus the truck definitively
stops after 380 hours.

PWM EV1 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied to
EV1 output (B16).
(A – Premium only) (255 steps)

PWM EV2 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied to
EV2 output (B17).
(A – Premium only) (255 steps)

PWM EV3 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied to
EV3 output (B18).
(A – Premium only) (255 steps)

PWM EV4 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied to
EV4 output (B19).
(A – Premium only) (255 steps)

PWM EV5 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied to
EV5 output (B9).
(A – Premium only) (255 steps)

MC VOLTAGE 0% ÷ 100% This parameter specifies the duty-cycle (tON/TPWM) of the PWM
applied to the main-contactor output (A16) during the first
(A) (by 1% steps) second after the activation signal that causes the main
contactor to close.

MC VOLTAGE RED. 0% ÷ 100% This parameter defines a percentage of MC VOLTAGE

parameter and it determines the duty-cycle applied after the
(A) (by 1% steps) first second of activation of the contactor.
Example 1
MC VOLTAGE = 100%
MC VOLTAGE RED = 70%
The contactor is closed by applying 100% PWM to the coil
for one second, then duty-cycle is reduced to 70%.
Example 2
MC VOLTAGE = 70%
MC VOLTAGE RED. = 100%
The contactor is closed by applying 70% PWM to the coil
for one second, then duty-cycle is kept at the same value.
Example 3
MC VOLTAGE = 70%
MC VOLTAGE RED = 70%
The contactor is closed by applying 70% PWM to the coil
for one second, then duty-cycle is reduced to 49%.

EB VOLTAGE 0% ÷ 100% This parameter specifies the duty-cycle (tON/TPWM) of the PWM
applied to the main-contactor output (A18) during the first
(A) (by 1% steps) second after the activation signal that causes the
electromechanical brake to release.

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 ADJUSTMENT

Parameter Allowable range Description

EB VOLTAGE RED. 0% ÷ 100% This parameter defines a percentage of EB VOLTAGE

parameter and it determines the duty-cycle applied after the
(A) (by 1% steps) first second since when the electromechanical brake is
released.
Example 1
EB VOLTAGE = 100%
EB VOLTAGE RED = 70%
The electromechanical brake is released by applying 100%
PWM to the coil, then duty-cycle is reduced to 70%.
Example 2
EB VOLTAGE = 70%
EB VOLTAGE RED. = 100%
The electromechanical brake is closed by applying 70%
PWM to the coil for one second, then duty-cycle is kept at
the same value.
Example 3
MC VOLTAGE = 70%
MC VOLTAGE RED = 70%
The electromechanical brake is closed by applying 70%
PWM to the coil for one second, then duty-cycle is reduced
to 49% (70% of 70%).

MAX MOTOR TEMP. 60°C ÷ 175°C This parameter defines the motor temperature above which a
50% cutback is applied to the maximum current. Cutback is
(T, TM, P, CO) (by steps of 1°C) valid only during motoring, while during braking the 100% of
the maximum current is always available independently by the
temperature.

STOP MOTOR TEMP. 60°C ÷ 190°C This parameter defines the maximum motor temperature
permitted, above which the controller stops driving the motor.
(T, TM, P, CO) (by steps of 1°C)

A.SENS.MAX SE Volt This parameter records the maximum offset voltage at the sine
analog input during the auto-teaching procedure.
(A – Only sin/cos
customized HW) It can be compared with the A.SENS.OFFSET SR entry value.

A.SENS.MIN SE Volt This parameter records the minimum offset voltage at the sine
analog input during the auto-teaching procedure.
(A – Only sin/cos
customized HW) It can be compared with the A.SENS.OFFSET SR entry value.

A.SENS.MAX CE Volt This parameter records the maximum offset voltage at the
cosine analog input during the auto-teaching procedure.
(A – Only sin/cos
customized HW) It can be compared with the A.SENS.OFFSET CR entry value.

A.SENS.MIN CE Volt This parameter records the minimum offset voltage at the
cosine analog input during the auto-teaching procedure.
(A – Only sin/cos
customized HW) It can be compared with the A.SENS.OFFSET CR entry value.

MOT.T. T.CUTBACK OFF, ON When this parameter is ON, the control linearly reduces the
motor torque basing on the motor temperature. Reference
(A) limits of the linear reduction are MAX MOTOR TEMP and
TEMP. MOT. STOP.

VACC SETTING Volt See the PROGRAM VACC procedure in paragraphs 0 and
12.2.6.
(A)

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7.2.4 SPECIAL ADJUST.

4 Note: SPECIAL ADJUST. must only be accessed by skilled people. To change

settings in this group of settings, a special procedure is needed. Ask for this
procedure directly to a Zapi technician. In SPECIAL ADJUST. there are
factory-adjusted parameters that should be changed by expert technicians only.

SPECIAL ADJUST.

Allowable
Parameter Description
range

ADJUSTMENT #01 0% ÷ 255% (Factory adjusted). Gain of the first traction-motor current-sensing
amplifier.
(Read Only) (by 1% steps)
NOTE: only Zapi technicians can change this value through a special
(A) procedure.

ADJUSTMENT #02 0% ÷ 255% (Factory adjusted). Gain of the second traction-motor current-sensing
amplifier.
(Read Only) (by 1% steps)
NOTE: only Zapi technicians can change this value through a special
(A) procedure.

CURR. SENS. COMP OFF, ON (Factory adjusted). This parameter enables or disables the linear
compensation for the current sensors.
(A)
NOTE: only Zapi technicians can change this value through a special
procedure.

DIS.CUR.FALLBACK OFF, ON This parameter disables or enables current reduction (applied after one
minute of traction).
(A)
ON = current reduction is disabled.
OFF = current reduction is enabled.

SET CURRENT 450A ÷ 650A (Factory adjusted). This parameter defines the nominal maximum current
that the inverter can provide to the motor, in ARMS.
(Read Only)
The available values are:
(A)
ACE3 ACE3 PW
24V - 700Arms
36/48V 600Arms 650Arms
80V 450Arms 550Arms

SET TEMPERATURE 0°C ÷ 255°C (Factory adjusted). This parameter calibrates the controller-temperature
reading.
(A) (by 1°C steps)

HW BATTERY 0÷3 This parameter defines the battery voltage range. Reserved.
RANGE
NOTE: only Zapi technicians can change this value.
(Read Only)
(T, TM, P, CO)

DUTY PWM CTRAP 0% ÷ 100% (Factory adjusted). This parameter defines the duty-cycle for the
overcurrent-detection circuit, i.e. its level of intervention. Reserved.
(Read Only)
NOTE: only Zapi technicians can change this value.
(A)

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 SPECIAL ADJUST.

Allowable
Parameter Description
range

HW EXTENSION ABSENT, This parameter defines the controller version.

PRESENT
(A) ABSENT = ACE3 standard version.
PRESENT = ACE3 premium version.

PWM AT LOW FREQ (Factory adjusted). This parameter defines the power-bridge PWM
frequency at low speed.
(A)
NOTE: only Zapi technicians can change this value through a special
procedure.

PWM AT HIGH FREQ (Factory adjusted). This parameter defines the power-bridge PWM
frequency at high speed.
(A)
NOTE: only Zapi technicians can change this value through a special
procedure.

FREQ TO SWITCH (Factory adjusted). This parameter defines the electrical frequency at
which the switching frequency is changed from “PWM AT LOW FREQ” to
(A) “PWM AT HIGH FREQ”.
NOTE: only Zapi technicians can change this value through a special
procedure.

DITHER AMPLITUDE 0% ÷ 13% This parameter defines the dither signal amplitude. The dither signal is a
square wave added to the proportional-valve set-point. In this way the
(A) response to set-point variations results optimized. This parameter is a
percentage of the valve maximum current. Setting the parameter to 0%
means the dither is not used.
The available values are:
0.0%, 1.0%, 2.5%, 4.0%, 5.5%, 7.0%, 8.5%, 10%, 11.5%, 13.0%

DITHER FREQUENCY 20.8 Hz ÷ This parameter defines the dither frequency.

83.3 Hz
(A) The available values are:
20.8, 22.7, 25, 27.7, 31.2, 35.7, 41.6, 50, 62.5, 83.3

HIGH ADDRESS 0÷4 This parameter is used to access special memory addresses. Reserved.
(A) NOTE: only Zapi technicians can change this value.

CAN BUS SPEED 20 kbps ÷ 500 This parameter defines the CAN bus data-rate in kbps.
kbps
(A) The available values are:
20, 50, 125, 250, 500

EXTENDED FORMAT OFF, ON This parameter defines the CAN bus protocol.
(A) ON = standard format (11 bit);
OFF = extended format (29bit).

DEBUG OFF, ON This parameter enables or disables special debug messages. Reserved.
CANMESSAGE
(A)

CONTROLLER TYPE 0÷9 This parameter defines the controller type. Reserved.
(A) NOTE: only Zapi technicians can change this value.

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 SPECIAL ADJUST.

Allowable
Parameter Description
range

SAFETY LEVEL 0÷3 This parameter defines the safety level of the controller, i.e. the
functionality of the supervisor microcontroller.
(T, TM, P, CO)
0 = supervisor µC does not check any signal.
1 = supervisor µC checks the inputs and the outputs.
2 = supervisor µC checks the inputs and the motor set-point.
3 = supervisor µC checks the inputs, the outputs and the motor set-
point.

RS232 CONSOLLE OFF ÷ ON This parameter enables or disables the console to change settings.
Reserved.
(A)
NOTE: only Zapi technicians can change this value.

ID CANOPEN OFST 0 ÷ 56 This parameter defines the offset of the CANopen frame IDs.
(CO) (by steps of 8)

2ND SDO ID OFST 0 ÷ 126 This parameter defines if another SDO communication channel has to be
added. Specify an ID offset different from 0 in order to enable the
(A) (by steps of 2) channel.

VDC START UP LIM 0% ÷ 255% This parameter defines the battery voltage (as percentage of the nominal
voltage) above which delivered power is reduced in order to avoid an
(T, TM, P, CO) (by 1% steps) overvoltage condition during braking.

VDC UP LIMIT 0% ÷ 255% This parameter defines the battery voltage (as percentage of the nominal
voltage) above which the inverter stops and gives a LOGIC FAILURE #1
(T, TM, P, CO) (by 1% steps) alarm in order to avoid a damaging overvoltage condition.

VDC START DW LIM 0% ÷ 255% This parameter defines the battery voltage (as percentage of nominal
voltage) below which delivered power is reduced in order to avoid an
(T, TM, P, CO) (by 1% steps) undervoltage condition (typically during accelerations with low battery).

VDC DW LIMIT 0% ÷ 255% This parameter defines the battery voltage (as percentage of nominal
voltage) below which the inverter stops and gives a LOGIC FAILURE #3
(T, TM, P, CO) (by 1% steps) alarm in order to avoid an uncontrolled shutdown due to an undervoltage
condition.

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7.2.5 HARDWARE SETTING
The HARDWARE SETTING parameters group includes the motor-control-related
parameters. Only those parameters the user can modify are here described.

4 For descriptions and teaching about missing parameters contact a Zapi technician.

HARDWARE SETTING

Parameter Allowable range Description

TOP MAX SPEED 0 Hz ÷ 600 Hz This parameter defines the maximum motor speed.
(T, TM, P, CO) (by steps of 10 Hz)

CONF.POSITIVE LC 0÷2 This parameter defines the positive supply configuration

for the main-contactor coil.
(A)
0 = it is connected to PEB (A17)
1 = it is connected to KEY (A1)
2 = it is connected to SEAT input (A6)

FEEDBACK SENSOR 0÷4 This parameter defines the type of the adopted speed
sensor.
(A)
0 = incremental encoder
1 = sin/cos sensor
2 = incremental encoder + sin/cos sensor
3 = incremental encoder + sin/cos sensor + index
4 = PWM absolute sensor + incremental encoder +
index
5 = resolver

ROTATION CW ENC OPTION#1, OPTION#2 This parameter defines the configuration of the encoder.
(A) OPTION#1 = channel A anticipates channel B
OPTION#2 = channel B anticipates channel A

ROTATION CW MOT OPTION#1, OPTION#2 This parameter defines the sequence of the motor phases.
(A) OPTION#1 = U-V-W corresponds to forward direction.
OPTION#2 = V-U-W corresponds to forward direction.

ENCODER PULSES 1 32 ÷ 1024 This parameter defines the number of encoder pulses per
revolution. It must be set equal to ENCODER PULSES 2;
(T, TM, P, CO) otherwise the controller raises an alarm.
The available options are:
32, 48, 64, 80, 64, 128, 256, 512, 1024
NOTE: with standard HW the capability to use
encoders with high number of pulses could be
limited depending on the speed. Ask to Zapi
technicians before changing this parameter.

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 HARDWARE SETTING

Parameter Allowable range Description

ENCODER PULSES 2 32 ÷ 1024 This parameter defines the number of encoder pulses per
revolution. It must be set equal to ENCODER PULSES 1;
(T, TM, P, CO) otherwise the controller raises an alarm.
The available options are:
32, 48, 64, 80, 64, 128, 256, 512, 1024
NOTE: with standard HW the capability to use
encoders with high number of pulses could be
limited depending on the speed. Ask to Zapi
technicians before changing this parameter.

MOTOR P. PAIRS 1 1 ÷ 30 This parameter defines the number of pole pairs of the
traction motor. It must be set equal to MOTOR P. PAIRS 2;
(T, TM, P, CO) otherwise the controller raises an alarm.

MOTOR P. PAIRS 2 1 ÷ 30 This parameter defines the number of pole pairs of the
traction motor. It must be set equal to MOTOR P. PAIRS 1;
(T, TM, P, CO) otherwise the controller raises an alarm.

7.2.6 HYDRO SETTING

HYDRO SETTING

Parameter Allowable range Description

HYDRO TIME 0 s ÷ 200 s This parameter defines the delay time between the
release of the hydraulic-function request and the actual
(A) (steps of 1 s) stop/release of the associated output, according to the
HYDRO FUNCTION setting and the HW configuration.

HYDRO FUNCTION NONE ÷ OPTION #2 This parameter defines how the pump feeding hydraulics is
managed.
(A)
NONE = no hydraulic functions are present;
KEYON = ACE3 constantly drives the pump motor
from key-on.
RUNNING = ACE3 drives the pump motor only upon
an associated request (for example a lift request).
OPTION #1 = ACE3 does not drive the pump motor,
but the truck integrates hydraulics and ACE3 acts as
master controller managing a valve. The output that
drives the hydraulic valve (for example EVP) is
activated at key-on.
OPTION #2 = like OPTION#1, except the valve is
driven only upon request.

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 7.3 TESTER function
The TESTER function gives real-time feedbacks about the state of controller, motor
and command devices. It is possible to know the state (active/inactive) of the digital
I/Os, the voltage value of the analog inputs and the state of the main variables used
for the motor and hydraulics control.
In the following tables, “Parameter” columns also report between brackets lists of
the controller types where each parameter is available.
Controller types are coded as:
A = All controller types
T = Traction controllers (in single motor applications)
TM = Traction master controllers (in multiple motor applications)
TS = Traction supervisor controllers (in multiple motor applications)
P = AC pump controllers
CO = CANopen controllers
N = none

7.3.1 Master microcontroller

The following table lists the master microcontroller data that can be monitored
through the TESTER function.

TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

KEY VOLTAGE Volt (0.1 V) Key voltage measured in real time.

(A)

BATTERY VOLTAGE Volt (0.1 V) Battery voltage measured in real time (across the DC
bus).
(A)

DC BUS CURRENT Ampere (1 A) Estimation of the DC current the inverter is drawing from
the battery.
(A)

BATTERY CHARGE Percentage (1%) Residual battery charge as percentage of the full charge.
(A)

MOTOR VOLTAGE Percentage (1%) Theoretical phase-to-phase voltage to be applied at the

motor terminals, as a percentage of the supply voltage.
(A)
The actual applied voltage is changed by INDEX
OVERMOD. (see next item).

INDEX OVERMOD. Percentage (1%) Correction applied to the motor-voltage set-point in order
to compensate for the actual battery voltage.
(A)
The actual motor voltage delivered is the product of
MOTOR VOLTAGE and INDEX OVEMOD. .

FREQUENCY Hertz (0.1 Hz) Frequency of the current sine-wave that the inverter is
supplying to the motor.
(A)

AFFZP0BB – ACE3 – User Manual Page – 63/139

 TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

MEASURED SPEED Hertz (0.1 Hz) Motor speed measured through the encoder and
expressed in the same unit of FREQUENCY (Hz).
(A)

SLIP VALUE Hertz (0.01 Hz) Motor slip, i.e. difference between the current frequency
and the motor speed (in Hz).
(A)

CURRENT RMS Ampere (1 A) Root-mean-square value of the line current supplied to

the motor.
(A)
2 2
 

IMAX LIM. TRA Ampere (1 A) Instantaneous value of the maximum current the inverter
can apply to the motor to satisfy a traction request. The
(A) value is evaluated basing on actual conditions (inverter
temperature, motor temperature, etc…).

IMAX LIM. BRK Ampere (1 A) Instantaneous value of the maximum current the inverter
can apply to the motor to satisfy a braking request. The
(A) value is evaluated basing on actual conditions (inverter
temperature, motor temperature, etc…).

ID FILTERED RMS Ampere (1 A) Projection of the current vector on the d-axis, expressed
in root-mean-square Ampere.
(A)

IQ FILTERED RMS Ampere (1 A) Projection of the current vector on the q-axis, expressed
in root-mean-square Ampere.
(A)

IQIMAX LIM. TRA Ampere (1 A) Maximum value of the q-axis current component,
according to traction-related settings, expressed in
(A) root-mean-square Ampere.

IQIMAX LIM. BRK Ampere (1 A) Maximum value of the q-axis current component,
according to braking-related settings, expressed in
(A) root-mean-square Ampere.

FLAGS LIMITATION ON, OFF Flag for any current limitation being active, for example
thermal current cutback, maximum current reached, etc. .
(A)

MOT. POWER WATT Watt (1 W) Estimation of the power supplied to the motor.
(A)

-3
STATOR FLUX MWB 10 Weber (0.1 mWb) Estimation of the motor magnetic flux.
(A)

MOTION TORQUE NM Newton Meter (0.1 Nm) Estimation of the motor torque.
(A)

STEER ANGLE Degrees (1°) Current steering-wheel angle. When the steering is
straight ahead STEER ANGLE is zero.
(T, TM)

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 TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

TEMPERATURE Celsius degrees (1 °C) Temperature measured on the inverter base plate.
(A) This temperature is used for the HIGH TEMPERATURE
alarm.

MOTOR TEMPERAT. Celsius degrees (1 °C) Motor-windings temperature.

(A) Normally the sensor is a PTC Philips KTY84-130. This
temperature is used for the MOTOR OVERTEMP alarm.

A6 TILLER OFF/ON Status of the TILLER/SEAT input (A6).

(T, TM)

A11 QI/PB OFF/ON Status of the Pedal-Brake/Quick-Inversion input (A11)

(T, TM)

B13 HS OFF/ON Status of the Hard&Soft input (B13).

(T, TM)

A4 FW SW OFF/ON Status of the forward input (A4).

(T, TM, TS)

A4 ENABLE OFF/ON Status of the driving-demand input (A4).

(T, TM, TS)

A5 BW SW OFF/ON Status of the backward input (A5).

(T, TM)

B11 AUX3 OFF/ON Status of the AUX3 input (B11) that enables EV3
(T, TM)

B4 AUX1 OFF/ON Status of the AUX3 input (B4) that enables EV1
(T, TM)

B5 AUX2 OFF/ON Status of the AUX3 input (B5) that enables EV2
(T, TM)

A13 SR/HB OFF/ON Status of the Speed-Reduction/Hand-Brake input (A13).

(T, TM)

B6 FW-INCH OFF/ON Status of the forward-inching input (B6).

(TS)

B13 L-BW-IN OFF/ON Status of the backward-inching input (B13).

(TS)

A6 SEAT OFF/ON Status of the TILLER/SEAT input (A6).

(P)

AFFZP0BB – ACE3 – User Manual Page – 65/139

 TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

B13 SPD1 OFF/ON Status of the 1ST-speed input (B13).

(P)

A11 HYDRO OFF/ON Status of the hydraulic-steering input (A11).

(P)

A4 LFT/E OFF/ON Status of the lift input (A4).

(P)

A5 LOWER OFF/ON Status of the lowering input (A5).

(P)

B6 SPD2 OFF/ON Status of the 2ND-speed input (B6).

(P)

B4 SPD3 OFF/ON Status of the 3RD-speed input (B4).

(P)

B5 SPD4 OFF/ON Status of the 4TH-speed input (B5).

(P)

B11 SPD5 OFF/ON Status of the 5TH-speed input (B11).

(P)

A13 CUTBAC1 OFF/ON Status of the speed-reduction input (A13).

(P)

NODE ID 0 ÷ 56 Node ID setting for CAN OPEN Protocol

(CO)

TARGET SPEED 10 Hertz (1 daHz) This value shows the speed setpoint transmitted over
CAN OPEN protocol. It is expressed in tenths of Hz.
(CO)

BRAKING REQUEST 0 ÷ 255 This value shows the braking setpoint transmitted over
CAN OPEN protocol.
(CO)

CONTROL WORD 0 ÷ 65535 It shows the Control Word transmitted upon CAN OPEN
protocol.
(CO)

STATUS WORD 0 ÷ 65535 It shows the Status Word travelling upon CAN OPEN
protocol.
(CO)

WARNING SYSTEM 0 ÷ 65535 In case of warning it shows the related warning code.
(CO)

TARGET EVP1 Percentage (1%) This value shows the setpoint of proportional
electrovalve EVP1 in CAN Open configuration.
(CO)

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 TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

TORQUE REQ. Newton Meter (1 Nm) This value shows the torque setpoint for AC motor in
CAN Open configuration.
(CO)

TORQUE BRK REQ. Newton Meter (1 Nm) This value shows the torque setpoint during braking for
AC motor in CAN Open configuration.
(CO)

A3 POT#1 Volt (0.01V) Voltage of the analog signal on A3.

(A)

A10 POT#2 Volt (0.01V) Voltage of the analog signal on A10.

(A)

B2 POT#3 Volt (0.01V) Voltage of the analog signal on B2.

(A)

B10 POT#4 Volt (0.01V) Voltage of the analog signal on B10.

(A)

B3 POT#5 Volt (0.01V) Voltage of the analog signal on B3.

(A)

SIN FB. INPUT Volt (0.01 V) Voltage of sine input (B7).

(A – Only for BLE3 with
sin/cos sensor)

COS FB. INPUT Volt (0.01 V) Voltage of cosine input (B14).

(A – Only for BLE3 with
sin/cos sensor)

A19 SET EVP Percentage (1%) This value shows the setpoint of proportional
electrovalve EVP.
(A)

B16 OUTPUT EV1 OFF/ON It shows the status of the EV1 output (B16).
(A – Only Premium
version)

B17 OUTPUT EV2 OFF/ON It shows the status of the EV2 output (B17).
(A – Only Premium
version)

B18 OUTPUT EV3 OFF/ON It shows the status of the EV3 output (B18).
(A – Only Premium
version)

B19 OUTPUT EV4 OFF/ON It shows the status of the EV4 output (B19).
(A – Only Premium
version)

AFFZP0BB – ACE3 – User Manual Page – 67/139

 TESTER (Master)

Unit of measurement
Parameter Description
(resolution)

B9 OUTPUT EV5 OFF/ON It shows the status of the EV5 output (B9).
(A – Only Premium
version)

A16 MAIN CONT. Percentage (1%) This value shows the voltage applied over the main
contactor coil. It corresponds to the duty cycle value of
(A) PWM applied and it is expressed in percentage.

A18 ELEC.BRAKE Percentage (1%) This value shows the voltage applied over the electro
mechanic brake coil. It corresponds to the duty cycle
(A) value of PWM applied and it is expressed in percentage.

CTRAP HW Units (1) Number of hardware-overcurrent occurrences.

(A)

A.SENS.OFFSET SR Digital units Offset of the encoder sine signal, acquired during the
absolute sensor acquisition automatic procedure.
(A – Only for BLE3 with
sin/cos sensor)

A.SENS.OFFSET CR Digital units Offset of the encoder cosine signals, acquired during the
absolute sensor acquisition automatic procedure.
(A – Only for BLE3 with
sin/cos sensor)

ANGLE OFFSET Degrees Angle offset between the orientation of the rotor and the
position sensor.
(A – Only for BLE3 with
sin/cos sensor)

ANGLE OFFSET ENC Degrees Angle offset between the orientation of the rotor and the
index signal (on an ABI encoder).
(A – Only for BLE3 with
sin/cos sensor)

ROTOR POSITION Degrees Real-time absolute orientation of the rotor.

(A – Only for BLE3 with
sin/cos sensor)

TRUCK SPEED km/h (0.1 km/h) Speed of the truck (it requires custom software
embedding gear ratio and wheels radius).
(T, TM, CO)

ODOMETER KM km (1km) Odometer: overall distance traveled by the truck.

(T, TM, CO)

CPU TIME F US - Reserved for Zapi technicians use.

(A)

CPU TIME M US - Reserved for Zapi technicians use.

(A)

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7.3.2 Supervisor microcontroller
The following table lists the supervisor microcontroller data that can be monitored
through the TESTER function.

TESTER (Supervisor)

Unit of measure
Parameter Description
(resolution)

MEASURED SPEED Hertz (0.1 Hz) Motor speed measured through the encoder and
expressed in the same unit of FREQUENCY (Hz).
(A)

A4 OFF/ON Status of input A4.

(A)

A5 OFF/ON Status of input A5.

(A)

A11 OFF/ON Status of input A11.

(A)

B13 OFF/ON Status of input B13.

(A)

B6 OFF/ON Status of input B6.

(A)

B4 OFF/ON Status of input B4.

(A)

B5 OFF/ON Status of input B5.

(A)

B11 OFF/ON Status of input B11.

(A)

A13 OFF/ON Status of input A13.

(A)

A3 POT#1 Volt (0.01V) Voltage of analog input A3.

(A)

A10 POT#2 Volt (0.01V) Voltage of analog input A10.

(A)

B2 POT#3 Volt (0.01V) Voltage of analog input B2.

(A)

B10 POT#4 Volt (0.01V) Voltage of analog input B10.

(A)

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 TESTER (Supervisor)

Unit of measure
Parameter Description
(resolution)

B3 POT#5 Volt (0.01V) Voltage of analog input B3.

(A)

CTRAP THRESOLD Volt (0.01 V) Threshold voltage of the hardware overcurrent.

(A)

WARNING SYSTEM - In case of warning it shows the correspondent warning

code.
(CO)

7.4 Set-up procedure for traction inverter

This section describes the basic set-up procedure for the ACE3 inverter in traction
configuration. If you need to replicate the same set of settings on different
controllers, use the SAVE and RESTORE sequence (see chapter 8); otherwise go
down the following sequence.
- In ADJUSTMENT, set BATTERY VOLTAGE according to your set-up (see
paragraph 7.2.3).
- Check the wiring and that all commands are functioning. Use the TESTER
function to have real-time feedback about their state.
- Perform the accelerator acquisition using the PROGRAM VACC procedure
(see paragraph 8.1).
- Set the maximum current for traction and braking in MAX. CURRENT TRA
and MAX. CURRENT BRK (see paragraph 7.2.1).
- Set the motor-related parameters. It is suggested to discuss them with Zapi
technicians.
- Set SET MOT.TEMPERAT according to the type of the motor thermal
sensor adopted.
- Set the acceleration delay (ACCEL MODULATION and ACCEL DELAY
parameters). Test the behavior in both directions.
- Set the FREQUENCY CREEP starting from 0.3 Hz. The machine should
just move when the drive request is active. Increase the level accordingly.
- Set SPEED REDUCTION as required by your specifications.
- Set the other performance-related parameters such as
RELEASE BRAKING, INVERSION BRAKING, DECELERATION BRAKING,
PEDAL BRAKING, SPEED LIMIT BRAKING, MAX SPEED FORW,
MAX SPEED BACK.
- Make the choice for the truck behavior on a slope (STOP ON RAMP and
AUXILIARY TIME parameters).
- Test the truck in all operative conditions (with and without load, on flat and
on ramp, etc.).
At the end of your modifications, re-cycle the key switch to make them effective.
Page – 70/139 AFFZP0BB – ACE3 – User Manual
7.4.1 Sin/cos-sensored case
Sin/Cos sensors have a sinusoidal output voltage, with variable amplitude and
offset, and normally sin/cos wave has an arbitrary shift with respect to magnetic field
“0” position. Offset, amplitude and angle must be set before starting a PM for the
first time.
Preliminary settings are the same described above. Plus, an automatic procedure,
embedded in the inverter software, must be activated only one time at
commissioning, to let the inverter acquire the values.
Before starting the procedure, please be sure that the motor is free to spin, with a
minimum load on the shaft.
- In OPTIONS, select ABS SENS. ACQUIRE.
- Select NO at the request of saving data (otherwise the main coil will be
opened).
- A message ACQUIRING ABS indicates that the acquisition procedure is
ready to start.
- Use the TESTER function to monitor the motor speed for the further steps.
- Activate the TILLER and FW (or BW) microswitches. Motor starts running in
open-loop mode.
- Because of the open-loop mode, it is normal if the reported speed is not
perfectly stable, but value on display must be, in any case, quite fixed.
- If the motor does not spin, it vibrates or speed on display oscillates too
much, stop the acquisition procedure releasing the FW or BW command
(see troubleshooting at the paragraph end).
- The first phase, where motor is spinning at low speed (something like 5Hz),
allows the Inverter to acquire signal offset and amplitude for both channels.
- After the previous steps are completed, rotor is aligned to the magnetic field
origin, and the angle between sin/cos zero value is acquired and stored.
- The next part is a sort of verification when motor is accelerated up to 50 Hz
in closed-loop mode.
- Because of the closed loop, the speed reported on display must be stable.
- If something has gone wrong (rotor is not correctly aligned because of
friction on the shaft or any other problem), it is possible that rotor starts
spinning at uncontrolled speed with high current absorption. The only way to
stop it is by switching the inverter off using the key switch.
- When the procedure is correctly completed, the main contactor opens and
display shows ACQUIRE END.
- Turn off and then on again the key switch; verify that motor can run
according to the accelerator input in both direction.
Inverter goes down the procedure automatically, every phase is marked by a
different message on display.
In case of problems, mainly in the first phase, please:
- Check that PM motor pole pairs is set correctly.

AFFZP0BB – ACE3 – User Manual Page – 71/139

 - In HARDWARE SETTING increase the ABS.SENS. ACQ.ID parameter (the
motor current used for the open-loop phase) so to have more torque and
perhaps solve some friction problems (ID RMS MAX must be set
congruently).
- If increasing ABS.SENS. ACQ.ID is not enough, increase the
ABS.SENS.A.KTETA parameter. It manages the speed in the open-loop
phase and in some situations faster speed can help to achieve a more even
rotation.

4 Offset angle can also be manually refined using the MAN.OFFSET ANGLE
parameter. However, sensor voltage range must be first acquired using the
automatic procedure.

7.5 Set-up procedure for pump inverter

This section describes the basic set-up procedure for the ACE3 inverter in pump
configuration. If you need to replicate the same set of settings on different
controllers, use the SAVE and RESTORE sequence (see chapter 8); otherwise go
down the following sequence.
- In ADJUSTMENT, set BATTERY VOLTAGE according to your set-up (see
paragraph 7.2.3).
- Check the wiring and that all commands are functioning. Use the TESTER
function to have real-time feedback about their state.
- Perform the accelerator acquisition using the PROGRAM VACC procedure
(see paragraph 8.1).
- Set the maximum current for lift and lowering in MAX. CURRENT TRA and
MAX. CURRENT BRK (see paragraph 7.2.1).
- Set the motor-related parameters. It is suggested to discuss them with Zapi
technicians.
- Set SET MOT.TEMPERAT according to the type of the motor thermal
sensor adopted.
- Set the acceleration delay (ACCEL MODULATION and ACCEL DELAY
parameters). Test the behavior in both directions.
- Set the FREQUENCY CREEP starting from 0.3 Hz. The pump should just
run when the request is active. Increase the level accordingly.
- Set SPEED REDUCTION as required by your specifications.
- Set the other performance-related parameters such as MAX SPEED LIFT,
1ST SPEED COARSE, 2ND SPEED COARSE, 3RD SPEED COARSE.
- Set hydraulic-steering-related parameters, such as HYD SPEED FINE and
HYDRO TIME.
- Test the pump in all operative conditions (with and without load, etc.).
At the end of your modifications, re-cycle the key switch to make them effective.

Page – 72/139 AFFZP0BB – ACE3 – User Manual

8 OTHER FUNCTIONS

8.1 PROGRAM VACC function

This function enables the adjustment of the minimum and maximum useful levels of
the accelerator voltage, in both direction. This function is particularly useful when it
is necessary to compensate for asymmetry of mechanical elements associated with
the potentiometer, especially relating to the minimum level.
The following two graphs show the output voltage of a potentiometer versus the
mechanical angle of the control lever. Angles MI and MA indicate the points where
the direction switches close, while 0 represents the mechanical zero of the lever, i.e.
its rest position. Also, the relationship between motor voltage (Vmot) and
potentiometer voltage (Vacc) is shown. After the adjustment procedure, Vmot
percentage is mapped over the useful voltage ranges of the potentiometer, for both
directions. On the other hand, before calibration it results mapped over the default
0 – 5 V range.

Before ‘PROGRAM VACC’ After ‘PROGRAM VACC’

PROGREAM VACC can be carried out through Zapi PC CAN Console or through
Zapi Smart Console. For the step-by-step procedures of the two cases, refer to
paragraphs 0 and 12.2.6.

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 8.2 PROGRAM LIFT / LOWER function
This function enables to adjust the minimum and maximum useful signal levels of lift
and lowering request. This function is useful when it is necessary to compensate for
asymmetry of the mechanical elements associated with the potentiometer,
especially relating to the minimum level.
This function looks for and records the minimum and maximum potentiometer wiper
voltage over the full mechanical range of the lever.
The values to be acquired are organized in the ADJUSTEMNT list, they are:
- MIN LIFT DC
- MAX LIFT DC
- MIN LOWER
- MAX LOWER
See paragraphs 12.1.4 or 12.2.7 for acquiring procedure.

8.3 PROGRAM STEER function

This enables the adjustment of the minimum and maximum useful signal levels of
the steering control. This function is useful when it is necessary to compensate for
asymmetry with the mechanical elements associated with the steer.
This function looks for and remembers the minimum, neutral and maximum voltage
over the full mechanical range of the steering. It enables compensation for
dissymmetry of the mechanical system between directions.
The values to be acquired are organized in the ADJUSTEMNT group; they are:
- STEER RIGHT VOLT
- STEER LEFT VOLT
- STEER ZERO VOLT
See paragraphs 12.1.5 or 12.2.8 for acquiring procedure.

Page – 74/139 AFFZP0BB – ACE3 – User Manual

 8.4 Acceleration time
The ACCEL DELAY parameter allows to define the acceleration rate depending on
the final-speed setpoint and on ACCEL MODULATION.
- ACCEL MODULATION = OFF
Acceleration time can be obtained applying this formula:

∙
100
- ACCEL MODULATION = ON
Acceleration time is evaluated differently by software for final-speed setpoint
values above or below 100 Hz.
Case 1 (black trace in the graph):
 Final-speed setpoint = 100 Hz
 ACCEL DELAY = 2,5 s
Acceleration time results 2.5 s.
Case 2 (red trace in the graph):
 Final-speed setpoint = 60 Hz
 ACCEL DELAY = 2,5 s
Acceleration rate is re-scaled so that acceleration time results equal to
ACCEL DELAY, in this case 2.5 s.
Case 3 (green trace in the graph):
 Final-speed setpoint = 150 Hz
 ACCEL DELAY = 2,5 s
Acceleration time results:
150
100
∙ 2.5 3,75  

Figure 1: Acceleration time

AFFZP0BB – ACE3 – User Manual Page – 75/139

 8.5 Deceleration time
The DECEL. BRAKING parameter allows to define the deceleration rate depending
on final-speed setpoint. Deceleration time is evaluated differently by software for
speed steps greater or smaller than 100 Hz.
Case 1 (black trace in the graph):
 Initial speed = 110 Hz
 Final-speed setpoint = 10 Hz
 DECEL. BRAKING = 2,5 s
The deceleration time results 2.5 s.
Case 2 (red trace in the graph):
 Initial speed = 60 Hz
 Final-speed setpoint = 10 Hz
 DECEL. BRAKING = 2,5 s
The deceleration rate is re-scaled so that the deceleration time results
equal to DECEL. BRAKING, in this case 2.5 s.
Case 3 (green trace in the graph):
 Initial speed = 150 Hz
 Final-speed setpoint = 10 Hz
 DECEL. BRAKING = 2,5 s
The deceleration time results:
150
∙ 2.5 3,75  
100

4 Note: This example is valid for all the braking-related parameters:

DECEL. BRAKING, INVER. BRAKING, RELEASE BRAKING, TILLER BRAKING,
PEDAL BRAKING, SPEED LIMIT BRK, STEER BRAKING.

Page – 76/139 AFFZP0BB – ACE3 – User Manual

 8.6 Acceleration smoothness
Smoothing-related parameters define a parabolic profile to the acceleration or
deceleration ramp near 0 rpm. Values have not a phisycal meaning: 1 means linear
ramp, higher values (up to 5) result in smoother the accelerations.

Figure 2: Smoothness

4 Note: This example is valid for ACC SMOOTH, BRK SMOOTH, INV SMOOTH.

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 8.7 Steering curve
Steering-related parameters (CURVE SPEED 1, CURVE CUTBACK, STEER DEAD
ANGLE, STEER ANGLE 1 and STEER ANGLE 2) define a speed-reduction profile
dependent on the steering-wheel angle.
The profile is valid both for positive and negative angle values.
Example:
 Three-wheel CB truck
 Permitted steering-wheel angles = -90° ÷ 90°
 CURVE SPEED 1 = 50%
 CURVE CUTBACK = 30%
 STEER DEAD ANGLE = 40°
 STEER ANGLE 1 = 50°
 STEER ANGLE 2 = 80°
This parameters set builds the speed profile represented in the graph below.

Page – 78/139 AFFZP0BB – ACE3 – User Manual

 8.8 Throttle response
The ACE3 controls the truck speed by means of a not linear function of the
accelerator position, as to provide a better resolution of the speed control when the
truck is moving slowly.
For the definition of such response, the following parameters are used:
 THROTTLE 0 ZONE [% of MAX VACC]
 THROTTLE X1 POINT [% of MAX VACC]
 THROTTLE Y1 POINT [% of MAX SPEED]
 THROTTLE X2 POINT [% of MAX VACC]
 THROTTLE Y2 POINT [% of MAX SPEED]
 THROTTLE X3 POINT [% of MAX VACC]
 THROTTLE Y3 POINT [% of MAX SPEED]
The speed remains at the FREQUENCY CREEP value as long as the voltage from
the accelerator potentiometer is below THROTTLE 0 ZONE. Basically this defines a
dead zone close to the neutral position.
For higher potentiometer voltages, the speed setpoint grows up as a polygonal
chain defined by the following table of points.

Throttle signal Speed setpoint

[% of MAX VACC] [% of MAX VACC]
0 FREQUENCY CREEP
THROTTLE 0 ZONE FREQUENCY CREEP
THROTTLE X1 POINT THROTTLE Y1 POINT
THROTTLE X2 POINT THROTTLE Y2 POINT
THROTTLE X3 POINT THROTTLE Y3 POINT
MAX VACC MAX SPEED
The following graph better displays the throttle – speed relationship.

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 8.9 NLC & NEB output
For the NLC output (A16) [or NEB output (A18)] there is the possibility to set a pull-
in voltage and to define a retention voltage continuously applied to the coil.
MC VOLTAGE [or EB VOLTAGE] parameter specifies the duty cycle applied in the
first second after key-on and MC VOLT RED [or EB VOLT RED] determines the
duty-cycle applied after that, necessary to keep the contactor closed [or brake
disengaged] according to this formula:
% ∙

Figure 3: NMC & NEB Output management

Example 1:
MC VOLTAGE = 100%
MC VOLTAGE RED = 70%
The contactor is closed by applying 100% of duty-cycle to the coil and then then it is
reduced to 70%.
Example 2:
MC VOLTAGE = 70%
MC VOLTAGE RED. = 100%
The contactor is closed by applying 70% of duty-cycle to the coil and then it is kept
at the same value.
Example 3:
MC VOLTAGE = 70%
MC VOLTAGE RED = 70%
The contactor is closed by applying 70% of duty-cycle to the coil and then it is
reduced to 49% (70% of 70%).

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 8.10 Battery-charge detection
During operating condition, the battery-charge detection makes use of two
parameters that specify the full-charge voltage (100%) and the discharged-battery
voltage (10%): BAT.MAX.ADJ and 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-discharge detection occurs when
the battery is not totally discharged, it is necessary to reduce BAT.MIN.ADJ).
Moreover, BDI ADJ STARTUP adjusts the level of the battery charge table at the
start-up, in order to evaluate the battery charge at key-on. The minimum variation of
the battery charge that can be detected depends on the BDI RESET parameter.
The battery-charge detection works as the following procedure.
Start-up
1) The battery voltage is read from key input when the battery current is zero,
that is when the output power stage is not driven. It is evaluated as the
average value over a window of time, hereafter addressed as Vbatt.
2) Vbatt is compared with a threshold value which comes as function of the
actual charge percentage; by this comparison a new charge percentage is
obtained.
3) The threshold value can be changed with the BDI ADJ STARTUP parameter.
4) If the new charge percentage is within the range “last percentage (last value
stored in EEPROM) ± BDI RESET” it is discarded; otherwise charge
percentage is updated with the new value.
Operating condition
Measure of the battery voltage, together with the charge percentage at the time of
the voltage sampling, give information about the instantaneous battery current.
1) The battery voltage is read when the battery current is not zero, that is when the
output power stage is driven. Vbatt is evaluated as the average value over a
window of time.
2) Vbatt is compared with a threshold value which comes as function of the actual
charge percentage; by this comparison the current provided by the battery is
obtained.
3) Current obtained at step 2 integrated over time returns the energy drawn from
the battery, in Ah.
4) Charge percentage is dynamically updated basing on the energy from step 3.
Threshold values for the battery charge can be modified by means of
BAT.MAX.ADJ. and BAT.MIN.ADJ. as to adapt the battery-charge detection to the
specific battery in use.

AFFZP0BB – ACE3 – User Manual Page – 81/139

 8.11 EVP control
EVP can be controlled as an analog current-controlled valve or as an on/off valve.
 EVP TYPE = ANALOG
The analog control of the EVP coil is made by means of a linear relationship
between the lowering-potentiometer voltage and the set-point for the current
applied to the valve. Considering the case when the EVP request refers to the
lowering valve, the upper and lower limits of the linear profile are given by
MIN LOWER – MIN EVP and MAX LOWER – MAX EVP. Instead, EVP current
is kept at zero for potentiometer voltages below MIN LOWER.

EVP analog control.

 EVP TYPE = DIGITAL

If EVP is set to work as an on/off valve, the MIN EVP parameter is disabled and
the current set point applied to the valve is only dependent on MAX EVP.
The dynamic delay of the current set-point variations, for both ANALOG and
DIGITAL cases, depends on the EVP OPEN DELAY and EVP CLOSE DELAY
parameters (see paragraph 7.2.1):
 OPEN DELAY determines the current increase rate, i.e. it defines the time
needed to increase the EVP current from zero up to the maximum.
 CLOSE DELAY determines the current decrease rate, i.e. it defines the
time needed to decrease the EVP current from the maximum down to zero

Page – 82/139 AFFZP0BB – ACE3 – User Manual

 EVP control: evolution over time.

Example 1:
Lowering output is set to be analog and the lowering request consists of a step
whose amplitude corresponds to MAX EVP.
The current is first set to the MIN EVP and then it is linearly increased up to
MAX EVP for the time set by the OPEN DELAY parameter.
In the same way, when the lowering request is released while the set-point is at the
maximum, the current is linearly reduced down to the minimum in a time equal to
CLOSE DELAY and, after that transition is completed, it is set to zero.

Example 2:
Lowering output is set to be digital.
As soon as the lowering request is applied, the current is increased from zero to
MAX EVP in a time equal to OPEN DELAY.
In the same way, when the lowering request is released, the current set-point is
linearly reduced down to zero in a time equal to CLOSE DELAY.

AFFZP0BB – ACE3 – User Manual Page – 83/139

 8.12 Torque profile
By setting the proper parameter, it is possible to define a limit for the maximum
torque demand (through set points) in the weakening area, for matching two goals:
1. Not overtaking the maximum torque profile of the motor.
2. Superimposing a limiting profile to the maximum torque as to get different
drive performances (Eco mode, Medium performance, High performance).

Torque profile

Torque curves

Page – 84/139 AFFZP0BB – ACE3 – User Manual

 8.13 Steering table
Steering table allows to automatically calibrate the rotation applied to the steering
wheels so to obtain the desired steering angle of the truck.
The STEER TABLE parameter defines whether to adopt a custom or predefined
steering table:
 NONE = custom steering table, according to the following parameters:
o WHEELBASE MM: distance between the front axle and the rear axle
of the truck.
o FIXED AXLE MM: axle width of the axle where the fixed wheels are.
o STEERING AXLE MM: axle width of the axle where the steering
wheels are.
All three previous parameters must be expressed in millimeters.
 OPTION#1 = three-wheels predefined steering table.
 OPTION#2 = four-wheels predefined steering table

Geometrical steering-related parameters.

AFFZP0BB – ACE3 – User Manual Page – 85/139

9 FAULTS DIAGNOSTIC SYSTEM
The fault diagnostic system of ACE3 controller consists of two main groups of faults:
 ALARMS
Faults which cause the power section to stop, meaning the power bridge opens
and, when possible, the main contactor opens and the electromechanical brake
is applied.
Alarms are related to:
- Hardware failures in the motor or in the controller that forbid to run the truck.
- Safety-related failures.
 WARNINGS
Faults which do not stop the truck or stop it by mean of a controlled regenerative
braking. The controller still works well, but it has detected conditions that require
to stop the truck, or at least to reduce its performance, without opening the
power devices.
Warnings are related to:
- Wrong sequences of operations by the operator.
- Conditions that require performance reduction in order to prevent major
failures (high temperature, …).

9.1 Alarms – Master uC

Restart CAN
MDI ZAPI LED
Error code Effect Condition OPEN
procedure CODE CODE CODE
CODE

MC is not closed,
Valves or
VDC LINK OVERV. EB is applied, Stand-by, running Traction/Pump 0XFFCA 77 202 77
Traction/Pump, valves Request
stopped
MC is opened, EB is
applied,
HOME SENS.ERR XX Running Key re-cycle 0xFFB0 3 176 3
EVP stopped

MC is not closed,
IMS ERROR EB is applied, Start-up Key re-cycle 0XFFA7 4 167 4
Traction/Pump, valves
stopped
MC is not closed, Valves or
SHORT CIRCUIT EB is applied, Running Traction/Pump 0xFFA6 5 166 5
Traction/Pump, valves
stopped Request

MC is not closed,
SHORT CIRCUIT KO EB is applied, Start-up, stand-by Key re-cycle 0xFFA5 5 165 5
Traction/Pump, valves
stopped
MC is not closed,
PWM ACQ.ERROR EB is applied, Start-up Key re-cycle 0xFFA4 6 164 6
Traction/Pump, valves
stopped
MC is opened, EB is
Start-up, stand-by,
WATCHDOG applied, Traction/Pump, Key re-cycle 0x6010 8 8 8
running
valves stopped
MC is closed or opened ,
EB is applied, Traction/ Pump
EVP DRIV. SHORT. EVP off 0x5003 9 215 9
request
EVP stopped

CONTROLLER MISM. MC is not closed, Start-up Install the correct 0xFFEF 12 239 12
software and Key

Page – 86/139 AFFZP0BB – ACE3 – User Manual

 Restart CAN
MDI ZAPI LED
Error code Effect Condition OPEN
procedure CODE CODE CODE
CODE

MC is not closed,
Valves or
VDC LINK OVERV. EB is applied, Stand-by, running Traction/Pump 0XFFCA 77 202 77
Traction/Pump, valves Request
stopped
re-cycle
EB is applied,
Traction/Pump, valves
stopped
MC is not closed,
Start-up, stand-by, Valves or Traction/
SEAT MISMATCH 0xFFDE 15 222 15
EB is applied, running Pump request
Traction/Pump stopped

MC is not closed, Valves or

Traction/Pump
LOGIC FAILURE #1 EB is applied, Stand-by, running 0x5114 19 19 19
Traction/Pump, valves Request
stopped

MC is not closed, Valves or

Traction/Pump
LOGIC FAILURE #2 EB is applied, Start-up, stand-by, 0XFF12 18 18 18
Traction/Pump, valves Request
stopped

MC is not closed,
Valves or
LOGIC FAILURE #3 EB is applied, Start-up, stand-by Traction/Pump 0XFF11 17 17 17
Traction/Pump, valves
Request
stopped
MC is not closed,
Valves or
EB is applied, Start-up, stand-by, Traction/Pump
LC COIL OPEN 0xFFE6 22 230 22
Traction/Pump, valves running
Request
stopped

Valves or
IQ MISMATCHED Traction is stopped Running Traction/Pump 0xFFF5 24 245 24
Request
MC is not closed,
INIT VMN LOW 01
INIT VMN LOW 02 EB is applied, Start-up Key re-cycle 0x3121 30 207 30
Traction/Pump, valves
INIT VMN LOW 03 stopped

MC is not closed,
INIT VMN HIGH 81
INIT VMN HIGH 82 EB is applied, Start-up Key re-cycle 0x3111 31 206 31
Traction/Pump, valves
INIT VMN HIGH 83 stopped

MC is not closed,
Valves or
EB is applied, Traction/Pump
VMN HIGH Start-up, stand-by 0x3110 31 31 31
Traction/Pump, valves
Request
stopped

MC is not closed,
Valves or
VMN LOW EB is applied, Start-up Traction/Pump 0x3120 30 30 30
Traction/Pump, valves
Request
stopped

HW FAULT 11 MC is not closed,

HW FAULT 12 EB is applied, Start-up Key re-cycle 0xFFE3 32 227 32
HW FAULT 13 Traction/Pump stopped
MC is not closed,
HW FAULT 01
HW FAULT 02 EB is applied, Start-up Key re-cycle 0xFFE3 32 227 32
HW FAULT 03 Traction/Pump stopped

MC is not closed,

EB is applied, Start-up, stand-by,

POSITIVE LC OPEN Key re-cycle 0xFFD5 35 213 35
Traction/Pump, valves running
stopped

MC is opened, EB is
Valves or
FIELD ORIENT KO applied, Traction/Pump, Running 0xFFFD 36 253 36
Traction/Pump
valves stopped

AFFZP0BB – ACE3 – User Manual Page – 87/139

 Restart CAN
MDI ZAPI LED
Error code Effect Condition OPEN
procedure CODE CODE CODE
CODE

MC is not closed,
Valves or
VDC LINK OVERV. EB is applied, Stand-by, running Traction/Pump 0XFFCA 77 202 77
Traction/Pump, valves Request
stopped
Request

MC is not closed
(command is not Valves or
CONTACTOR CLOSED activated), Start-up Traction/Pump 0x5442 37 37 37
Request
EB is applied,
Traction/Pump stopped
MC is opened, Valves or
EB is applied, Start-up, stand-by, Traction/Pump 38
CONTACTOR OPEN 0x5441 38 38
Traction/Pump, valves running Request
stopped

Traction is stopped
Traction/ Pump
POWER MISMATCH Running 0xFFD4 39 212 39
EB is applied, request
MC is opened

MC is not closed, The alarms

EB is applied, disappears as soon
WRONG SET BAT Start-up as the voltage 0x3100 41 251 41
Traction/Pump, valves
stopped comes back into the
correct range
MC is not closed,
MOT.PHASE SH.36
EB is applied, Traction/ Pump
MOT.PHASE SH.37 Start-up 0xFFC4 47 196 47
Traction/Pump, valves request
MOT.PHASE SH.38
stopped
MC is not closed, Valves or
STBY I HIGH EB is applied, Start-up, stand-by Traction/Pump 0x2311 53 53 53
Traction/Pump stopped Request

OVERLOAD Traction is stopped Running Key re-cycle 0xFFB4 57 180 57

MC is not closed,
Valves or
CAPACITOR CHARGE EB is applied, Start-up Traction/Pump 0x3130 60 60 60
Traction/Pump, valves
Request
stopped
Valves or
Traction stopped, EB Traction/Pump 64
TILLER ERROR Stand-by, running 0xFFB9 64 185
applied Request

MC is opened, EB is Valves or
Start-up, stand-by, Traction/Pump
NO CAN MSG. applied, Traction/Pump, 0X8130 67 248 67
running
valves stopped Request

MC is opened, EB is
WRONG RAM MEM. applied, Traction/Pump, Stand-by Key re-cycle 0xFFD2 71 210 71
valves stopped

MC is opened (the Valves or

command is released), EB Start-up, stand-by, Traction/Pump
DRIVER SHORTED 0x3211 74 74 74
is applied, Traction/Pump, running
valves stopped Request

MC is opened (the Valves or

command is released), EB Start-up, stand-by, Traction/Pump
CONTACTOR DRIVER 0x3221 75 75 75
is applied, Traction/Pump, running Request
valves stopped
MC is opened,
Start-up Valves or
EB is applied, (immediately after Traction/Pump
MC-EF COIL SHOR. 0x2250 76 223 76
Traction/Pump, valves MC closing), stand-
by, running Request
stopped

MC is opened , EB is
SPEED FB. ERROR applied, Running Key re-cycle 0xFFAF 81 175 81
EVP stopped

ENCODER ERROR MC is opened, EB is Running Valves or 0xFF52 82 82 82

applied, Traction/Pump, Traction/Pump

Page – 88/139 AFFZP0BB – ACE3 – User Manual

 Restart CAN
MDI ZAPI LED
Error code Effect Condition OPEN
procedure CODE CODE CODE
CODE

MC is not closed,
Valves or
VDC LINK OVERV. EB is applied, Stand-by, running Traction/Pump 0XFFCA 77 202 77
Traction/Pump, valves Request
stopped
valves stopped Request

MC is not closed,
WRONG ENC SET EB is applied, Start-up Key re-cycle 0xFF51 83 181 83
Traction/Pump, valves
stopped
MC is opened,
ANALOG INPUT EB is applied, Stand-by, running Key re-cycle 0xFFFA 96 237 96
traction/pump stopped
MC is opened (the Valves or
command is released), EB Start-up, stand-by, Traction/Pump
CTRAP THRESHOLD 0xFFEB 99 235 99
is applied, Traction/Pump, running
valves stopped Request

MC is opened,
AUX BATT. SHORT EB is applied, Running Key re-cycle 0x5001 27 194 27
traction/pump stopped
MC is not closed,
POS. EB. SHORTED EB is applied, Start-up Key re-cycle 0x3223 84 195 84
Traction/Pump, valves
stopped
MC is opened,
Start-up, stand-by, Key re-cycle 88
VDC OFF SHORTED EB is applied, 0xFFC8 88 200
running
traction/pump stopped
MC is opened,
Start-up, stand-by,
VKEY OFF SHORTED EB is applied, Key re-cycle 0x5101 20 220 20
running
traction/pump stopped
MC is opened,
POWERMOS
EB is applied, Start-up Key re-cycle 0xFFE9 89 233 89
SHORTED
traction/pump stopped
MC is opened, Valves or
BUMPER STOP EB is applied, Stand-by, running Traction/Pump 0xFFA2 0 162 0
traction/pump stopped Request
MC is not closed,
EB is applied, Start-up, stand-by, Key re-cycle
WRONG SET KEY 0x3101 41 170 41
Traction/Pump, valves running
stopped
MC is not closed,
WRONG SET EB is applied, Start-up, stand-by,
Key re-cycle 0x3100 41 251 41
BATTERY Traction/Pump, valves running
stopped

AFFZP0BB – ACE3 – User Manual Page – 89/139

9.1.1 Troubleshooting of master-uC alarms

1) VDC LINK OVERV.

Cause
This fault is displayed when the controller detects an overvoltage condition.
Overvoltage threshold is 65 V for 36/48V controllers and 116 V for 80V
controllers.
As soon as the fault occurs, power bridge and MC are opened. The condition is
triggered using the same HW interrupt used for undervoltage detection, uC
discerns between the two evaluating the voltage present across DC-link
capacitors:
- High voltage  Overvoltage condition
- Low/normal voltage  Undervoltage condition
Troubleshooting
If the alarm happens during the brake release, check the line contactor contact
and the battery power-cable connection.

2) LOGIC FAILURE #1
Cause
This fault is displayed when the controller detects an undervoltage condition at
the key input (A1).
Undervoltage threshold is 11V for 36/48V controllers and 30 V for 80V
controllers.
Troubleshooting (fault at startup or in standby)
- Fault can be caused by a key input signal characterized by pulses below
the undervoltage threshold, possibly due to external loads like DC/DC
converters starting-up, relays or contactors during switching periods,
solenoids energizing or de-energizing. Consider to remove such loads.
- If no voltage transient is detected on the supply line and the alarm is
present every time the key switches on, the failure probably lies in the
controller hardware. Replace the logic board.
Troubleshooting (fault displayed during motor driving)
- If the alarm occurs during motor acceleration or when there is a
hydraulic-related request, check the battery charge, the battery health and
power-cable connections.

3) LOGIC FAILURE #2
Cause
Fault in the hardware section of the logic board which deals with voltage
feedbacks of motor phases.
Troubleshooting
The failure lies in the controller hardware. Replace the controller.

Page – 90/139 AFFZP0BB – ACE3 – User Manual

 4) LOGIC FAILURE #3
Cause

An hardware problem in the logic board due to high currents (overload). An

overcurrent condition is triggered even if the power bridge is not driven.
Troubleshooting
The failure lies in the controller hardware. Replace the controller.

5) POSITIVE LC OPEN
Cause
The voltage feedback of LC driver (A16) is different from expected, i.e. it is not
in accordance with the driver operation.
Troubleshooting
- Verify LC coil is properly connected.
- Verify CONF. POSITIVE LC parameter is set in accordance with the actual
coil positive supply (see paragraph 7.2.5). Software, depending on the
parameter value, makes a proper diagnosis; a mismatch between the
hardware and the parameter configuration could generate a false fault.
- In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.

6) CTRAP THRESHOLD
Cause
This alarm occurs when a mismatch is detected between the setpoint for the
overcurrent detection circuit (dependent on parameter DUTY PWM CTRAP, see
paragraph 7.2.4) and the feedback of the actual threshold value.
Troubleshooting
The failure lies in the controller hardware. Replace the logic board.

7) WATCH DOG
Cause
This is a safety related test. It is a self-diagnosis test that involves the logic
between master and supervisor microcontrollers.
Troubleshooting
This alarm could be caused by a CAN bus malfunctioning, which blinds
master-supervisor communication.

8) WRONG RAM MEM. 05

Cause
The algorithm implemented to check the main RAM registers finds wrong
contents: the register is “dirty”. This alarm inhibits the machine operations.
Troubleshooting
Try to switch the key off and then on again, if the alarm is still present replace
the logic board.

AFFZP0BB – ACE3 – User Manual Page – 91/139

 9) TILLER ERROR
Cause
Input mismatch between Hard&Soft input (A11) and tiller/seat input (A6): the two
inputs are activated at the same time.
Troubleshooting
- Check if there are wrong connections in the external wiring.
- Using the TESTER function verify that inputs are in accordance with the
actual state of the external switches.
- Check if there is a short circuit between A11 and A6.
- In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.

10) OVERLOAD
Cause
The motor current has overcome the limit fixed by hardware.
Troubleshooting
Reset the alarm by switching key off and on again.
If the alarm condition occurs again, ask for assistance to a Zapi technician. The
fault condition could be affected by wrong adjustments of motor parameters.

11) FIELD ORIENT. KO

Cause
The error between the Id (d-axis current) setpoint and the estimated Id is out of
range.
Troubleshooting
Ask for assistance to a Zapi technician in order to do the correct adjustment of
the motor parameters.

12) IQ MISMATCHED
Cause
The error between the Iq (q-axis current) setpoint and the estimated Iq is out of
range.
Troubleshooting
Ask for assistance to a Zapi technician in order to do the correct adjustment of
the motor parameters.

13) EVP DRIV. SHORT.

Cause
- The EVP driver is shorted (output A19).
- The microcontroller detects a mismatch between the valve set-point and
the feedback of the EVP output.
Troubleshooting
- Check if there is a short circuit or a low-impedance conduction path
between the negative of the coil and -BATT.

Page – 92/139 AFFZP0BB – ACE3 – User Manual

 - Collect information about:
- the voltage applied across the EVP coil,
- the current in the coil,
- features of the coil.
Ask for assistance to Zapi in order to verify that the software diagnoses are in
accordance with the type of coil employed.
- If the problem is not solved, it could be necessary to replace the controller.

14) CAPACITOR CHARGE

It is related to the capacitor-charging system:

Cause
When the key is switched on, the inverter tries to charge the power capacitors
through the series of a PTC and a power resistance, checking if the capacitors
are charged within a certain timeout. If the capacitor voltage results less than
20% of the nominal battery voltage, the alarm is raised and the main contactor
is not closed.
Troubleshooting
- Check if an external load in parallel to the capacitor bank, which sinks
current from the capacitors-charging circuit, thus preventing the caps from
charging well. Check if a lamp or a dc/dc converter or an auxiliary load is
placed in parallel to the capacitor bank.
- The charging resistance or PTC may be broken. Insert a power resistance
across line-contactor power terminals; if the alarm disappears, it means that
the charging resistance is damaged.
- The charging circuit has a failure or there is a problem in the power section.
Replace the controller.

15) MOT.PHASE SH.

Cause
Short circuit between two motor phases. The number that follows the alarm
identifies where the short circuit is located:
- 36  U – V short circuit
- 37  U – W short circuit
- 38  V – W short circuit
AFFZP0BB – ACE3 – User Manual Page – 93/139
 Troubleshooting
- Verify the motor phases connection on the motor side
- Verify the motor phases connection on the inverter side
- Check the motor power cables.
- Replace the controller.
- If the alarm does not disappear, the problem is in the motor. Replace it.

16) INIT VMN LOW 01/02/03

Cause
Before switching the LC on, the software checks the power-bridge voltage
without driving it. The software expects the voltage to be in a “steady state”
value. If it is too low, this alarm occurs.
Troubleshooting
- Check the motor power cables.
- Check the impedance between U, V and W terminals and -Batt terminal of
the controller.
- Check the motor leakage to truck frame.
- If the motor connections are OK and there are no external low impedance
paths, the problem is inside the controller. Replace it.

17) INIT VMN HIGH 81/82/83

Cause
Before switching the LC on, the software checks the power-bridge voltage
without driving it.
The software expects the voltage to be in a “steady state” value.
If it is too high, this alarm occurs.
Troubleshooting
- Check the motor power cables;
- Check the impedance between U, V and W terminals and -Batt terminal of
the controller.
- Check the motor leakage to truck frame.
- If the motor connections are OK and there are no external low impedance
paths, the problem is inside the controller. Replace it.

Page – 94/139 AFFZP0BB – ACE3 – User Manual

 18) VMN LOW
Cause 1
Start-up test. Before switching the LC on, the software checks the power bridge:
it turns on alternatively the high-side power MOSFETs and expects the phase
voltages increase toward the positive rail value. If one phase voltage is below
66% of the rail voltage, this alarm occurs.
Cause 2
Motor running test. When the motor is running, the power bridge is on and the
motor voltage feedback tested; if it is lower than expected value (a range of
values is considered), the controller enters in fault state.
Troubleshooting
- If the problem occurs at start up (the LC does not close at all), check:
o motor internal connections (ohmic continuity);
o motor power-cables connections;
o if the motor connections are OK, the problem is inside the controller;
replace it.
- If the alarm occurs while the motor is running, check:
o motor connections;
o that the LC power contact closes properly, with a good contact;
o if no problem is found, the problem is inside the controller. Replace it.

19) VMN HIGH

Cause 1
Before switching the LC on, the software checks the power bridge: it turns on
alternatively the low-side power MOSFETs and expects the phase voltages
decrease down to -BATT. If the phase voltages are higher than 10% of the
nominal battery voltage, this alarm occurs.
Cause 2
This alarm may also occur when the start-up diagnosis has succeeded and so
the LC has been closed. In this condition, the phase voltages are expected to be
lower than half the battery voltage. If one of them is higher than that value, this
alarm occurs.
Troubleshooting
- If the problem occurs at start-up (the LC does not close), check:
o motor internal connections (ohmic continuity);
o motor power cables connections;
o if the motor connections are OK, the problem is inside the controller.
Replace it.
- If the alarm occurs while the motor is running, check:
o motor connections;
o that the LC power contact closes properly, with a good contact;
o if no problem is found, the problem is inside the controller. Replace it.

AFFZP0BB – ACE3 – User Manual Page – 95/139

 20) HW FAULT 11/12/13
Cause
At each start-up the supervisor microcontroller checks that the hardware circuit
intended to enable and disable the LC driver (A16) works properly.
Troubleshooting
This type of fault is not related to external components. Replace the logic board.

21) HW FAULT 01/02/03

Cause
At each start-up the supervisor microcontroller checks that the hardware circuit
for enabling and disabling of the power bridge works properly.
Troubleshooting
This type of fault is not related to external components. Replace the logic board.

22) POWER MISMATCH

Cause
The error between the power setpoint and the estimated power is out of range.
Troubleshooting
Ask for assistance to a Zapi technician about the correct adjustment of the
motor parameters.

23) SEAT MISMATCH

Cause
This alarm can appear only in a Traction + Pump configuration.
There is an input mismatch between the traction controller and the pump
controller relatively to the seat input (A6): the two values recorded by the two
controllers are different.
Troubleshooting
- Check if there are wrong connections in the external wiring.
- Using the TESTER function verify that the seat inputs are in accordance
with the actual state of the external switch.
- In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.

24) STBY I HIGH

Cause
In standby, the sensor detects a current value different from zero.
Troubleshooting
The current sensor or the current feedback circuit is damaged. Replace the
controller.

Page – 96/139 AFFZP0BB – ACE3 – User Manual

 25) CONTROLLER MISM.
Cause
The software is not compatible with the hardware. Each controller produced is
“signed” at the end of line test with a specific code mark saved in EEPROM
according to the customized Part Number.
According with this “sign”, only the customized firmware can be uploaded.
Troubleshooting
- Upload the correct firmware.
- Ask for assistance to a Zapi technician in order to verify that the firmware is
correct.

26) ENCODER ERROR

Cause
This fault occurs in the 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 of milliseconds. This condition is related to an
encoder failure.
Troubleshooting
- Check the electrical and the mechanical functionality of the encoder and the
wires crimping.
- Check the mechanical installation of the encoder, if the encoder slips inside
its housing it will raise this alarm.
- Also the electromagnetic noise on the sensor can be the cause for the
alarm. In these cases try to replace the encoder.
- If the problem is still present after replacing the encoder, the failure is in the
controller.

27) SPEED FB. ERROR

Cause
This alarm occurs if the absolute position sensor is used also for speed
estimation. If signaled, it means that the controller measured that the engine
was moving too quick.
Troubleshooting
- Check that the sensor used is compatible with the software release.
- Check the sensor mechanical installation and if it works properly.
- Also the electromagnetic noise on the sensor can be a cause for the alarm.
- If no problem is found on the motor or on the speed sensor, the problem is
inside the controller, it is necessary to replace the logic board.

28) WRONG ENC SET

Cause
Mismatch between “ENCODER PULSES 1” parameter and “ENCODER
PULSES 2” parameter (see paragraph 7.2.5).

AFFZP0BB – ACE3 – User Manual Page – 97/139

 Troubleshooting
Set the two parameters with the same value, according to the adopted encoder.

29) CONTACTOR CLOSED

Cause
Before driving the LC coil, the controller checks if the contactor is stuck. The
controller drives the power bridge for several dozens of milliseconds, trying to
discharge the capacitors bank. If the capacitor voltage does not decrease by
more than 20% of the key voltage, the alarm is raised.
Troubleshooting
It is suggested to verify the power contacts of LC; if they are stuck, is necessary
to replace the LC.

30) CONTACTOR OPEN

Cause
The LC coil is driven by the controller, but it seems that the power contacts do
not close. In order to detect this condition the controller injects a DC current into
the motor and checks the voltage on power capacitor. If the power capacitors
get discharged it means that the main contactor is open.
Troubleshooting
- LC contacts are not working. Replace the LC.
- If LC contacts are working correctly, contact a Zapi technician.

31) CONTACTOR DRIVER

Cause
The LC coil driver is not able to drive the load. The device itself or its driver
circuit is damaged.
Troubleshooting
This type of fault is not related to external components; replace the logic board.

32) LC COIL OPEN

Cause
This fault appears when no load is connected between the NLC output (A16)
and the positive voltage (for example +KEY).
Troubleshooting
- Check the wiring, in order to verify if LC coil is connected to the right
connector pin and if it is not interrupted.
- If the alarm is still present, than the problem is inside the logic board;
replace it.

33) MC-EF COIL SHOR.

Cause
This alarm occurs when there is an overload of the MC driver (A16) and EB
driver (A17). As soon as the overload condition disappears, the alarm will be
removed automatically by releasing and then enabling a travel demand.

Page – 98/139 AFFZP0BB – ACE3 – User Manual

 Troubleshooting
- Check the connections between the controller outputs and the loads.
- Collect information about characteristics of the coils connected to the two
drivers and ask for assistance to a Zapi technician in order to verify that the
maximum current that can be supplied by the hardware is not exceeded.
- In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.

34) ANALOG INPUT

Cause
This alarm occurs when the A/D conversion of the analog inputs returns frozen
values, on all the converted signals, for more than 400 ms. The goal of this
diagnosis is to detect a failure in the A/D converter or a problem in the code flow
that skips the refresh of the analog signal conversion.
Troubleshooting
If the problem occurs permanently it is necessary to replace the logic board.

35) DRIVER SHORTED

Cause
The driver of the LC coil is shorted.
Troubleshooting
- Check if there is a short or a low impedance pull-down between NLC (A16
(A26)) and –BATT.
- The driver circuit is damaged; replace the logic board.

36) POWER ACQ. ERROR

Cause
This alarm occurs only when the controller is configured to drive a PMSM and
the feedback sensor selected in the HARDWARE SETTING list is ENCODER
ABI + PWM.
The controller does not detect correct information on PWM input at start-up.
Troubleshooting
- Re-cycle the key.
- Check the sensor in order to verify that it works properly.
- Check the wiring.
- If the problem occurs permanently it is necessary to substitute logic board.

37) HOME SENSOR CORR

Cause
The controller detected a difference between the estimated absolute orientation
of the rotor and the position of the index signal (ABI encoder).
It is caused by a wrong acquisition of the angle offset between the orientation of
the rotor and the index signal.

AFFZP0BB – ACE3 – User Manual Page – 99/139

 Troubleshooting
Repeat the auto-teaching procedure.

38) NO CAN MSG. 09

Cause
This fault is signaled when there is no communication with the supervisor uC.
Troubleshooting
This type of fault is not related to external components; replace the logic board.

39) WRONG SET BAT. 05

Cause
At start-up, the controller checks the battery voltage (measured at key input)
and it verifies that it is within a range of ±20% around the nominal value.
Troubleshooting
- Check that the SET BATTERY parameter inside the ADJUSTMENT list
matches with the battery nominal voltage.
- Through the TESTER function, check that the KEY VOLTAGE reading
shows the same value as the key voltage measured with a voltmeter on pin
A1. If it does not match, then modify the ADJUST BATTERY parameter
according to the value read by the voltmeter.
- Replace the battery.

40) IMS ERROR

Cause
At start-up, the controller checks the presence of IMS board. If the IMS board is
not well connected, this alarm appears.
Troubleshooting
- Replace the controller

41) SHORT CIRCUIT

Cause
The controller continuously checks that the Three-phase bridge works properly
and that a short-circuit between motor phases is not present.
Troubleshooting
- Check that motor phases are correctly connected.
- Verify that motor phases are not shot-circuited.
- Replace the controller.
- In case the problem is not solved, replace the motor.

42) SHORT CIRCUIT KO

Cause
The HW dedicated to detect faults on power bridge does not work properly

Page – 100/139 AFFZP0BB – ACE3 – User Manual

 Troubleshooting
- Replace the controller.

43) VDC OFF SHORTED

Cause
The logic board measures a key voltage value that is constantly out of range,
above the maximum allowed value.
Troubleshooting
- Check that the battery has the same nominal voltage of the inverter.
- Check the battery voltage, if it is out of range replace the battery.
- In case the problem is not solved, replace the logic board.

44) VKEY OFF SHORTED

Cause
The logic board measures a key voltage that is constantly out of range, below
the minimum allowed value.
Troubleshooting
- Check that the battery has the same nominal voltage of the inverter.
- Check the battery voltage, if it is out of range replace the battery.
- In case the problem is not solved, replace the logic board.

45) POWERMOS SHORTED

Cause
The DC-link voltage drops to zero when a high-side MOSFET is turned on.
Troubleshooting
- Check that motor phases are correctly connected.
- Check that there is no dispersion to ground for every motor phases.
- In case the problem is not solved, replace the controller.

46) BUMPER STOP

Cause
The two digital inputs dedicated to the bumper functionality are high at the same
time.
Troubleshooting
- Turn off one or both inputs dedicated to the bumper functionality;
- If the alarm occurs even if the inputs are in the rest position, check if the
microswitches are stuck.
- In case the problem is not solved, replace the logic board.

47) WRONG SET KEY

Cause
The measured key voltage is not the right one for the inverter.

AFFZP0BB – ACE3 – User Manual Page – 101/139

 Troubleshooting
- Check if the SET KEY VOLTAGE parameter in the ADJUSTMENT list is set
in accordance with the key voltage.
- Check if the key voltage is ok using a voltmeter, if not check the wiring.
- In case the problem is not solved, replace the logic board.

48) WRONG SET BATTERY

Cause
The measured battery voltage is not the right one for the inverter.
Troubleshooting
- Check if the battery voltage (measured between the +Batt and -Batt
terminals of the inverter) is ok using a voltmeter, if not check the wiring;
- Record the value stored inside the HARDWARE BATTERY RANGE
parameter in the SPECIAL ADJUST. list and contact a Zapi technician.
- In case the problem is not solved, replace the logic board.

Page – 102/139 AFFZP0BB – ACE3 – User Manual

 9.2 Alarms – Supervisor uC
Indication
Machine
status
Error Restart CAN
Effect When the ZAPI
Code test is procedure OPEN MDI LED
CODE
CODE CODE BLINKS
done

MC is opened,
Stand-by,
WATCHDOG EB is applied, Key re-cycle 0X6010 8 8 8
running
traction/pump stopped

MC is not closed, Install the correct

CONTROLLER EB is applied, software and Key
Start-up 0XFFEF 12 239 12
MISM. Traction/Pump, valves re-cycle
stopped
MC is opened,
SP MISMATCH xx EB is applied, Running Key re-cycle 0XFFF2 15 242 15
traction/pump stopped

MC is opened,
OUT MISMATCH xx EB is applied, Running Key re-cycle 0XFFE3 16 227 16
traction/pump stopped

MC is opened, Valves or
Stand-by, Traction/Pump
LOGIC FAILURE #1 EB is applied, 0X5114 19 19 19
running
traction/pump stopped Request

MC is opened, Valves or
Stand-by, Traction/Pump
LOGIC FAILURE #3 EB is applied, 0XFF11 17 17 17
running
traction/pump stopped Request

MC is opened, EB is Start-up,
applied, Key
INPUT MISMATCH standby, 0XFFD5 58 213 58
Traction/Pump re-cycle
stopped running

Start-up,
Traction/ Pump motor
W.SET. TG-EB stand-by, Key re-cycle 0XFFD4 59 212 59
is stopped
running

MC is opened, EB is Valves or
Start-up,
applied, Traction/Pump
NO CAN MSG. stand-by, 0X8130 67 248 67
Traction/Pump, valves
running Request
stopped

MC is opened, EB is
WRONG RAM MEM. applied, Key re-cycle
Stand-by 0XFFD2 71 210 71
05 Traction/Pump, valves
stopped

MC is not closed,
Valves or
EB is applied, Stand-by, Traction/Pump
VDC LINK OVERV. 0XFFCA 77 202 77
Traction/Pump, valves running Request
stopped

MC is not closed,
WRONG ENC SET EB is applied, Start-up Key re-cycle 0XFF51 85 201 85
Traction/Pump, valves
stopped
MC is opened,
Stand-by,
ANALOG INPUT EB is applied, Key re-cycle 0XFFFA 96 237 96
running
traction/pump stopped

AFFZP0BB – ACE3 – User Manual Page – 103/139

9.2.1 Troubleshooting of supervisor-uC alarms

1) INPUT MISMATCH
Cause:
The supervisor microcontroller records different input values with respect to the
master microcontroller.
Troubleshooting:
- Compare the values read by master and slave through the TESTER
function.
- Ask for the assistance to a Zapi technician.
- If the problem is not solved, replace the logic board.

2) W.SET. TG-EB
Cause:
Supervisor microcontroller has detected that the master microcontroller has
imposed a wrong setpoint for TG or EB output
Troubleshooting:
- Check the matching of the parameters between master and supervisor.
- Ask for the assistance of a Zapi technician.
- If the problem is not solved, replace the logic board.

3) LOGIC FAILURE #1
Cause:
This fault is displayed when the controller detects an undervoltage condition at
the key input (A1).
Undervoltage threshold is 11V for 36/48V controllers and 30 V for 80V
controllers.
- Fault can be caused by a key input signal characterized by pulses below
the undervoltage threshold, possibly due to external loads like DC/DC
converters starting-up, relays or contactors during switching periods,
solenoids energizing or de-energizing. Consider to remove such loads.
- If no voltage transient is detected on the supply line and the alarm is
present every time the key switches on, the failure probably lies in the
controller hardware. Replace the logic board.
Troubleshooting (fault displayed during motor driving)
- If the alarm occurs during motor acceleration or when there is a
hydraulic-related request, check the battery charge, the battery health and
power-cable connections.

4) LOGIC FAILURE #3
Cause
A hardware problem in the logic board due to high currents (overload). An
overcurrent condition is triggered even if the power bridge is not driven.
Troubleshooting
The failure lies in the controller hardware. Replace the controller.
Page – 104/139 AFFZP0BB – ACE3 – User Manual
 5) VDC LINK OVERV.
Cause
This fault is displayed when the controller detects an overvoltage condition.
Overvoltage threshold is 65 V for 36/48V controllers and 116 V for 80V
controllers.
As soon as the fault occurs, power bridge and MC are opened. The condition is
triggered using the same HW interrupt used for undervoltage detection, uC
discerns between the two evaluating the voltage present across DC-link
capacitors:
- High voltage  Overvoltage condition
- Low/normal voltage  Undervoltage condition
Troubleshooting
If the alarm happens during the brake release, check the line contactor contact
and the battery power-cable connection.

6) WATCH DOG
Cause:
This is a safety related test. It is a self-diagnosis test that involves the logic
between master and supervisor microcontrollers.
Troubleshooting
This alarm could be caused by a CAN bus malfunctioning, which blinds
master-supervisor communication.

7) WRONG RAM MEM. 05

Cause:
The algorithm implemented to check the main RAM registers finds wrong
contents: the register is “dirty”. This alarm inhibits the machine operations.
Troubleshooting
Try to switch the key off and then on again, if the alarm is still present replace
the logic board.

8) SP MISMATCH XX
Cause:
This is a safety related test. The master μC has detected a supervisor μC wrong
set point.
Troubleshooting:
- Check the matching of the parameters between master and supervisor.
- Ask for assistance to a Zapi technician.
- If the problem is not solved, replace the logic board.

9) OUT MISMATCH XX
Cause:
This is a safety related test. Supervisor μC has detected that master μC is
driving traction motor in a wrong way (not corresponding to the operator
request).
AFFZP0BB – ACE3 – User Manual Page – 105/139
 Troubleshooting:
- Checks the matching of the parameters between Master and Supervisor.
- Ask for assistance to a Zapi technician.
- If the problem is not solved, replace the logic board.

10) CONTROLLER MISM.

Cause:
The software is not compatible with the hardware. Each controller produced is
“signed” at the end of line test with a specific code mark saved in EEPROM
according to the customized Part Number.
According with this “sign”, only the customized firmware can be uploaded.
Troubleshooting
- Upload the correct firmware.
- Ask for assistance to a Zapi technician in order to verify that the firmware is
correct.

11) ANALOG INPUT

Cause:
This alarm occurs when the A/D conversion of the analog inputs returns frozen
values, on all the converted signals, for more than 400 ms. The goal of this
diagnosis is to detect a failure in the A/D converter or a problem in the code flow
that skips the refresh of the analog signal conversion.
Troubleshooting
If the problem occurs permanently it is necessary to replace the logic board.

12) WRONG ENC SET

Cause:
Mismatch between “ENCODER PULSES 1” parameter and “ENCODER
PULSES 2” parameter (see paragraph 7.2.5).
Troubleshooting
Set the two parameters with the same value, according to the adopted encoder.

13) NO CAN MSG.

Cause:
This is a safety related test. It is a self-diagnosis test that checks the
communication between master and supervisor microcontrollers.
Troubleshooting:
This alarm could be caused by a CAN bus malfunctioning, which blinds master-
supervisor communication

Page – 106/139 AFFZP0BB – ACE3 – User Manual

 9.3 Warnings – Master uC
Machine Indication
status
Error Restart
Effect When the CAN
Code test is procedure MDI ZAPI LED
OPEN
done CODE CODE BLINKS
CODE

MC is opened, Start-up,
WAITING FOR NODE EB is applied, Key re-cycle 0x0000 0 224 0
Traction/Pump stand-by,
stopped running
The maximum current
Start-up,
is reduced to half and Battery recharge,
BATTERY LOW standby, 0XFF42 0 66 0
speed is reduced (if key re-cycle
running
CHECK OPTION=1)
Controller
DATA ACQUISITION Traction is stopped Traction request 0x0000 0 247 0
calibration

Start-up,
Check-up done, key
CHECK UP NEEDED stand-by, 0x0000 0 249 0
re-cycle
running

It depends by
WARNING SLAVE Supervisor uC 0xFF01 1 244 1

Sensor
ACQUIRING A.S. Key re-cycle 0xFFAB 2 171 2
Acquiring
Sensor
ACQUIRE END Key re-cycle 0xFFAD 2 173 2
Acquiring

ACQUIRE ABORT 0xFFAC 2 172 2

SIN/COS D.ERR Traction is stopped running Traction request 0xFFA8 3 168 3

ENCODER D.ERR Traction is stopped running Traction request 0xFFA9 3 169 3

MC is opened (the
command is released), Start-up, Valves
EVP DRIVER OPEN EB is applied, stand-by, 0xFFF8 9 240 9
Traction/Pump, valves running Request
stopped
MC is not closed,
Start-up, Valves or
EVP COIL OPEN EB is applied, stand-by, Traction/Pump 0x5002 9 214 9
Traction/Pump, valves running Request
stopped
MC is not closed ,

HW FAULT EV XX EB is applied, Start-up Key re-cycle 0xFFEE 16 238 16

Traction/Pump
stopped
Start-up,
Traction/Pump
STALL ROTOR stand-by, Key-on recycle 0xFFD3 11 211 11
stopped
running
Controller works using
EEPROM KO Continuous 0x3610 13 208 13
Default parameters

No effect Traction/ Pump

PARAM RESTORE Start-up 0X000 14 209 14
request

COIL SHOR. EVAUX EV stopped EV on Valve EV request 0xFFF1 21 241 21

MC is opened (the Start-up,

command is released), Valves
CONT DRIV EV XX stand-by, 0xFFE8 21 232 21
EB is applied, running Request
Traction/Pump, valves

AFFZP0BB – ACE3 – User Manual Page – 107/139

 Machine Indication
status
Error Restart
Effect When the CAN
Code test is procedure MDI ZAPI LED
OPEN
done CODE CODE BLINKS
CODE
stopped

MC is opened (the
command is released), Start-up, Valves or
DRV SHOR EV XX EB is applied, stand-by, Traction/Pump 0xFFF9 21 234 21
Traction/Pump, valves running Request
stopped
MC is not closed, MC is not closed,
Start-up,
PEV OPEN XX EB is applied, stand-by, EB is applied, 0xFFDB 25 217 25
Traction/Pump, valves running Traction/Pump,
stopped valves stopped
MC is closed ,
HW FAULT EB 01
HW FAULT EB 02 EB is applied, Start-up Key re-cycle 0xFFE5 34 229 34
HW FAULT EB 03 Traction/Pump
stopped
MC remain closed, EB
is applied (the Valves or
Stand-by,
EB. DRIV.SHRT. command is released), Traction/Pump 0x3222 40 254 40
Traction/Pump, valves running
Request
stopped

MC remain closed, EB
Valves or
is applied (the
EB. DRIV.OPEN Traction/Pump
command is released), Running 0x3224 42 246 42
Traction/Pump, valves Request
stopped

MC remain closed, EB
is applied (the Start-up, Valves or
EB. COIL OPEN command is released), Stand-by, Traction/Pump 0xFFD8 43 216 43
Traction/Pump, valves running Request
stopped
Start-up,
HANDBRAKE Traction/ Pump motor Traction/ Pump
stand-by, 0xFFDD 46 221 46
is stopped request
running

MC remain closed, EB Valves or

Start-up,
is applied (the Traction/Pump
THROTTLE PROG. 0xFFF3 48 243 48
command is released), Stand-by,
Traction stopped Request

Start-up,
LIFT + LOWER Pump is stopped stand-by, Pump request 0xFFBB 49 187 49
Running
Start-up, Valves or
TILLER OPEN LC opens stand-by, Traction/Pump 0x0000 51 228 51
running Request
Valve, pump, traction
stopped, Valves or Traction/
WRONG ZERO Start-up 0x3201 58 252 58
LC opened, EB Pump request
applied
The maximum current Start-up,
THERMIC SENS. KO is reduced to half and stand-by, 0x4211 61 250 61
speed is reduced running

Traction controller
reduces the max Start-up,
TH. PROTECTION current linearly from stand-by, 0x4210 62 62 62
Imax (85°C) down to running
0A (105°C)

Page – 108/139 AFFZP0BB – ACE3 – User Manual

 Machine Indication
status
Error Restart
Effect When the CAN
Code test is procedure MDI ZAPI LED
OPEN
done CODE CODE BLINKS
CODE

No effect, the warning Traction/Pump

BRAKE RUN OUT is only displayed Continuous 0xFFCC 63 204 63
through the console Request

Reload HM from MDI Start-up Key re-cycle 0x0000 94 0 94

The maximum current

Start-up,
is reduced to half and
MOTOR TEMPERAT. stand-by, 0x4110 65 65 65
speed is reduced
running

MC stays closed, EB is
MOTOR TEMP. applied,
Continuous 0xFFB2 65 178 65
STOP Traction/Pump, valves
stopped

The maximum current Start-up,

SENS MOT TEMP
is reduced to half and stand-by, 0x4311 68 218 68
KO
speed is reduced running

Start-up,
Traction/ Pump motor Valves or Traction/
EPS RELAY OPEN stand-by, 0xFFCD 70 205 70
is stopped Pump request
Running

Traction/ Pump motor Start-up,

VACC NOT OK is stopped stand-by, Traction/ request 0xFF4E 78 78 78
running

Traction/ Pump motor Start-up,

INCORRECT START Traction request 0xFF4F 79 79 79
is stopped stand-by

Start-up,
FORW + BACK Traction is stopped stand-by, Traction request 0xFF50 80 80 80
running

Start-up,
VACC OUT OF Traction/ Pump motor Traction/ Pump
Stand-by, 0xFFE2 85 226 85
RANGE is stopped request
Running

Start-up,
PEDAL WIRE KO Traction is stopped Stand-by, Traction request 0xFF56 86 86 86
Running

MC opened, EB is
applied,
WRONG SLAVE VER Traction/Pump, valves Start-up Key re-cycle 0xFFC5 91 197 91
stopped

Controller works, but

Start-up,
CURRENT GAIN with low maximum 0x6302 92 236 92
stand-by
current

MC stays closed, EB is
applied,
PARAM TRANSFER Continuous Key re-cycle 0xFFC7 93 199 93
Traction/Pump, valves
stopped

Reload HM Start-up Key re-cycle 0x0000 94 0 94

EB is applied,
STEER SENSOR KO Continuous Key re-cycle 0xFFB3 95 179 95
traction/pump stopped
MC stays closed, EB is Save again the
M/S PAR CHK MISM applied, Start-up parameter and Key 0xFFC6 97 198 97
Traction/Pump, valves re-cycle

AFFZP0BB – ACE3 – User Manual Page – 109/139

 Machine Indication
status
Error Restart
Effect When the CAN
Code test is procedure MDI ZAPI LED
OPEN
done CODE CODE BLINKS
CODE
stopped

EB is applied,
Start-up, Valves or Traction/
TORQUE PROFILE Traction/Pump motor 0xFFC9 98 201 98
stand-by Pump request
is stopped

9.3.1 Troubleshooting of master-uC warnings

1) WAITING FOR NODE

Cause:
The controller receives from the CAN bus the message that another controller in
the net is in fault condition; as a consequence the controller itself cannot enter
into an operative status, but it has to wait until the other node comes out from
the fault status.
Troubleshooting:
Check if any other device on the CAN bus is in fault condition.

2) TORQUE PROFILE
Cause:
There is an error in the choice of the torque profile parameters.
Troubleshooting:
Check in the HARDWARE SETTING menu the value of those parameters.

3) STEER SENS KO
Cause:
The voltage read by the microcontroller at the steering-sensor input is not within
the STEER RIGHT VOLT ÷ STEER LEFT VOLT range, programmed through
the STEER ACQUIRING function (see paragraph 8.3).
Troubleshooting:
- Acquire the maximum and minimum values coming from the steering
potentiometer through the STEER ACQUIRING function. If the alarm is still
present, check the mechanical calibration and the functionality of the
potentiometer.
- If the problem is not solved, replace the logic board.

4) DATA ACQUISITION
Cause:
Controller in calibration state.
Troubleshooting:
The alarm ends when the acquisition is done.

Page – 110/139 AFFZP0BB – ACE3 – User Manual

 5) ACQUIRING A.S.
Cause:
Controller is acquiring data from the absolute feedback sensor.
Troubleshooting:
The alarm ends when the acquisition is done.

6) ACQUIRE END
Cause:
Absolute feedback sensor acquired.

7) ACQUIRE ABORT
Cause:
The acquiring procedure relative to the absolute feedback sensor aborted.

8) SIN/COS D.ERR
Cause:
This alarm occurs only when the controller is configured as PMSM and the
feedback sensor selected is sin/cos.
The signal coming from sin/cos sensor has a wrong direction.
Troubleshooting:
- Check the wirings.
- If the motor direction is correct, swap the sin and cos signals.
- If the motor direction is not correct, swap two of the motor cables.
- If the problem is not solved, contact a Zapi technician.

9) ENCODER D.ERR
Cause:
This alarm occurs only when the controller is configured as PMSM and the
feedback sensor selected is the encoder. The A and B pulse sequence is not
correct.
Troubleshooting:
- Check the wirings.
- If the motor direction is correct, swap A and B signals.
- If the motor direction is not correct, swap two of the motor cables.
- If the problem is not solved, contact a Zapi technician.

10) BRAKE RUN OUT

Cause:
The CPOT BRAKE input read by the microcontroller is at its maximum value
without the hand-brake request.
Troubleshooting:
Check the mechanical calibration and the functionality of the brake
potentiometer. If the alarm is still present, replace the logic board.
AFFZP0BB – ACE3 – User Manual Page – 111/139
 11) RELOAD HM FROM MDI
Cause:
The hour-meter of the controller is transferred and recorded on the hour-meter
of the standard MDI.

12) CHECK UP NEEDED

Cause:
This is a warning to point out that it is time for the programmed maintenance.
Troubleshooting:
Turn on the CHECK UP DONE option after that the maintenance service.

13) PARAM TRANSFER

Cause:
Master uC is transferring parameters to the supervisor.
Troubleshooting:
Wait until the end of the procedure. If the alarm remains longer, re-cycle the
key.

14) THROTTLE PROG.

Cause:
A wrong profile has been set in the throttle profile.
Troubleshooting:
Set properly the throttle-related parameters (see paragraph 8.8).

15) INCORRECT START

Cause:
Incorrect starting sequence. Possible reasons for this alarm are:
- A travel demand active at key-on.
- Man-presence sensor active at key on.
Troubleshooting:
- Check wirings.
- Check microswitches for failures.
- Through the TESTER function, check the state of the inputs are coherent
with microswitches states.
- If the problem is not solved, replace the logic board.

16) VACC OUT OF RANGE

Cause:
The CPOT input read by the microcontroller is not within the MIN VACC ÷ MAX
VACC range, programmed through the PROGRAMM VACC function (see
paragraph 8.1).

Page – 112/139 AFFZP0BB – ACE3 – User Manual

 Troubleshooting:
- Acquire the maximum and minimum potentiometer values through the
PROGRAM VACC function. If the alarm is still present, check the
mechanical calibration and the functionality of the accelerator potentiometer.
- If the problem is not solved, replace the logic board.

17) PEDAL WIRE KO

This is not implemented in ACE3.
Troubleshooting:
- Ask for help to a Zapi technician.

18) FORW + BACK

Cause:
This alarm occurs when both the travel requests (FW and BW) are active at the
same time.
Troubleshooting:
- Check that travel requests are not active at the same time.
- Check the FW and BW input states through the TESTER function.
- Check the wirings relative to the FW and BW inputs.
- Check if there are failures in the microswitches.
- If the problem is not solved, replace the logic board.

19) HANDBRAKE
Cause:
Handbrake input is active.
Troubleshooting:
- Check that handbrake is not active by mistake.
- Check the SR/HB input state through the TESTER function.
- Check the wirings.
- Check if there are failures in the microswitches.
- If the problem is not solved, replace the logic board.

20) EVP DRIVER OPEN

Cause:
The EVP driver (A19) is not able to drive the EVP coil. The device itself or its
driving circuit is damaged.
Troubleshooting:
This fault is not related to external components. Replace the logic board.

21) EVP COIL OPEN

Cause:
No load is connected between the NEVP output (A19) and the electrovalve
positive terminal.
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 Troubleshooting:
- Check the EVP condition.
- Check the EVP wiring.
- If the problem is not solved, replace the logic board.

22) M/S PAR CHK MISM

Cause:
At start-up there is a mismatch in the parameter checksum between the master
and the supervisor microcontrollers.
Troubleshooting:
Restore and save again the parameters list.

23) TILLER OPEN

Cause:
Tiller/seat input has been inactive for more than 30 seconds.
Troubleshooting:
- Activate the tiller/seat input.
- Check the tiller/seat input state through the TESTER function.
- Check the wirings.
- Check if there are failures in the microswitches.
- If the problem is not solved, replace the logic board.

24) 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 for assistance to a Zapi technician in order to do the adjustment procedure
of the current gain parameters.

25) COIL SHOR. EVAUX

Cause:
This alarm occurs when there is an overload of one or more EV driver. As soon
as the overload condition has been removed, the alarm disappears by releasing
and then enabling a travel demand.
Troubleshooting:
- Check the EVs conditions.
- Check the wiring.
- Collect information about characteristics of EV coils and ask assistance to a
Zapi technician.
- If the problem is not solved, replace the logic board.

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 26) LIFT+LOWER
Cause:
Both the pump requests (LIFT and LOWER) are active at the same time.
Troubleshooting:
- Check that LIFT and LOWER requests are not active at the same time.
- Check the LIFT and LOWER input states through the TESTER function.
- Check the wirings.
- Check if there are failures in the microswitches.
- If the problem is not solved, replace the logic board.

27) WRONG SLAVE VER.

Cause:
Wrong software version on supervisor uC.
Troubleshooting:
Upload the correct software version or ask for assistance to a Zapi technician.

28) SENS MOT TEMP KO

Cause:
The output of the motor thermal sensor is out of range.
Troubleshooting:
- Check if the resistance of the sensor is what expected measuring its
resistance.
- Check the wiring.
- If the problem is not solved, replace the logic board.

29) HW FAULT EB 01/02/03

Cause:
At start-up, the hardware circuit dedicated to enable and disable the EB driver
(A18) is found to be faulty.
Troubleshooting:
This type of fault is not related to external components. Replace the logic board.

30) HW FAULT EV 01/02/04/08/10/20/40/80

Cause:
At start-up, the hardware circuit dedicate to enable and disable the EV drivers is
found to be faulty.
Troubleshooting:
This type of fault is not related to external components. Replace the logic board.

31) WRONG ZERO

Cause:
At start-up the amplifiers used to measure the motor voltage sense voltages
above 3 V or below 2 V.

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 Troubleshooting:
This type of fault is not related to external components. Replace the logic board.

32) EPS RELAY OPEN

Cause:
The controller receives from EPS information about the safety contacts being
open.
Troubleshooting:
Verify the EPS functionality.

33) VACC NOT OK

Cause:
At key-on and immediately after that, the travel demands have been turned off.
This alarm occurs if the ACCELERATOR reading (in TESTER function) is more
than 1 V above the minimum value acquired during the PROGRAM VACC
procedure.
Troubleshooting:
- Check the wirings.
- Check the mechanical calibration and the functionality of the accelerator
potentiometer.
- Acquire the maximum and minimum potentiometer value through the
PROGRAM VACC function.
- If the problem is not solved, replace the logic board.

34) STALL ROTOR

Cause:
The traction rotor is stuck or the encoder signal is not correctly received by the
controller.
Troubleshooting:
- Check the encoder condition.
- Check the wiring.
- Through the TESTER function, check if the sign of FREQUENCY and
ENCODER are the same and if they are different from zero during a traction
request.
- If the problem is not solved, replace the logic board.

35) PARAM RESTORE

Cause:
The controller has restored the default settings. If a CLEAR EEPROM has been
made before the last key re-cycle, this warning informs you that EEPROM was
correctly cleared.
Troubleshooting:
- A travel demand or a pump request cancel the alarm.

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 - If the alarm appears at key-on without any CLEAR EEPROM performed,
replace the controller.

36) EB. DRIV.SHRT.

Cause:
- The EB driver is shorted.
- The microcontroller detects a mismatch between the valve setpoint and the
feedback at the EB output.
Troubleshooting:
- Check if there is a short or a low impedance path between the negative coil
terminal and -BATT.
- Check if the voltage applied is in accordance with the parameters set (see
paragraph 7.2.5).
- If the problem is not solved, replace the controller.

37) PEV NOT OK

Cause:
The PEV connector (B1, only for ACE3 Premium version) is not connected to
the battery or the voltage is different from expected. This alarm occurs if one
output among EVP, EV1, EV2, EV3, EV4 and EV5 is present or the AUX OUT
function is active (POSITIVE EB = 1 or 2).
Troubleshooting:
Check connector B1: it must be connected to the battery voltage (after the main
contactor).

38) EB COIL OPEN

Cause:
This fault appears when no load is connected between the NEB output (A18)
and the EB positive terminal (PEB).
Troubleshooting:
- Check the EB coil.
- Check the wiring.
- If the problem is not solved, replace the logic board.

39) EB DRIV OPEN

Cause:
The EB 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 logic board.

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 40) CONT DRIV EV 02/04/08/20
Cause:
One or more on/off valve drivers are not able to drive the load.
- 02  EV1
- 04  EV2
- 08  EV3
- 20  EV4
If more than one output is affected by this fault condition, the code shown will
correspond to the sum of the faulty-EVs codes.
Troubleshooting:
The device or its driving circuit is damaged. Replace the controller.

41) DRIV SHORT EV 02/04/08/20

Cause:
One or more on/off valve drivers are shorted.
- 02  EV1
- 04  EV2
- 08  EV3
- 20  EV4
If more than one output is affected by this fault condition, the code shown will
correspond to the sum of the faulty-EVs codes.
Troubleshooting:
- Check if there is a short circuit or a low impedance path between the
negative terminal of the coils and -BATT.
- If the problem is not solved, replace the logic board.

42) EEPROM KO
Cause:
A HW or SW defect of the non-volatile embedded memory storing the controller
parameters. This alarm does not inhibit the machine operations, but it makes
the truck to work with the default values.
Troubleshooting:
Execute a CLEAR EEPROM procedure (refer to the 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 be replaced by the default parameters.

43) WARNING SLAVE

Cause:
Warning on supervisor uC.
Troubleshooting:
Connect the Console to the supervisor uC and check which alarm is present.

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 44) TH. PROTECTION
Cause:
The temperature of the controller base plate is above 85 °C.
The maximum current is proportionally decreased with the temperature excess
from 85 °C up to 105 °C. At 105°C the current is limited to 0 A.
Troubleshooting:
It is necessary to improve the controller cooling. To realize an adequate cooling
in case of finned heat sink important factors are the air flux and the cooling-air
temperature. If the thermal dissipation is realized by applying the controller base
plate onto the truck frame, the important factors are the thickness of the frame
and the planarity and roughness of its surface.
If the alarm occurs when the controller is cold, the possible reasons are a
thermal-sensor failure or a failure in the logic board. In the last case, it is
necessary to replace the controller.

45) MOTOR TEMPERAT.

Cause:
This warning occurs when the temperature sensor is open (if digital) or if it has
overtaken the MAX MOTOR TEMP threshold (if analog) (see paragraph 7.2.3).
Troubleshooting:
- Check the temperature read by the thermal sensor inside the motor through
the MOTOR TEMPERATURE reading in the TESTER function.
- Check the sensor ohmic value and the sensor wiring.
- If the sensor is OK, improve the cooling of the motor.
- If the warning is present when the motor is cool, replace the controller.

46) THERMIC SENS. KO

Cause:
The output of the controller thermal sensor is out of range.
Troubleshooting:
This kind of fault is not related to external components. Replace the controller.

47) MOTOR TEMP. STOP

Cause:
The temperature sensor has overtaken the STOP MOTOR TEMP. threshold (if
analog, see paragraph 7.2.3).
Troubleshooting:
- Check the temperature read by the thermal sensor inside the motor through
the MOTOR TEMPERATURE reading in the TESTER function.
- Check the sensor ohmic value and the sensor wiring.
- If the sensor is OK, improve the cooling of the motor.
- If the warning is present when the motor is cool, replace the controller.

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 48) BATTERY LOW
Cause:
The battery charge is evaluated to be lower than 10% of the full charge and the
BATTERY CHECK setting is other than 0 (refer to SET OPTION menu).
Troubleshooting:
- Check the battery charge and charge it if necessary.
- If the battery is actually charged, measure the battery voltage through a
voltmeter and compare it with the value in the BATTERY VOLTAGE reading
in the TESTER function. If they are different, adjust the ADJUST BATTERY
parameter with the value measured through the voltmeter.
- If the problem is not solved, replace the logic board.

9.4 Warnings overview (supervisor uC)

Machine Indication
Error status when Restart
Effect CAN OPEN MDI ZAPI LED
Code the test is procedure
done CODE CODE CODE BLINKS
EB is applied,
STEER SENS KO traction/pump stopped Continuous Key re-cycle 0xFFC3 95 200 95

PARAM RESTORE Traction/

No effect Start-up 0X000 14 209 14
Pump request

Controller works using

EEPROM KO Continuous 0x3610 13 208 13
Default parameters

9.4.1 Troubleshooting of supervisor-uC warnings

1) STEER SENS KO
Cause:
The voltage read by the microcontroller at the steering-sensor input is not within
the STEER RIGHT VOLT ÷ STEER LEFT VOLT range, programmed through
the STEER ACQUIRING function (see paragraph 8.3).
Troubleshooting:
- Acquire the maximum and minimum values from the steering potentiometer
through the STEER ACQUIRING function.
- Check the mechanical calibration and the functionality of the potentiometer.
- If the problem is not solved, replace the logic board.

2) PARAM RESTORE
Cause:
The controller has restored the default settings. If a CLEAR EEPROM has been
made before the last key re-cycle, this warning informs you that EEPROM was
correctly cleared.

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 Troubleshooting:
- A travel demand or a pump request cancels the alarm.
- If the alarm appears at key-on without any CLEAR EEPROM performed,
replace the controller.

3) EEPROM KO
Cause:
A HW or SW defect of the non-volatile embedded memory storing the controller
parameters. This alarm does not inhibit the machine operations, but it makes
the truck to work with the default values.
Troubleshooting:
Execute a CLEAR EEPROM procedure (refer to the 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 be replaced by the default parameters.

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10 SPARE PARTS
Recommended spare parts for ACE3 inverters are here listed.

Part number Description ACE3 Version

C16590 Protected 500 A strip UL Fuse. 36/48V, 650 A

36/48V, 600 A

C16589 Protected 400 A strip UL Fuse. 80V, 550 A

C16588 Protected 350 A strip UL Fuse. 80V, 450 A

C16520 10 A 20 mm Control Circuit Fuse All

C29509 SW 200 80 V All

Single Pole Contactor

C29532 SW 200 48 V All

Single Pole Contactor

C12531 Ampseal 23 pins female connector All

C12591 Ampseal 23 pins female connector, blue Premium version

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11 PERIODIC MAINTENANCE
Check the wear and condition of the moving and fixed contactors contacts.
Electrical contacts should be checked every 3 months.
Check the foot pedal or tiller microswitch. Using a suitable multi-meter, confirm that
there is no electrical resistance between the contacts by measuring the voltage drop
across 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 NON ORIGINAL PARTS!
The installation of this electronic controller should be made according to the
diagrams included in this manual. Any variations or special requirements should be
made after consulting a Zapi agent. The supplier is not responsible for any problem
that arises from wiring methods that differ from information included in this manual.
During periodic checks, if a technician finds any situation that could cause damage
or compromise safety, the matter should be bought to the attention of a Zapi agent
immediately. The agent will then take the decision regarding operational safety of
the machine.
Remember that battery-powered machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

U IMPORTANT NOTE ABOUT WASTE MANAGEMENT:

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

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12 APPENDICES
The goal of this chapter is to give the operator a general overview about the use of
Zapi PC CAN Console and Zapi Smart Console.
The description focuses on the basic information about connection and settings.
For additional functionalities available for both tools, it is suggested to contact Zapi
technicians in order to receive more detailed information or dedicated
documentation.

12.1 Appendix A: PC CAN Console user guide

Windows Pc CAN Console uses standard Zapi communication protocol to display
inverter information. It provides all standard Zapi Console functions with the easier
handling of Windows environment. Besides, Pc CAN Console offers the possibility to
save parameter configurations into a file and to restore them onto the control
afterwards.
Before running Pc CAN Console, the user must install it launching "setup.exe".

12.1.1 PC CAN Console configuration

Running the PC Can Console software, the following window appears:

The first step to accomplish is to define the CAN device attached to the PC, so
select the “Configuration” (Alt-C)  Can Device (Ctrl-C) menu or click on Can
Device icon.

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 From this form you can define the CAN device in use (IXXAT, IFAK or Peak) and the
CAN communication speed. Once you have defined the CAN interface, you have to
choose which CAN device you want to connect to: choose “Connection”  “Set
Node” (or press the “Set Node” icon).

Once you have chosen the node you want to connect to, start the connection. Insert
the password in order to have the possibility to change the parameters: choose
“Configuration”  “Enter Password”. Type the password: “ZAPI”

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12.1.2 Parameter download
Once you are connected to the selected node, you need to download the inverter
parameters: choose “Function”  “Parameter” menu (or press the “Parameter”
icon).

Then click on the “Receive” button: the parameters will be downloaded

automatically.
When the parameters have been all received, you can change their values.

12.1.3 How to modify parameters

Before doing any change, save the old parameters set by clicking “File”  “Save”
(give the file an understandable name for ease of future use).
The complete list of parameters will be saved as a csv file in order to be opened with
Microsoft Excel® or any other spreadsheet tool.
The file contains the whole list of parameter and for each one various data are
available, in particular:

 Parameter value as it is saved within the controller (“Value” column).

 Parameter value as it is shown by console or similar tools (“Scaled Value”
column).
 Name of the menu where parameter is placed (“Name menu” column).

File name is generated as a hexadecimal code of the time and date of saving.
This codification prevents any overwrite of previously saved files.
Once you have selected the menu inside that resides the parameter you want to
change, it is possible to modify the value using the “+” and “–“ buttons.
Click on the “Store” button to save the changes on EEPROM.

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 Program Vacc
Choose “Function”  “Program Vacc” menu.

When “Acquire” is pressed, the PROGRAM VACC procedure starts:

 Select the Enable switch, if any;
 Select the direction switch (either forward or backward);
 Depress the pedal to its maximum excursion.
Displayed values will vary accordingly to operator inputs.

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12.1.4 Lift & Lower acquisition
Once you have connected to the inverter, you need to download the parameters;
choose “Function”  “Parameter” menu (or press the “Parameter” icon).
Choose “Adjustment” menu.
Select the value you want to acquire by pressing the “acquiring” button, the
acquisition will start:

- Select the Enable switch, if any.

- Select the control switch (either lift or lower).
- Move the control sensor (lift/lower potentiometer) to the correct position
according to what you are acquiring.
- Press “Stop Teach” button.
The procedure is the same for both lift and lower potentiometers.

12.1.5 Steering acquisition

Once you have connected you need to receive the inverter parameter; choose
“Function”  “Parameter” menu (or press the “Parameter” icon).
Choose “Adjustment” menu.
Select the value to acquire by pressing “acquiring” button, the acquisition will start:
the procedure is the same described for Lift & Lower acquisition in the previous
paragraph.

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12.1.6 TESTER functionality
From the main page you can also access to the TESTER function from the Function
menu (Alt-u)Tester (Ctrl-T) menu where you can check some inverter information.

12.1.7 Alarm Logbook

This window will display the alarms stored in the controller.
For every alarm will be shown the working hour at which it’s occurred, the motor
temperature and the number of repetitions.

Four buttons are present:

Update  user can update alarm logbook;
Clear  user can clear alarm logbook on inverter EEPROM;
Close  closes the window;
Print  prints alarm logbook data on the selected printer.

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 12.2 Appendix B: Zapi Smart Console user guide

12.2.1 Operational Modes

Smart Console has been designed to have multiple ways of operation. Three modes
can be identified:
 Serial connection powered by four standard AA size batteries placed in the
battery holder of the console.
 CAN bus connection powered by four standard AA size batteries placed in the
battery holder of the console.
 CAN bus connection with Smart Console supplied by an external dc source. This
source may be a standard battery (lead-acid or other type) or a dc/dc converter
Current-loop serial connection
Smart Console offers the same serial connection as the well-known Console Ultra.
Main features of this operational mode are:
 Current-loop serial communication.
 Console is connected to a single controller only (even if Remote Console option
is available).
 Selectable baud-rate.
 Zapi can provide the serial cable compatible with Molex SPOX connector used in
Console Ultra.
CAN bus connection
The Smart Console can connect to an existing CAN line and connect with any Zapi
controller inside this line.
Main features of this operational mode:
 It can be connected to a CAN line composed of any combination of modules,
both Zapi ones and non-Zapi ones;
 Supported speeds: 125, 250, 500 kbps;
 It sees the entire CAN line and all CAN modules.

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12.2.2 The keyboard
The keyboard is used to navigate through the menus. It features some keys with
special functions and a green led. Different button functions are shown below.
UP and DOWN keys
In most cases a menu is a list of items: these items are ordered in rows. The
selected item is highlighted in light blue .
Up and down keys are used to move the selection up and down: in other words they
are used to roll or scroll the menu.
LEFT and RIGHT keys
Normally used to increase and decrease the value associated with the selected
item.
OK and ESC keys
OK key is used either to confirm actions or to enter a submenu.
ESC is used either to cancel an action or to exit a menu.
F1, F2, F3 keys
These buttons have a contextual use. The display will show which F button can be
used and its function.
ON key
Used while operating with internal batteries.

4 While the Smart Console is powered from external sources on pin CNX8 the ON
button is deactivated regardless the presence of the batteries.

Green LED
When the console is powered running the green LED is on.
Green LED can blink in certain cases which will be described better in the following
sections.

12.2.3 Home Screen

After showing the Zapi logo, the HOME SCREEN will appear on the display:

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 From top:
 First line tells which firmware version is running inside the console, in this case
ZP 0.15.
 RS232 Console: enter this menu to start a serial connection as in the Console
Ultra.
 CAN Console: enter this menu to establish a CAN connection.
 AUTOSCAN CAN: another way to establish a CAN connection.
 Console Utilities and Menu Console: ignore them at the moment.
 The current hour is shown at the bottom right.
Moreover, the green LED is on and still.
The “RS232” line is already highlighted at the start-up. Press OK key to start a serial
connection.
Display prompts a message to inform you that a connection attempt is ongoing.
If serial connection fails a “NO COMMUNICATION” warning will be shown after
some seconds: press ESC key and look for what is preventing the connection.

4 Please notice the red dot appearing on the top right of the display every time you
press a button. It indicates that the console has received the command and it is
elaborating the request. If the red dot does not appear when a button is pressed,
there is probably a failure inside the keyboard or the console has stalled.

12.2.4 Connected
If connection is successful, the display will show a page similar to the next one.

This menu shows basic information about the controller, in a similar way to the
console Ultra.
 First line displays the controller firmware.
 Second line shows controller voltage, controller current and hour meter.
 Last line shows the current alarm code, if present.
Press OK to access the MAIN MENU.

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 MAIN MENU contains the complete list of menus available in the controller. Contrary
to Console Ultra there are no “hidden” menus which must be reached by some
combinations of buttons: here all menus are visible.
Use UP and DOWN keys to navigate the list: once you find the desired menu press
OK to enter it.

12.2.5 How to modify parameters

From MAIN MENU enter the desired menu (for example the PARAMETER
CHANGE menu).

With UP and DOWN keys you can scroll the list: once you have highlighted the
parameter you want to modify, press either LEFT or RIGHT keys to decrease or
increase the parameter value.

4 Keep LEFT/RIGHT button pressed to continuously repeat the value modification

(“auto-repeat” function): this function will speed up the procedure in case many
parameter values must be changed.

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 You can press ESC to exit the menu at any time. In case parameters have been
modified, the console will prompt the request to confirm/discard changes.

4 Description above is valid for every menu which contains parameters and options
like SET OPTIONS, ADJUSTMENT, HARDWARE SETTING, etc.

12.2.6 PROGRAM VACC

PROGRAM VACC menu has been slightly modified from old consoles.
Upon entering this menu the console shows the current programmed values.

When OK is pressed, PROGRAM VACC procedure starts. Console invites you:

 to select the enable switch, if any;
 to select the direction switch (either forward or backward);
 to depress the pedal to its maximum excursion.
Displayed values vary accordingly to operator inputs.

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4 Sequence above can slightly vary depending on controller firmware. Anyway the
logic remains the same: before programming the min/max values, execute any
starting sequence which is necessary, then press the pedal or push the joystick.

When ESC is pressed, console asks if programmed values must be saved or

discarded.

12.2.7 Lift and Lower acquisition

From MAIN MENU go into the Adjustment menu.
With UP and DOWN keys you can scroll the list: once you have highlighted a value
you want acquire, press OK.
When OK is pressed, the procedure starts:
 select the Enable switch, if any;
 select the control switch if any (either lift or lower);
 move the control sensor (lift/lower potentiometer) to the correct position
according to what you are acquiring.

Displayed values vary accordingly to operator inputs.

4 Sequence above can slightly vary depending on controller firmware. Anyway the
logic remains the same: before programming the min/max values, execute any
starting sequence which is necessary, then press the pedal or push the joystick.

It is possible to acquire all the values in only one session.

At the end you can press ESC and the console will prompt a request to
confirm/discard changes.

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12.2.8 Steer acquisition
From MAIN MENU go into the Adjustment menu.
The procedure to follow is the same described in previous paragraph.

12.2.9 TESTER
Compared to standard console Ultra, the TESTER menu has been deeply modified.
Now it shows four variables at once: use UP/DOWN keys to scroll the list.

12.2.10 Alarms
ALARMS menu has changed from Console Ultra. Display shows all controller
alarms at once.

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4 Five is the maximum number of alarm codes which is stored inside the controller.

Colors are used to separate recurrent alarm codes from rare events. In order of
increasing frequency, alarm names can be:
 White: up to 5 occurrences
 Yellow: up to 20,
 Orange: up to 40,
 Red: more than 40.
Use UP/DOWN to select a certain alarm in the list: if OK is pressed, additional
information about that alarm are displayed.
Press F1 to clear the alarm logbook of the controller: once F1 is pressed, the
console asks for confirmation.

12.2.11 Download parameter list into a USB stick

When Smart Console is connected to a controller, it has the possibility to download
all parameters into a USB stick.
To use this function, go into the menu SAVE PARAMETER USB in the
MAIN MENU.
File format
The complete list of parameters is saved as a csv file in order to be opened with
Microsoft Excel® or any other spreadsheet tool.
The file is formatted in the same way as if it has been created with the PC CAN
Console. Thus it contains the whole list of parameter and, for each one, various data
are available, in particular:
 Parameter value as it is saved within controller (“Value” column).
 Parameter value as it is shown by console or similar tools (“Scaled Value”
column).
 Name of the menu where parameter is placed tools (“Name menu” column).
File name is generated as an hexadecimal code of the time and date of save.
This codification prevents any overwrite of previously saved files.
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 Download procedure
After entering SAVE PARAMETER TO USB, the Smart Console checks the
presence of a USB stick. If the stick is not connected, it asks the operator to connect
one.
When the stick is present, the display shows the content, starting from the root
directory (/) of the filesystem. Display looks like the following picture.

Notice that only directories are shown, not single files.

While exploring the content, the navigation buttons work in the following way:
 Up/down keys scroll the list.
 Right key explore the highlighted directory: its content (directories only) will
be shown immediately.
 Left key returns one level back in the directory tree: it does not work in the
root directory.
 Esc returns to HOME SCREEN.
 OK starts download.
When saving files, the console creates a subdirectory whose name has eight digits:
 First four digits are controller type.
 Fifth and sixth digits are the customer identification code.
 Seventh and eight digits are the code of the software installed inside the
controller.
An example of this code is the first directory name (VMNCNA11) shown in the
previous figure.
If parameters are downloaded multiple times from the same controller, or from
another controller whose eight digit code is the same, all parameter files are saved
in the same location.
If the directory does not exist, it is created when download is carried out for the first
time.

Page – 138/139 AFFZP0BB – ACE3 – User Manual

 To download parameters, proceed as follows:
1. Navigate the directory list and go into the directory where you want to save
the parameters.
2. If this directory already contains the subdirectory with the correct 8 digits go
to step 3. If it is not present, a new subdirectory will be created automatically.
Do not enter the subdirectory manually.
3. Press OK to start parameter download. A progression bar shows the ongoing
process.
4. When finished, press ESC so to return to MAIN MENU. USB stick can be
removed safely.
Connect the USB stick to a PC and enter the directory of point 1). A subdirectory
with the correct name and, inside this one, a csv file are present.

4 During download the led blinks slowly to indicate the console is running.

4 When download has finished USB stick can be unplugged safely.

U Do not remove USB stick during download or the file will result empty or
corrupted.

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