Flexi ACiON User Manual V12

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Flexi ACiON
Control Panel
Service Guide
Publication N°: ZUKFlexiACiON

Edition: January 2022 Issue 12
Contents
1. Introduction..................................................................................................................................... 4
2. Inverter Specification’s..................................................................................................................... 5
2.1 Technical specifications ACE3 Inverter ..................................................................................... 5
2.1.1 ACE3 Inverter Block Diagram ................................................................................................... 5
2.2 Technical specifications ACE2 Hydraulic Pump Inverter ........................................................... 6
2.2.1 ACE2 Inverter Block Diagram ................................................................................................... 6
2.3 Technical specifications AC0 Hydraulic Steer Inverter .............................................................. 7
2.3.1 AC0 Inverter Block Diagram ..................................................................................................... 7
3. Specification for the Input Devises of the Inverters.......................................................................... 8
3.1.0 Digital Inputs............................................................................................................................ 8
3.1.1 Switching Thresholds ............................................................................................................... 8
3.1.2 Micro Switches......................................................................................................................... 8
3.1.3 Accelerator Unit....................................................................................................................... 8
3.1.4 Motor Thermal Sensors............................................................................................................ 9
3.1.5 Speed Feedback....................................................................................................................... 9
4. Specification for the Input Devises of the Inverters.......................................................................... 9
4.1. Material Overview.................................................................................................................... 9
4.1.1 Connection Cables ................................................................................................................... 9
4.1.2 Contactors .............................................................................................................................10
4.1.3 Fuses......................................................................................................................................10
4.1.4 Insulation of the truck frame..................................................................................................10
5. Protection & Safety Features .........................................................................................................11
5.1.1 Protection Features ...............................................................................................................11
5.1.2 Safety Features ......................................................................................................................11
6. EMC ...............................................................................................................................................12
7. Various Suggestions .......................................................................................................................12
8. Operational Features .....................................................................................................................13
8.1.0 Diagnosis................................................................................................................................13
9. Description of the power connections ...........................................................................................14
10. Drawings....................................................................................................................................15
10.1 Mechanical Drawings .............................................................................................................15
10.2 Electrical Drawing ..................................................................................................................16

11. Description of the Parameters ...................................................................................................17
11.1 ACE3 Traction Inverter ...........................................................................................................17
11.1.1 Parameters ........................................................................................................................17
11.1.2 Set Options ........................................................................................................................19
11.1.3 Adjustments.......................................................................................................................23
11.1.4 Special Adjustments...........................................................................................................26
11.1.5 Hardware Settings..............................................................................................................26
11.2 ACE2 Lift Motor Inverter ........................................................................................................27
11.2.1 Parameters ........................................................................................................................27
11.2.2 Set Options ........................................................................................................................29
11.2.3 Adjustments.......................................................................................................................31
11.3 AC0 Steer ...............................................................................................................................33
11.3.1 Parameters ........................................................................................................................33
11.3.2 Set Options ........................................................................................................................34
11.3.3 Set Adjustments.................................................................................................................35
12. Troubleshooting.........................................................................................................................36
12.1 ACE3 Traction Inverter Alarm List & Descriptions...................................................................36
12.2 ACE2 Lift Inverter Alarm List & Descriptions...........................................................................58
12.3 AC0 Steer Inverter Alarm List & Descriptions .........................................................................71
13. Periodic Maintenance ................................................................................................................78
14. Service Equipment .....................................................................................................................79
14.1 Required Hardware................................................................................................................79
15. Service Contacts.........................................................................................................................80

1. Introduction
The ACE3 Traction, ACE2 Pump, and AC0 Steer inverter control panel has been developed to perform
the electric traction, Steer and hydraulic functions of the Flexi ACe Articulating Fork Lift Truck. This
Manual provides important information about the control panel and motors, it presents instructions,
guidelines and diagrams related to the control equipment.

2. Inverter Specification’s
2.1 Technical specifications ACE3 Inverter
Inverter for traction AC asynchronous 3-phase motors, Regenerative braking functions.

Digital control based upon microcontroller
Voltage:......................................................................................................................48V
Inverter maximum current (48V):........................................................ 600A (RMS) for 2'
Continuous output current (48V): ............................................. 300A (RMS) continuous
Inverter operating frequency: ................................................................................ 8 kHz
Dc chopper Maximum current (48V) (1):....................................................... 220A for 2’
Chopper Operating frequency (1):........................................................................ 16 kHz
External temperature working range: ......................................................... -30°C ÷ 40°C
Maximum heatsink temperature (start of the thermal cutback)..............................85°C
2.1.1 ACE3 Inverter Block Diagram

2.2 Technical specifications ACE2 Hydraulic Pump Inverter
Inverter for Hydraulic Pump AC asynchronous 3-phase motors, Regenerative braking functions.
Voltage:......................................................................................................................48V
1 hour output current (48V): ..................................................... 300A (RMS) continuous
Dc chopper Maximum current (48V) (1):....................................................... 225A for 2’
Chopper Operating frequency (1):.......................................................................... 8 kHz
2.2.1 ACE2 Inverter Block Diagram

2.3 Technical specifications AC0 Hydraulic Steer Inverter
Inverter for Hydraulic Steer AC asynchronous 3-phase motor, Regenerative braking functions.
Voltage:......................................................................................................................48V
Boost output current (48V): ...............................................................170A (RMS)for 10’
2.3.1 AC0 Inverter Block Diagram

3. Specification for the Input Devises of the Inverters
3.1.0 Digital Inputs
Digital inputs work in the voltage range [-Batt; +Batt]. Pull-down resistance to –Batt is built-in.
Functional devices (like FW, BACK, LIFT, DESCENT, HORN, H&S, TILLER, BELLY switches) are Normally
Open; so related function becomes active when the micro switch closes.
Safety devices (like CUTBACK switches) are Normally Closed; so related function becomes active when
the micro switches open.
3.1.1 Switching Thresholds
Switching threshold: 4,3V [±0,5V]

Input impedance: 13,5kOhm [±1kOhm]
3.1.2 Micro Switches
It is suggested that micro switches have a contact resistance lower than 0,1Ohm and a leakage
current lower than 100µA.
When full load connected, the voltage between the key switch contacts must be lower than 0.1V.
If the micro switch to be used has different characteristic, it is suggested to discuss them and their
application with Zapi technicians.
3.1.3 Accelerator Unit
The accelerator unit can consist of a potentiometer or a Hall effect device. It should be in a 3-wire
configuration. The potentiometer is supplied through with about 12 Vdc.
CPOT signal ranges is from 0 to 10 V. Potentiometer value should be in the 0.5 - 10 kΩ range;
generally, the load should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this range.
The standard connection for the potentiometer is the one in the Left side of Figure 3–1
(potentiometer on one end at rest)
in combination with a couple of
Travel demand switches. On
request it is also possible the
handling in the Right side of Figure
3–1 (potentiometer in
the middle at rest) in

combination with at least one Travel Demand switch. We strongly advice against the adoption of the
Right side configuration without travel demand switch at all, because of a safety issue.
3.1.4 Motor Thermal Sensors
Each of the AC motors is equipped with an analogue thermal sensor which protects the motors
against overheating.
Traction Motor – KTY84-130
Pump Motor & Steer Motor – PT1000
3.1.5 Speed Feedback
The motor control is based upon the motor speed feedback (sensor software). The speed transducer
is an incremental encoder, with two phases shifted at 90°.
Note (1): The encoder resolution and the motor poles pair (the controller can handle), is specified in
the home page display of the handset.
The pulses per revolution of the devises is:-
Traction – 80PPR Encoder
Pump – 64PPR Encoder
Steer – 64PPR Encoder
4. Specification for the Input Devises of the Inverters
4.1. Material Overview
Before starting it is necessary to have the required material for a correct installation. Otherwise a
wrong choice of cables or other parts could lead to failures/ misbehaviour/ bad performances
4.1.1 Connection Cables
For the auxiliary circuits, use cables 0.5mm² section at least.

For power connections to the battery, use cables having a minimum section of 50 mm².
For power connections to the Traction Motor, use cables having a minimum section of 50 mm².
For power connections to the Pump Motor, use cables having a minimum section of 50 mm².
For power connections to the Steer Motor, use cables having a minimum section of 25 mm².

For the optimum inverter performance, the cables to the battery should be run side by side and be as
short as possible.
4.1.2 Contactors
A main contactor is adopted to connect and cut off the battery to the controller. The output which
drives the main contactor coil is on/off (the coil is driven by the ACE3 Traction Inverter with the full
battery voltage). The output which drives the main contactor coil is switched at high frequency (1 kHz)
with a programmable duty cycle; this feature is useful to decrease the power dissipation of the
contactor coil.
The EN1175 states the main Contactor is not mandatory (under proper conditions); anyway, it is
useful to protect the inverter against reverse battery polarity and to cut off the battery from the
power mosfets if a failure in the three phase bridge occurs.
4.1.3 Fuses
10A Blade Fuses are used for protection of the auxiliary circuits connected to the inverters
For the power fuses to the inverters: -
ACE3 – 400A
ACE2 – 350A
AC0 – 100A
4.1.4 Insulation of the truck frame
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.

5. Protection & Safety Features
5.1.1 Protection Features
The Inverters are protected against some controller injuries and malfunctions: -
Battery polarity inversion it is necessary to fit a MAIN CONTACTOR 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 thermal increase. The temperature can never exceed 105 °C.
Protection against uncontrolled movements, the main contactor will not close if:
The Power unit is not functioning.
The Logic is not functioning perfectly.
The output voltage of the accelerator does not fall below the minimum voltage value stored, with 1 V
added.
Running micro switch in closed position.
Low battery charge When the battery charge is low, the maximum current is reduced to the half of
the maximum current programmed.
Protection against accidental Start up, A precise sequence of operations are necessary before the
machine will start. Operation cannot begin if these operations are not carried out correctly.
5.1.2 Safety Features
ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of
control system and to UNI EN1175-1 norm. The safety of the machine is strongly related to
installation; length, layout and screening of electrical connections have to be carefully designed.
ZAPI is always available to cooperate with the customer in order to evaluate installation and
connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve
the safety of the machine, according to customer requirements.
The Machine manufacturer holds the responsibility for the truck safety features and related approval.

6. EMC
EMC and ESD performances of an electronic system are strongly influenced by the installation. Special
attention must be given to the lengths and the paths of the electric connections and the shields. This
situation is beyond ZAPI's control. Zapi can offer assistance and suggestions, based on its years’
experience, on EMC related items. However, ZAPI declines any responsibility for non-compliance,
malfunctions and failures, if correct testing is not made.
The machine manufacturer holds the responsibility to carry out machine validation, based on existing
norms (EN12895 for industrial truck; EN50081-2 for other applications)
7. Various Suggestions
Never combine SCR low frequency choppers with Zapi modules. The filter capacitors contained in the
Zapi module would change the SCR chopper operation and subject to excessive workload. If it is
necessary to use two or more control units, the chopper should be of the Zapi family.
During battery recharge, the Zapi Modules must be completely disconnected from the battery.
Besides changing the charging current seen by the battery charger, the module can be damaged by
higher than normal voltages supplied via the charger.

8. Operational Features
- Speed control.
- Optimum behaviour on a slope if the speed feedback is used:
a) The motor speed follows the accelerator, starting a regenerative braking if the speed
overtakes the speed set-point
b) The system can perform an electrical stop on a ramp (the machine is electrically hold on a
slope) for a programmable time (if encoder is used)
- Stable speed in every position of the accelerator.
- Regenerative release braking based upon deceleration ramps.
- Regenerative braking when the accelerator pedal is partially released (deceleration).
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the main contactor is
present.
- The release braking ramp can be modulated by an analogue input, so that a proportional
brake feature is obtained.
- Optimum sensitivity at low speeds.
- Voltage boost at the start and with overload to obtain more torque (with current control).
- The inverter can drive an electromechanical brake.
- High efficiency of motor and battery due to high frequency commutations.
- Modification of parameters through the programming console.
- Internal hour-meter with values that can be displayed on the console.
- Memory of the last five alarms with relative hour-meter and temperature displayed on the
console.
- Test function within console for checking main parameters.
- Direct communication between traction AC inverter and pump DC chopper.
- Backing forward and reverse options are available, with the tune and the speed of the
function programmable with Zapi handset.
8.1.0 Diagnosis
The microcontrollers continually monitor the inverter and the chopper and carry out diagnostic
procedures on the main functions.
The diagnosis is made in 4 points:
1) Diagnosis at start-up that checks: watch-dog, Current Sensors, Capacitor charging, phase’s
voltages, pump motor output, contactor drivers, can-bus interface, presence of a start requirement,
connection with the Can Tiller.
2) Standby Diagnosis that checks: watch-dog, phase’s voltages, pump motor output, Contactor
Drivers, Current Sensors, can-bus interface.
3) Driving diagnosis that checks: Watchdog, Current sensors, Contactor(s), can-bus interface.
4) Continuous Diagnosis that checks: power stage temperature, motor temperature, Battery
Voltage.

Error codes are provided in two ways. The digital console can be used, which gives a detailed
information about the failure; the failure code is also sent on the Can-Bus to the CAN Display
9. Description of the power connections
View of the power bars:
-B Negative of the battery.

+B Positive of the battery.
U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the
motor.

10. Drawings
10.1 Mechanical Drawings
Control Panel Layout:
Hydraulic Motor Layout:

A
F
B
E
D
H
C
G
10.2
K6
1
1
OR
F1 400A
REV.
POLARITY KEY SWITCH
GN DIODE ES.1 ES.2 KS.1
CPOT A3
FP.3 KS.2
OR CF1 10A EMG STOP
M
PPOT (12V) A2 KS.3
2
2
FP.5
BK CF2 10A KS.4
A9 NPOT (GND)
FP.4
OR
GY/WT
B13 MSW1 INPUT
OR
FP.2
Electrical Drawing
FP.1
1
RD/BK
A8 12v KEY A1
BN TMC.1

4

A15 GND
YL TMC.4 FWD / OFF / REV
OR
2
FWD A4 YL/BK
A7 ENC A DS1.1
RD/BK
GN TMC.2 DS1.5
BL/BK
ENCODER
A14 ENC B REV A5 RD/BK
WT TMC.3 DS1.6
FWD / OFF / REV
TRACTION MOTOR
3
3
DS2.5 DS2.1
DS2.6
1
A23 PTHERM
GN/RD TMC.6 RD/PK MAST MICRO
MAST SW B6
2
MM.2 MM.1 SEAT RELAY
YL
THERMAL
K4
TRACTION MOTOR
RD/GN SEAT SWITCH
SEAT SW A11
SS.2 SS.1
FOOT BRAKE
A6 FT BRAKE SEAT SW60
BK BS.1 BS.2 YL/RD
4
4
GY
SEAT RELAY B18
K4
HANDBRAKE
A13 H.BRAKE
BK HB.1 HB.2 WT GR/WH
LWR SOL. B9
SEAT BELT LS.2 LS.1
B4 SEATBELT LOWE SOLENOID
BK SB.1 SB.2 PR/RD
BL
HS FAN RELAY B17
K2
B12 HS FAN RELAY

B21 TRK FAN RLY B19 BL/WT
K3
5
5
CAN 120 Ohm

TRUCK FAN RELAY
TERMINATION.1
RD/BL
POS. EV B1
BK/YL
NMC A16
K6
REV. ALARM
48V 600A
BK LINE SU280
RB.- RB.+
GY/BK
CAN H A21
REV. LIGHT CAN L A20 GY/BL
6
6
BK R.LGT 2 R.LGT 1
ACE3 TRACTION INVERTER
WH
ACE3 CONNECTOR B - BLUE CONNECTOR
BL/BK
ACE3 CONNECTOR A - BLACK CONNECTOR
SAFETY LIGHT
BL/BK
RD/GN
BK BL/BK
BL
ESE.1
ECS.6 ESE.3
120 Ohm
ECS.4
ESE.4
INTERNAL CAN
TERMINATION.2
7
7
ECS.3
ESE.2
ECO SMART DISPLAY

ECS.1
F2 350A
KEY INPUT A1 RD/BK

48V 500A
GY/BK
PORT
CAN H A21
GY/BL
CAN L A20
4 3 2 1
M
DIAGNOSTIC
RD/GN
SEAT SW A4
ACE2 PUMP INVERTER
8
BN YL LP.3
A8 +12V CPOT A3
PE.1
YL OR/BL LP.1
A15 GND PPOT (5V) A2
PE.4
GN BN/GN LP.4
A7 ENC A GND A9
PE.2
ENCODER
WT
PUMP MOTOR
LIFT ACCELERATOR
A14 ENC B
PE.3
PK TILT SWITCH WT/GN
TILT A10 TS.2
Speed 2 TS.1
S.SHIFT SWITCH WT/GN
9
PR
S.SHIFT A5 SS.2
Speed 1 SS.1
PT.1 GN/RD
A22 P.THERM
PT.2 GN/BK A23 N.THERM
THERMAL
PUMP MOTOR
A11 SAFETY IN
10
10
F3 100A
RD/BK
48V 130A
KEY INPUT B1
GY/BK
CAN H A17
GY/BL
CAN L A7
RD/GN
SEAT SW B3
M
11
11
AC0 STEER PUMP INVERTER
CPOT B10
PK/BK S.2
SE.1 BN A9 +12V PPOT B12 OR/BK S.1
SE.4 YL GND B11
A10 GND WT/BK S.3
STEER SENSOR
SE.2 GN A19 ENC A

ENCODER
SE.3 WT
STEER MOTOR
A20 ENC B
12
12
ST.1 RD/BL
A13 P.THERM
ST.2 BL/GR
A12 N.THERM
THERMAL
STEER MOTOR
FHS.2 FHS.1
HORN FLOOR HORN PUSH
BK HC.2 HC.1 PK/PR HS.2 HORN PUSH HS.1

13
13
WORKLIGHTS WORKLIGHT SWITCH

C. Fenn
F.LGT 2
Designed by
F.LGT 1 OR
WORKLIGHTS
HEATSINK FANS X3
M. Teece
14
14
BL HSF.1 HSF.1 RD/BL

Checked by
K2
CHASSIS FANS X2
BK/WT CF.2 CF.1 RD/BL
K3
BEACON
Approved by - date
BK R.LGT 6 R.LGT 5 RD/BK

not intended by Zapi UK
15
15
reproduced, distributed or used in a manner
BK BK WT/GN
should be considered confidential and should not be
This drawing is the property of Zapi UK Ltd. All information
RD/BK
03.02.2020
OR
Originator Date
GY/BK
RD/BK
GY/BL
EZS 2042
Drawing No
17.02.2020
14
Issue
16
Last Modified Date
16
Flexi ACiON Wiring Schematic

Sheet
1 of 1
NTS
Scale
A
F
B
H
C
G
11. Description of the Parameters
11.1 ACE3 Traction Inverter

11.1.1 Parameters
Only Parameters relevant to the application are documented, all other parameters are not required.
PARAMETER CHANGE
Parameter Allowable range Description

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.
(by steps of 0.1 s)
A special software feature manages the acceleration ramp depending on
the speed set point
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 motor
(by steps of 0.1 s) from 100 Hz down to 0 Hz.
A special software feature manages the deceleration ramp depending on

the starting speed
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
(by steps of 0.1 s) motor from 100 Hz down to 0 Hz.
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
(by steps of 0.1 s) decelerate the motor from 100 Hz down to 0 Hz.
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
(by steps of 0.1 s) decelerate the motor from 100 Hz down to 0 Hz.
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 motor
(by steps of 0.1 s) from 100 Hz down to 0 Hz.
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 motor from
(by steps of 0.1 s) 100 Hz down to 0 Hz.
MAX SPEED FORW 0% ÷ 100% This parameter defines the maximum speed in forward direction as a
percentage of TOP MAX SPEED.
(by 1% steps)
MAX SPEED BACK 0% ÷ 100% This parameter defines the maximum speed in backward direction as a
percentage of TOP MAX SPEED.
(by 1% steps)

PARAMETER CHANGE

SMART STOP SPD 10% ÷ 100% This parameter defines the maximum speed performed when Smart Stop
is active. It represents a percentage of TOP MAX SPEED.
(by 1% steps)
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 SPEED.
(by 1% steps)
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 minimum.
(by steps of 0.1 Hz)
MAX. CURRENT TRA 0% ÷ 100% This parameter defines the maximum current applied to the motor
during acceleration, as a percentage of the factory-calibrated maximum
(by 1% steps) 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 maximum
(by 1% steps) current.
ACC SMOOTH 1÷5 This parameter defines the acceleration profile: 1 results in a linear ramp,
higher values result in smoother parabolic profiles.
(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 values result in
(by steps of 0.1) smoother parabolic profiles.
STOP SMOOTH 3 Hz ÷ 100 Hz This parameter defines the frequency at which the smoothing effect of
the acceleration profile ends.
(by steps of 1 Hz)
BRK SMOOTH 1÷5 This parameter defines the deceleration profile: 1 results in a linear
ramp, higher values result in smoother parabolic profiles.
(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.
(by steps of 1Hz)
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.
(by steps of 0.1 s)
ROLLING DW SPEED 1 Hz ÷ 50 Hz This parameter defines the maximum speed for the rolling-down
function.
(by steps of 1Hz)

11.1.2 Set Options
SET OPTIONS

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 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.
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

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

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 number
0÷6 2 accessible to the customer. The possible settings 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 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).

SET OPTIONS

BATTERY CHECK 0÷3 This option specifies the management of the low battery charge
situation. There are four levels of intervention:
0 = battery charge level is evaluated but ignored, meaning that no

action is taken when battery runs out.
1 = when the alarm BATTERY LOW is present, 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 equal to or lower than BATT.LOW
3 = when the alarm BATTERY LOW is present, control reduces the

maximum speed down to 24% of the full speed and lift function is
disabled.
With settings 1, 2 or 3: the alarm BATTERY LOW occurs when battery

level is evaluated to be lower or equal to parameter BATT.LOW
TRESHLD (see ADJUSTMENTS list).
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 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.
BMS PRESENCE OFF ÷ ON This parameter enables or disables the CAN communication between
the ACE3 controller and the Lithium Battery
SMART STOP ABSENT ÷ PRESENT This Parameter enables or disables the presence of the Smart Stop
bumpers.
MAIN POT. TYPE 0 ÷ 15 This parameter defines the type of the main potentiometer
connected to A3 contact.
This Must be set to 13

SET OPTIONS

SET MOT.TEMPERAT NONE ÷ OPTION#3 This parameter defines the type of motor temperature sensor
adopted.
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).

A23. The temperature sensor is a KTY 83-130 PTC (positive
thermal coefficient resistance)

A23. The temperature sensor is a PT1000 PTC (positive thermal
coefficient resistance).
M.C. FUNCTION OFF ÷ OPTION#2 This parameter defines the configuration for the main contactor or
line contactor output (A16, NLC: Negative Line Contactor).
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.
AUX HYD 1 NONE ÷ OPTION#1 NONE = Output not enabled on A18
BRAKE = Not Used
OPTION#1 = A18 is used to drive the Auxiliary Valve 1
AUX HYD 2 NONE = Output not enabled on A19
DIGITAL = A18 is used to drive the Auxiliary Valve 1
ANALOG = Not Used

SET OPTIONS

ACCEL MODULATION OFF, ON This parameter enables or disables the acceleration-modulation
function.
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 set point is greater than
100 Hz. Below 100 Hz the acceleration ramp is also proportional
to the speed set point, so that the acceleration duration results
equal to ACCEL DELAY.
TILTING CARRIAGE ABSENT, OPTION#2 This parameter Defines if the Tilting Carriage Valve is Present or
Absent
ABSENT = output not enabled, no on B16.
OPTION#1 = Not Used
OPTION#2 = B16 manages a voltage-controlled PWM-modulated

valve. The PWM frequency is 1kHz and the duty cycle depends
on PWM EV1 (ADJUSTMENT list).
HS FAN RELAY ABSENT, DIGITAL This parameter defines how the output B17 (NEV2) operates.
DIGITAL = B17 manages a voltage-controlled PWM-modulated valve.

The PWM frequency is 1kHz and the duty cycle depends on PWM
EV2 (ADJUSTMENT list).
SEAT RELAY ABSENT, DIGITAL This parameter defines how the output B18 (NEV3) operates.
ABSENT = output not enabled, no load on B18.
DIGITAL = B18 manages a voltage-controlled PWM-modulated

valve. The PWM frequency is 1kHz and the duty cycle depends
on PWM EV3 (ADJUSTMENT list).
TRUCK FAN RELAY ABSENT, DIGITAL This parameter defines how the output B19 (NEV4) operates.
DIGITAL = B19 manages an on/off valve.
LOWER SOLENOID ABSENT, DIGITAL This parameter defines how the output B9 (NEV5) operates.
DIGITAL = B9 manages an on/off valve.

SET OPTIONS

HIGH DYNAMIC OFF, ON This parameter enables or disables the High-Dynamic function.
ON = all acceleration and deceleration profiles set by dedicated

parameters are ignored and the controller works always with
maximum performance.
OFF = standard behavior.
DISPLAY TYPE 0÷9 This parameter defines which type of display is connected to the
inverter.
0 = none.
1 = MDI PRC.
2 = ECO DISPLAY.
3 = SMART DISPLAY.
4 = MDI CAN.
5 ÷ 9 = available for future developments.
SEAT BELT ABSENT ÷ PRESENT This parameter defines if the Seat Belt is Present or Absent, then set
Present the correct sequence must be followed to allow function
11.1.3 Adjustments
ADJUSTMENT

SET BATTERY 24V ÷ 80V This parameter defines the nominal battery voltage. The available
options are:
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 line test.
ADJUST BATTERY Volt Fine adjustment of the battery voltage measured by the controller.
Calibrated by Zapi production department during the end of line test.
SET POSITIVE PEB 12V ÷ 80V This parameter defines the supply-voltage value connected to CNA-3.
The available values are:
12V, 24V, 36V, 40V, 48V, 72V, 80V
THROTTLE 0 ZONE 0% ÷ 100% This parameter defines a dead band in the accelerator input curve.
(by 1% steps)

ADJUSTMENT

THROTTLE X1 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(by 1% steps)
THROTTLE Y1 MAP 0% ÷ 100% This parameter defines the accelerator input curve.
(by 1% steps)
(by 1% steps)
(by 1% steps)
(by 1% steps)
(by step of 1%)
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 algorithm for the adopted
(by steps of 0.1%) battery.
BAT. MAX ADJ. -12.8% ÷ 12.7% This parameter defines the maximum level of the battery-discharge
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.
(by steps of 0.1%)
BDI RESET 0% ÷ 100% This parameter defines the minimum variation of the battery-
discharge table to update the battery percentage at start-up. It is
(by 1% steps) used to calibrate the discharge algorithm for the adopted battery.
BATT.LOW TRESHLD 1% ÷ 50% This parameter defines the minimum charge percentage under which
the BATTERY LOW alarm rises.
(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 motor-torque
reduction.

ADJUSTMENT

SPEED FACTOR 0 ÷ 255 This parameter defines the coefficient used for evaluating the truck
speed (in km/h) from the motor frequency (in Hz), according to the
following formula:
*+#,-#./0 [12]
!"##$ [%&('] = 10 )
!"##$ *3/45+
LOAD HM FROM MDI OFF, ON This parameter enables or disables the transfer of the hour-meter to
a MDI unit.
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.
CHECK UP TYPE NONE ÷ OPTION#3 This parameter defines the CHECK UP NEEDED warning:
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).
(255 steps)
output (B17).
(255 steps)
output (B18).
(255 steps)
output (B19).
(255 steps)
output (B9).
(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 second
(by 1% steps) after the activation signal that causes the main contactor to close.

ADJUSTMENT

MC VOLTAGE RED. 0% ÷ 100% This parameter defines a percentage of MC VOLTAGE parameter and
it determines the duty-cycle applied after the first second of
(by 1% steps) 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%.
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 valid only
(by steps of 1°C) 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.
(by steps of 1°C)
MOT.T. T.CUTBACK OFF, ON When this parameter is ON, the control linearly reduces the motor
torque basing on the motor temperature. Reference limits of the
(A) linear reduction are MAX MOTOR TEMP and TEMP. MOT. STOP.
VACC SETTING Volt See the PROGRAM VACC procedure.
(A)
11.1.4 Special Adjustments
No settings in this menu should be altered without seeking authorisation from Flexi Design Dept.
11.1.5 Hardware Settings

11.2 ACE2 Lift Motor Inverter
11.2.1 Parameters
PARAMETER CHANGE

ACCELERATION 0 0.3 s ÷ 10 s This parameter defines the motor acceleration at 0 Hz. At level 0 the
acceleration is maximum. Increasing the parameter’s level the
(by steps of 0.1 s) acceleration decreases.
ACCELERATION 1 0.3 s ÷ 10 s This parameter defines the motor acceleration at ACC PROF. FREQ 1 [Hz].
At level 0 the acceleration is maximum. Increasing the parameter’s level
(by steps of 0.1 s) the acceleration decreases.
ACC PROF. FREQ 1 0 Hz ÷ 200 Hz In correspondence to this frequency in [Hz] the acceleration is defined by
the ACCELERATION 1 parameter
(by steps of 1Hz)
(by steps of 1Hz)
(by steps of 1Hz)
RELEASE BRAKING 0.3 s ÷ 10 s This parameter controls the deceleration ramp when the pump request
is released. The parameter sets the time needed to decelerate the
(by steps of 0.1 s) traction motor from 100Hz to 0Hz.
MAX SPEED LIFT 5 Hz ÷ 200 Hz This parameter defines the maximum speed for LIFT Function
(by steps of 1Hz)
1ST SPEED COURSE 5Hz ÷ 200Hz This parameter determines the pump maximum speed when SPEED 1
switch is closed.
(SIDE SHIFT) (by steps of 1Hz)
2ND SPEED COURSE 5Hz ÷ 200Hz This parameter determines the pump maximum speed when SPEED 2
switch is closed.
(TILT) (by steps of 1Hz)
3RD SPEED COURSE 5Hz ÷ 200Hz This parameter determines the pump maximum speed when SPEED 3
switch is closed.
(by steps of 1Hz)
AUX HYD 1 SPEED 5Hz ÷ 200Hz This parameter determines the pump maximum speed when aux hyd 1
switch is closed.
(by steps of 1Hz)

PARAMETER CHANGE

AUX HYD 2 SPEED 5Hz ÷ 200Hz This parameter determines the pump maximum speed when aux hyd 2
switch is closed.
(by steps of 1Hz)
FREQUENCY CREEP 0% ÷ 100% This parameter defines the Minimum speed when the LIFT ENABLE
switch is closed, but the accelerator is on a minimum position
(by 1% steps)
LIFT LOCK OUT 0% ÷ 100% This parameter defines the % of the battery charger which the Lift
functions will be disabled. (Should be set to 20%)
(by 1% steps)
MAX. CURRENT 0% ÷ 100% This parameter defines the maximum current applied to the motor as a
percentage of the factory-calibrated maximum current.
(by 1% steps)
HGT CUTBACK SPD 0% ÷ 100% This parameter defines the maximum speed performed when then
Height Cutout Slowdown input is active. (only used if Height Cutout is
(by 1% steps) Active)
LIFT HEIGHT CTB. 0% ÷ 100% This parameter defines the maximum speed performed when then LIFT
HEIGHT S.D is active. (only used if Height Select is Active)
(by 1% steps)
LIFT HEIGHT S.D 0% ÷ 100% This parameter sets the voltage at which the Height Slow Down will be
active. (only used if Height Select is Active)
(by 1% steps)
HGT CTB SP COUNT 0 ÷ 25 This parameter defines the counter that is activated when HGT CUTOUT
Slowdown is activated (input A6). The mast must reach HGT CUTOUT
(by 1 steps) STOP (input A13) before the counter reaches 0
A18 VALVE DELAY 0 ÷ 25 This parameter defines the closing delay for the AUX HYD 1 Valve
(by 1 steps)

11.2.2 Set Options
SET OPTIONS

DISPLAY TYPE 0÷4 This parameter defines which type of display is connected to the
inverter.
0 = none.
1 = MDI PRC.
2 = ECO DISPLAY.
3 = SMART DISPLAY.
4 = MDI CAN.
TILL/SEAT SWITCH HANDLE ÷ SEAT This input opens when the operator leaves the truck. It is connected
to a key voltage when the operator is present.
HANDLE = The input is managed as tiller input (no delay when

released).
SEAT = The input is managed as seat input (with a delay when

HOUR COUNTER RUNNING ÷ KEY ON RUNNING = The counter registers travel time only.
KEY ON = The counter registers when the "key" switch is

closed
BATTERY CHECK ON ÷ OFF ON = The battery discharge level check is carried out; when
the battery level reaches 10%, an alarm is signaled and the
maximum current is reduced to the half of the programmed
value
OFF = The battery discharge level check is carried out but no

alarm is signalled.
Very important: In the Combi system (pump + traction), the battery

discharge calculation for the complete system is carried out by the
traction inverter; the information about the pump inverter
consumption is sent on the can-bus line from the pump inverter to the
traction inverter. So the correct programming for the "Battery check"
option is OFF
SET MOT.TEMPERAT None ÷ Option#2 This parameter defines the type of motor temperature sensor
adopted.
OPTION#1 = an analog motor thermal sensor is connected. The

temperature sensor is a KTY 84-130 PTC (positive thermal

A23. The temperature sensor is a PT1000 PTC (positive thermal

SET OPTIONS

SMART STOP OUT ON ÷ OFF This parameter defines if the output should be driven when
the Smart Stop input is activated
HYD MULTI FUNCTION ON ÷ OFF This parameter defines if two hand hydraulic operation is
required (NOTE: you must fit restrictors to the Tilt and Side Shift
if Set ON)
HGT CUTOUT ON ÷ OFF This parameter defines if the Height Cutout is present on the
truck.
HGT CUTOUT OVR ON ÷ OFF This parameter defines if there is the Override option for the
Height Cutout
HEIGHT SELECTION ON ÷ OFF This Parameter defines if the Height Selection System is
present on the truck
OPT. HEIGHT #1 ON ÷ OFF This parameter defines if the HEIGHT CUTOUT Button 1 is
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
Present or Absent
TILTING CARRIAGE ON ÷ OFF This Parameter defines if the Tilting Carriage is required, if Set
ON when the Input A5 is High the ACE3 will drive the Tilting
Carriage Valve

11.2.3 Adjustments
ADJUSTMENT

SET BATTERY 24V ÷ 48V This parameter defines the nominal battery voltage. The available
options are:
24V, 36V, 48V
ADJUST BATTERY Volt Fine adjustment of the battery voltage measured by the controller.
THROTTLE 0 ZONE 0% ÷ 100% This parameter defines a dead band in the accelerator input curve.
(by 1% steps)
THROTTLE X MAP 0% ÷ 100% This parameter defines the lift accelerator input curve.
(by 1% steps)
THROTTLE Y MAP 0% ÷ 100% This parameter defines the lift accelerator input curve.
(by 1% steps)
BAT. MIN ADJ. -12.8% ÷ 12.7% This parameter defines the minimum level of the battery-discharge
BAT. MAX ADJ. -12.8% ÷ 12.7% This parameter defines the maximum level of the battery-discharge
ADJUSTMENT #3 % This parameter adjusts the updating of battery charge after Key-On.
Decreasing this parameter the minimum difference between the
battery voltages measured after Key-On and the last stored value,
necessary to update the charge with the new value measured,
decrease. It is used to calibrate the discharge algorithm with the
battery of the application

ADJUSTMENT

MIN LIFT VALUE 0.0 ÷ 5.0v Defines the minimum voltage at the input A3 (Lift Pot) that will run
the pump motor
MAX LIFT VALUE 0.0 ÷ 5.0v Defines the maximum voltage at the input A3 (Lift Pot) that will run
the pump motor
MAX LOWER VALUE 0.0 ÷ 5.0v Defines the maximum voltage at the input A3 (Lift Pot) that will Open
the Lower Valve
LOWER THRESHOLD 0.0 ÷ 5.0v Defines the minimum voltage at the input A3 (Lift Pot) that will Open
the Lower Valve
ADJUSTMENT

LIFT HEIGHT #1 0.0 ÷ 10.0V Defines the voltage at the input ACE3 B3 (Laser) for Height #1
CHK LASER 1 WAIT Not Used
CHK LASER 2 WAIT Not Used
MC VOLTAGE 0% ÷ 100% This parameter specifies the duty-cycle (TON/TPWM) of the

PWM applied to the main-contactor output during the first
(by 1% steps) second after the activation signal that causes the main contactor
to close.
MC VOLTAGE RID 0% ÷ 100% This parameter defines the percentage of MC VOLTAGE applied to
the main-contactor after the first second of activation of the
(by 1% steps) contactor.

11.3 AC0 Steer

11.3.1 Parameters
PARAMETER CHANGE

ACCELER. DELAY Level 0 ÷ Level 9 This parameter defines the acceleration ramp, i.e. the time needed to
speed up the motor from 0 Hz up to 100 Hz. At Level 9 the truck takes
(by steps of 1) long time to accelerate.
RELEASE BRAKING Level 0 ÷ Level 9 This parameter defines the deceleration ramp, i.e. the time needed to
brake the motor from 100 Hz to 0 Hz. At Level 9 the motor brakes
(by steps of 1) abruptly
MAX. CURRENT Level 0 ÷ Level 9 This parameter defines the maximum current applied to the motor as a
percentage of the factory-calibrated maximum current. Level 9 is
(by steps of 1) maximum current
HYDRO TIME 0.3 s ÷ 10 s This parameter defines the length of time in seconds that the steer
motor will continue to run once the SEAT Switch is opened.
(by steps of 0.1 s)
STEER SPEED 5 Hz ÷ 200 Hz This parameter defines the speed that the motor will run at when a
steering function is requested.
(by steps of 1Hz)

11.3.2 Set Options
SET OPTIONS

TILL/SEAT SWITCH HANDLE ÷ SEAT This input opens when the operator leaves the truck. It is connected

released).

SET INPUT #1 HANDLE ÷ SEAT This input opens when the operator leaves the truck. It is connected

released).

HOUR COUNTER RUNNING ÷ KEY ON RUNNING = The counter registers travel time only.
KEY ON = The counter registers when the "key" switch is closed
BATTERY CHECK ON ÷ OFF ON = The battery discharge level check is carried out; when the
battery level reaches 10%, an alarm is signaled and the maximum
current is reduced to the half of the programmed value
OFF = The battery discharge level check is carried out but no alarm is
signalled.
SET MOT.TEMPERAT None ÷ Option#2 This parameter defines the type of motor temperature sensor
adopted.
OPTION#1 = an analog motor thermal sensor is connected. 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 PT1000 PTC (positive thermal coefficient
resistance).

11.3.3 Set Adjustments
ADJUSTMENTS

MOTOR OVER TEMP With this setting, it is possible to raise a warning when the
motor temperature overtakes a threshold specified by the
MOTOR OVER TEMP value
SET MOTOR TEMP With this setting, it is possible to get a fine adjustment of the
temperature of the motor measured by the controller
SET BATTERY 24V ÷ 48V This parameter defines the nominal battery voltage. The
available options are:
24V, 36V, 48V
ADJUST BATTERY Volt Fine adjustment of the battery voltage measured by the
controller.
ADJUSTMENT #02 Level 0 ÷ Level 9 This parameter defines the minimum level of the
battery-discharge table. It is used to calibrate the discharge
(by steps of 1) algorithm for the adopted battery.
ADJUSTMENT #01 Level 0 ÷ Level 9 This parameter defines the maximum level of the
battery-discharge table. It is used to calibrate the discharge
(by steps of 1) algorithm for the adopted battery.

12. Troubleshooting
12.1 ACE3 Traction Inverter Alarm List & Descriptions
ACE3 Alarm Listing
ECO Smart Code Name Description

A8 On Traction WATCHDOG 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.
A17 On Traction 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.
Fault in the hardware section of the logic board which deals

with voltage feedbacks of motor phases.
Troubleshooting

controller

ACE3 Alarm Listing

This fault is displayed when the controller detects an under-

voltage condition at the key input (A1).
Under voltage 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 under-voltage threshold, possibly due to
external loads like DC/DC converters starting-up, relays or
contactors during switching periods, solenoids energizing or
de-energizing. Consider removing 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.

ACE3 Alarm Listing

A30 On Traction 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.

ACE3 Alarm Listing

A31 On Traction 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.
A37 On Traction 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

ACE3 Alarm Listing

A38 On Traction 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
A53 On Traction 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.
A60 On Traction CAPACITOR CHARGE 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.

ACE3 Alarm Listing

A62 On Traction 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:
Check that the cooling fans are working correctly
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.
A65 On Traction MOTOR TEMP Cause:
This warning occurs when the temperature sensor is open (if

digital) or if it has overtaken the MAX MOTOR TEMP threshold
(if analog)
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
A66 On Traction BATTERY LOW Cause:
W66 On Traction 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.

ACE3 Alarm Listing

A74 On Traction 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.
A75 On Traction 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.
A78 On Traction 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
A79 On Traction 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.

ACE3 Alarm Listing

A80 On Traction 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 micro switches.
A82 On Traction 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..
A126 On Traction CHK SMT STOP Cause
The measured voltage at the input B2 and B3 of ACE3 are out

of the allowable range
Troubleshooting
- Check the voltage at the inputs, they should be 2.5V
- Check the voltage at the output B8, it should be 5V
- Check the resistance of the smart stop switch, should be

100K
- If the problem is still present change Smart Stop Bumper

ACE3 Alarm Listing

A127 On Traction S.STOP INC RESET Cause
The Smart Stop Reset input B9 of the AC0 is high at Key ON
Troubleshooting
- Confirm the reset is not active at Key On
A128 On Traction SMART STOP Cause
One or both of the smart stop inputs B2 and B3 are at 5V, the
truck will be in slow speed
Troubleshooting
- Use the reset to recover the truck

- Check the smart stop switches are not stuck
A170 On Traction WRONG KEY VOLT The measured key voltage is not the right one for the inverter.
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.
A178 On Traction MOTOR TEMP STOP Cause:
The temperature sensor has overtaken the STOP MOTOR

TEMP. threshold (if analog, see paragraph 7.2.3).
Troubleshooting:

TESTER function.

the controller.

ACE3 Alarm Listing

A180 On Traction OVERLOAD Cause:
The Current in the motor has overtaken the hardware limit set
by the inverter.
Troubleshooting:
Cycle key switch and test truck to see if the alarm is

reproduced.
Check the condition of the battery, if low, replace the battery
A181 On Traction WRONG ENCODER SET Cause
Mismatch between “ENCODER PULSES 1” parameter and

“ENCODER PULSES 2” parameter
Troubleshooting
Set the two parameters with the same value, according to the
adopted encoder.
A181 On Traction WRONG ENCODER SET Cause
Mismatch between “ENCODER PULSES 1” parameter and

“ENCODER PULSES 2” parameter
Troubleshooting
Set the two parameters with the same value, according to the
adopted encoder.
A196 On Traction 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
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.

ACE3 Alarm Listing

A197 On Traction WRONG SLAVE VER. Cause:
Wrong software version on supervisor uC.
Troubleshooting:
Upload the correct software version or ask for assistance to a

Zapi technician.
A198 On Traction 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.
A199 On Traction 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.
A200 On Traction 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.
A201 On Traction 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.

ACE3 Alarm Listing

A202 On Traction VDC LINK OVER V. 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:
Troubleshooting
If the alarm happens during the brake release, check the line
contactor contact and the battery power-cable connection.
A205 On Traction EPS IN ALARM Cause
The steer inverter is an alarm state
Troubleshooting:
Verify the Steer functionality.
A206 On Traction INIT VMN HIGH Cause
Before switching the LC on, the software checks the power-

bridge voltage without driving it.
The software expects the voltage to be 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.

ACE3 Alarm Listing

A207 On Traction INIT VMN LOW Cause

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


Replace it.
A208 On Traction 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.
A209 On Traction 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 cancels the alarm.
- If the alarm appears at key-on without any CLEAR EEPROM

performed, replace the controller.

ACE3 Alarm Listing

A210 On Traction WRONG RAM MEM 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 controller
A211 On Traction 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.
A212 On Traction 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.
A213 On Traction 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
Software, depending on the parameter value, makes a proper

diagnosis; a mismatch between the hardware and the
parameter configuration could generate a false fault

ACE3 Alarm Listing

A218 On Traction SENS MOT TEMP KO Cause
The output of the motor temperature sensor is out of range
Troubleshooting
Check the wiring between the motor and ACE3 Inverter
Check the ohmic resistance of the motor temperature sensor
A219 On Traction PEB-PEVP NOT OK Cause
The PEV connector B1 is not connected to the battery or the

voltage is different to what is expected.
Troubleshooting
- Check that the input to B1 is 48V.
- check that the 10A Fuse (F2) is Ok
A220 On Traction 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.
A221 On Traction HANDBRAKE HANDBRAKE
Cause:
Handbrake input is active longer than allowed time
Troubleshooting:
- Check that handbrake is not active by mistake.
- Check the SR/HB input state through the TESTER function.
- Check if there are failures in the micro switches.
- If the problem is not solved, replace the ACE3

ACE3 Alarm Listing

A222 On Traction 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.
A223 On Traction COIL SHORT MC. 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.
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.

A224 On Traction WAITING FOR NODE Cause:
This alarm occurs when one of the other inverters is in an

alarm condition
Troubleshooting
Clear the alarms on all inverters

ACE3 Alarm Listing

A226 On Traction VACC OUT OF RANGE Cause:
The CPOT input read by the microcontroller is not within the

MIN VACC ÷ MAX VACC range, programmed through the
PROGRAM VACC function
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.
A227 On Traction HW FAULT 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.
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

A228 On Traction TILLER/SEAT 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 if there are failures in the microswitches.

ACE3 Alarm Listing

A230 On Traction 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, then the problem is inside the

logic board; replace it.
A232 On Traction CONT DRIV EV02/04/08/20 Cause:
One or more on/off valve drivers are not able to drive the load.
- 02 = EV1 – (B16) Not Used
- 04 = EV2 – (B17) Heat Sink Fan Relay
- 08 = EV3 – (B18) Seat Relay
- 20 = EV4 – (B19) Truck Fan Relay
- 80 = EV5 – (B9) Lower Solenoid
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.
A233 On Traction POWER MOS 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

phase.
- In case the problem is not solved, replace the controller.

ACE3 Alarm Listing

A234 On Traction DRIV SHORT EV02/04/08/20 Cause:
One or more on/off valve drivers are shorted.
- 02 = EV1 – (B16) Not Used
- ?? = EV5 – (B9) Lower Solenoid

codes.
Troubleshooting:
- Check if there is a short circuit or a low impedance path

between the negative terminal of the coils and -BATT.
A236 On Traction 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.
A237 On Traction ANALOGUE 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.
A238 On Traction HW FAULT EV Cause:

01/02/04/08/10/20/40/80
At start-up, the hardware circuit dedicate to enable and
disable the EV drivers is found to be faulty.
Troubleshooting:


ACE3 Alarm Listing

A239 On Traction 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.
A241 On Traction 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.

ACE3 Alarm Listing

A242 On Traction COIL OPEN EV Cause:
This alarm occurs when there is an Open Circuit of one or

more EV driver.
Troubleshooting:
Cause:
One or more on/off valve drivers are not able to drive the load.
- 02 = EV1 – (B16) Tilting Carriage
- 80 = EV5 – (B9) Lower Solenoid

codes.
Troubleshooting:
The device or its driving circuit is damaged. Replace the

controller.
A243 On Traction THROTTLE PROG. Cause:
A wrong profile has been set in the throttle profile.
Troubleshooting:
Set properly the throttle-related parameters
A244 On Traction WARNING SLAVE Cause:
Warning on supervisor uC.
Troubleshooting:
Connect the Console to the supervisor uC and check which

alarm is present
A245 On Traction IQ MISMATCHED Cause
The error between the Iq (q-axis current) set point 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.

ACE3 Alarm Listing

A248 On Traction NO CAN MESSAGE This fault is signaled when there is no communication with the
supervisor uC. Or one of the other inverters.
Troubleshooting
Check Can bus wiring and resistance (between CAN H and CAN
L you should read 60Ohms with the machine OFF)
A250 On Traction 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.

A251 On Traction WRONG SET BATT 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
A252 On Traction WRONG ZERO At start-up the amplifiers used to measure the motor voltage
sense voltages above 3 V or below 2 V.
Troubleshooting:

Replace the logic board
A253 On Traction FIELD ORIENT KO Cause

Troubleshooting
present replace the logic board.

12.2 ACE2 Lift Inverter Alarm List & Descriptions
ACE2 Alarm Listing

A13 On Pump EEPROM KO Cause:

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
A17 On Pump LOGIC FAILURE #3 Cause

Troubleshooting

controller.
A18 On Pump LOGIC FAILURE #2 Cause

Troubleshooting

controller

ACE2 Alarm Listing

A30 On Pump VMN LOW Cause

alarm occurs.
Troubleshooting


Replace it.
A31 On Pump VMN HIGH Cause


value.
Troubleshooting


Replace it
A53 On Pump 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.


ACE2 Alarm Listing

A60 On Pump CAPACITOR CHARGE Cause
Troubleshooting

capacitor bank.

damaged.

A62 On Pump TH. PROTECTION Cause:

Troubleshooting:


ACE2 Alarm Listing

A65 On Pump MOTOR TEMP Cause:

(if analog)
Troubleshooting:

TESTER function.

the controller
A66 On Pump BATTERY LOW Cause:
W66 On Pump 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.
A78 On Pump 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 mechanical calibration and the functionality of

the lifting potentiometer.
- Acquire the lifting potentiometer value through the ACE”

Adjustments Menu
- If the problem is not solved, replace the logic board

ACE2 Alarm Listing

A79 On Pump INCORRECT START Cause:

are:
- A travel HYDRAULIC active at key-on.
Troubleshooting:
- Check wirings.
- Check micro switches for failures.

are coherent with micro switches states.
A82 On Pump ENCODER ERROR Cause

encoder failure.
Troubleshooting




the failure is in the controller.
A214 On Pump HGT OVERRIDE ACTIVE Cause
This warning occurs when the operator has overridden the

Height Cutout System
A215 On Pump HGT CUTOUT REAC Cause
This warning occurs when the mast has reached the limit set
by the Height Cutout limit switch located on the mast

ACE2 Alarm Listing

A216 On Pump CHK HGT CUTOUT Cause
This Alarm occurs when Height Cutout sequence is incorrect,

the system has seen the Height Cutout Stop before the Height
Cutout Slow
Troubleshooting
- Verify that the reed switch strikers are fitted correctly and
that the magnet is present
- Confirm the operation of both switches, using the override

key set the mast to the height cutout stop location and verify
in the ACE2 Tester menu that they are switching
- confirm that the wiring is Ok between the controller and the

Height Cutout Switches
A217 On Pump CUTOUT NOT REACH Cause
This Alarm occurs if the input A6 Height Cutout Slow is open

and the HGT CTB SP COUNT has reached 0 before the input
A13 Height Cutout Stop is open
Troubleshooting
- Verify that the reed switch strikers are fitted correctly and
that the magnet is present
- Confirm the operation of both switches, using the
override key set the mast to the height cutout stop
location and verify in the ACE2 Tester menu that they are
switching
A218 On Pump KEYPAD NOT PRESS Cause
This Alarm occurs when HEIGHT SELECT is ON but the

controller cannot communicate with the CAN BUS Keypad.
Troubleshooting
- Verify that the setting HEIGHT SLECTION in ACE2 Set

Options is set correctly
- Confirm the wiring between the controller and the
keypad
- Verify if you have power to the can keypad
- With the machine turned OFF verify the resistance
between CAN H and CAN L, Should be 60Ohms
A219 On Pump CHK LASER Cause
The voltage input from the Laser is out of the specified range
allowed
Troubleshooting
- Verify the voltage coming from the laser

ACE2 Alarm Listing

A221 On Pump 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.

A222 On Pump WAITING FOR NODE Cause:

alarm condition
Troubleshooting
A223 On Pump WATCHDOG #1 Cause:
At start-up the watch dog signal is already active before the

software has
generated it. At stby or running condition the watchdog signal

is not active (in alarm status).
Troubleshooting:
The WD hardware circuit or microcontroller output port are

damaged. In both cases no external component are involved

software has
generated it. At stby or running condition the watchdog signal

is not active (in alarm status).
Troubleshooting:


ACE2 Alarm Listing

Cause:

software has generated it. At stby or running condition the
watch dog signal is not active (in alarm status).
Troubleshooting:

A228 On Pump TILLER/SEAT 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 if there are failures in the microswitches.
A229 On Pump SAFETY INPUT Cause:
The safety input is opened and accordingly the MC is opened

an EB/AUX OUT coil is driven.
Troubleshooting:
Check the CAN#11 input, if it is connected to –Batt and the

alarm is generated then there is a fault in the SAFETY IN
hardware circuit. Replace the logic board.

ACE2 Alarm Listing

A232 On Pump KEY OFF SHORT Cause:
This fault is displayed when the controller detects a low logic

level of Key-Off signal during Start-Up diagnosis.
Troubleshooting:
It is very likely the fault is due to an under voltage, so it is

suggested to check:
- Key input signal down-going pulses (below under voltage

threshold) due to external loads, like DC/DC converters
starting-up, relays or contactor switching, solenoids energizing
/ de-energizing.
- Check the connection of power cables to the battery

terminal, positive and negative, to MC and to controller +Batt
and –Batt, which must be screwed with a torque comprised in
the range 13Nm÷15Nm.

the alarm is present every time the key is switched ON, the
failure is probably in the controller hardware, so it is necessary
to replace the logic board.
A233 On Pump POWER MOS 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.
A236 On Pump CURRENT GAIN Cause:
The Maximum current gain parameters are at the default

values, which
means the maximum current adjustment procedure has not

been carried out yet.
Troubleshooting:
Ask the assistance of a Zapi technician to do the correct

adjustment procedure of the current gain parameters

ACE2 Alarm Listing

A237 On Pump ANALOGUE INPUT Cause:
This alarm occurs when the A/D conversion of the analog

inputs gives frozen
value, on all of the converted signals, for more than 400msec.

The goal of
this diagnosis is to detect a failure of the A/D converter or a

problem in the
code flow that omits the refreshing of the analog signal

conversion.
Troubleshooting:
If the problem occurs permanently it is necessary to substitute

ACE logic board.
A238 On Pump WRONG 0 VOLTAGE Cause:
At start-up the high resolution VMN feedback is not comprised

in a permitted
window of values centred around 2,5V. The circuit is damaged

in the controller.
Troubleshooting:
It is suggested to check:
- Motor internal connections (ohmic continuity)
- Motor power cables connections
- Motor leakage to truck frame
- If the motor connections are OK, the problem is inside the
controller,
A239 On Pump SAFETY OUTPUT Cause:
The safety out driver is shorted.
Troubleshooting:
- Check if there is a short or a low impedance pull-down

between SAFETY
OUT (CAN#19) and –BATT.
- The driver circuit is damaged in the logic board, which must

be replaced.

ACE2 Alarm Listing

A241 On Pump FLASH CHECKSUM Cause:
After Key-on the software verifies the integrity of program

stored in the flash
memory, if the verify has a negative result this alarm is

generated.
Troubleshooting:
The problem is in the microcontroller flash memory, which

could be damaged, or in the program stored inside, which
could be corrupted.
Try to program the logic again, if the alarms is still signaled the
problem is in the microcontroller. Replace the ACE logic board.
A242 On Pump ENCODER LOCKED Cause:

Troubleshooting:
- Check the wiring.

different from zero during a traction request..
A243 On Pump SENS MOT. TEMP KO Cause:
The output of the motor thermal sensor is out of range.
Troubleshooting:
Check the sensor ohmic value and the sensor wiring. If the
sensor is OK,
then the problem is inside the ACE logic board, replace it.
A245 On Pump WRONG RAM MEM Cause

Troubleshooting
present replace the logic board.

ACE2 Alarm Listing

A248 On Pump NO CAN MESSAGE This fault is signaled when there is no communication with the
other inverters.
Troubleshooting
A250 On Pump THERMIC SENS KO Cause:
Troubleshooting:

A251 On Pump WRONG SET BATT Cause

Troubleshooting


the voltmeter.
A252 On Pump HYDR MULTI FCTN Cause
More than one hydraulic function requested at the same time.
Troubleshooting:
- Check wirings.
- Check micro switches for failures.

are coherent with micro switches states.

ACE2 Alarm Listing

A253 On Pump SLIP PROFILE Cause:
There is an error on the choice of the parameters of the slip

profile.
Troubleshooting:
Check in the hardware setting menu the value of those

parameter

12.3 AC0 Steer Inverter Alarm List & Descriptions
AC0 Alarm Listing
Eco Smart Code Name Description

A8 On Steer WATCHDOG 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.
A13 On Steer EEPROM KO Cause:

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
A17 On Steer LOGIC FAILURE #3 Cause

Troubleshooting

controller.

Troubleshooting

controller

AC0 Alarm Listing

This fault is displayed when the controller detects an under

voltage condition at the key input (A1).
Under voltage 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 under voltage 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.

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.
A30 On Steer VMN LOW Cause

alarm occurs.
Troubleshooting


Replace it.

AC0 Alarm Listing

A31 On Steer VMN HIGH Cause


value.
Troubleshooting


Replace it
A49 On Steer I = 0 Ever Cause:
This test is carried out when the motor is running, and it

verifies
that the current feedback sensor is not constantly stuck to 0.
Troubleshooting:
If everything is ok for what it concerns the motor, the problem
could be in the current sensor or in the related circuit.
A53 On Steer STBY I HIGH Cause:
This diagnosis is executed only at key on

Then the outputs of the Current amplifiers must be in a
narrow window close to 2.5 Vdc (from 2.26 V to 2.74 V).
Otherwise this STBY I HIGH alarm occurs.
Troubleshooting:
If the alarm occurs permanently, it is necessary to replace the

controller.

AC0 Alarm Listing

A60 On Steer CAPACITOR CHARGE Cause:
Troubleshooting:

capacitor bank.
damaged.
A61 On Steer TH. PROTECTION Cause:

Troubleshooting:

A65 On Steer MOTOR TEMP Cause:

(if analog)
Troubleshooting:
TESTER function.
the controller

AC0 Alarm Listing

A66 On Steer BATTERY LOW Cause:
It occurs when the battery charge is calculated being less than

10% of the full charge and the BATTERY CHECK setting is other
than 0.
Troubleshooting:
Check battery calibration is OK
Recharge the battery
A69 On Steer CURRENT SENS KO Cause:
This alarm occurs when the procedure for the maximum

current set-up is in progress.
Troubleshooting:
The maximum current set-up is factory adjusted and so this

alarm never should happen when the controller is on the field.
So ask for the assistance of a Zapi technicians when this alarm
occurs.
A79 On Steer INCORRECT START Cause:

are:
- A travel demand active at key-on.
Troubleshooting:
- Check wirings.
- Check microswitches for failures.
are coherent with microswitches states.

AC0 Alarm Listing

A86 On Steer PEDAL WIRE KO Cause:
The SW continuously checks for the connection of the two

supply ends of the potentiometer in the accelerator. The test
consists of reading the voltage drop on a sense diode
connected between NPOT (CNB#11) and GND and cascaded
with the potentiometer: if the potentiometer gets
disconnected on PPOT or NPOT, no current flow in this sense
diode and the voltage on the NPOT connection collapses
down.
When the NPOT voltage is less than 0.3 V this alarm occurs.
This alarm occurs also when the NPOT voltage is higher than 2
Vdc (to detect also the condition of a broken sense diode).
Troubleshooting
:
Check the voltage on NPOT (CNB#11) and the potentiometer
connections.
A232 On Traction STALL ROTOR Cause:

Troubleshooting:

- Check the wiring.
different from zero during a traction request.
A236 On Steer WRONG SET BATT Cause:

Troubleshooting:

the voltmeter.

AC0 Alarm Listing

A248 On Steer CAN BUS KO Cause:
This fault is signaled when there is no communication with the

supervisor uC. Or one of the other inverters.
Troubleshooting:
A250 On Steer THERMIC SENS KO Cause:
Troubleshooting:

A252 On Steer WAITING FOR NODE Cause:

alarm condition
Troubleshooting

A253 On Steer ENCODER ERROR Cause

encoder failure.
Troubleshooting:

the failure is in the controller.

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

14. Service Equipment
14.1 Required Hardware
There are three devices which can be used to communicate with the ACe control panel:-
1.
Description Zapi UK Part number

Zapi Smart Console 16-FC2360
2.
Description Zapi UK Part number

Zapi Ultra Console 16-FC2009B

15. Service Contacts
Tech Support: +44 (0)121 557 6242
Tech Support: service@narrowaisle.co.uk
Tech Support: s.seymour@narrowaisle.co.uk
Spare Parts: parts@narrowaisle.co.uk


Flexi ACiON User Manual V12

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Narrow Aisle

Publication N°: ZUKFlexiACiON

Publication N°: ZUKFlexiACiON

Publication N°: ZUKFlexiACiON

Publication N°: ZUKFlexiACiON

2.1 Technical specifications ACE3 Inverter

Inverter for traction AC asynchronous 3-phase motors, Regenerative braking functions.

2.1.1 ACE3 Inverter Block Diagram

Publication N°: ZUKFlexiACiON

2.2.1 ACE2 Inverter Block Diagram

Publication N°: ZUKFlexiACiON

2.3.1 AC0 Inverter Block Diagram

Publication N°: ZUKFlexiACiON

3.1.0 Digital Inputs

3.1.1 Switching Thresholds

Switching threshold: 4,3V [±0,5V]

3.1.2 Micro Switches

3.1.3 Accelerator Unit

Publication N°: ZUKFlexiACiON

3.1.4 Motor Thermal Sensors

Traction Motor – KTY84-130

Pump Motor & Steer Motor – PT1000

3.1.5 Speed Feedback

Traction – 80PPR Encoder

Pump – 64PPR Encoder

Steer – 64PPR Encoder

4. Specification for the Input Devises of the Inverters

4.1. Material Overview

4.1.1 Connection Cables

For the auxiliary circuits, use cables 0.5mm² section at least.

Publication N°: ZUKFlexiACiON

For the power fuses to the inverters: -

4.1.4 Insulation of the truck frame

Publication N°: ZUKFlexiACiON

Connection Errors, all inputs are protected against connection errors.

The Power unit is not functioning.

The Logic is not functioning perfectly.

Running micro switch in closed position.

5.1.2 Safety Features

Publication N°: ZUKFlexiACiON

Publication N°: ZUKFlexiACiON

Publication N°: ZUKFlexiACiON

9. Description of the power connections

View of the power bars:

-B Negative of the battery.

Publication N°: ZUKFlexiACiON

10.1 Mechanical Drawings

Control Panel Layout:

Hydraulic Motor Layout:

Publication N°: ZUKFlexiACiON

Edition: January 2022 Issue 12

Publication N°: ZUKFlexiACiON

B12 HS FAN RELAY

CAN 120 Ohm

ACE3 TRACTION INVERTER

ECO SMART DISPLAY

KEY INPUT A1 RD/BK

AC0 STEER PUMP INVERTER

SE.2 GN A19 ENC A

BK HC.2 HC.1 PK/PR HS.2 HORN PUSH HS.1

WORKLIGHTS WORKLIGHT SWITCH

BL HSF.1 HSF.1 RD/BL