Zapi MDI-CAN - User Manual

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

Summary

Features

Specifications

Details the technical specifications and capabilities of the ZAPI MDI-CAN indicator.

Functional Descriptions

Explains the LED, display functions, software version, and battery state of charge indication.

Installation

Connection Scheme

Illustrates the wiring diagram and pinout for connecting the MDI-CAN unit.

Dimensions

Provides the physical dimensions of the MDI-CAN unit and its mounting components.

Connector Description

Details the pin assignments for both CANBUS and Serial communication versions.

Hour-Meter Memory Service

Alarms

Decoding of Alarms

Provides a table to interpret alarm codes displayed by the MDI-CAN unit.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The ZAPI MDI-CAN is an indicator designed for battery-powered vehicles equipped with a high-frequency traction controller from the Zapimos family. Its primary function is to provide essential information to the operator regarding the vehicle's status, battery charge, and operational hours, as well as to signal system alarms.

Function Description

The MDI-CAN operates as a microprocessor-based system, ensuring high precision, reliability, and adaptability in its measurements. It communicates directly with controllers via CAN-BUS, offering a streamlined connection. A serial link communication version is also available for point-to-point connection with a Zapi controller through its serial interface.

Unlike traditional indicators, the MDI-CAN is supplied directly from the chopper rather than the battery, allowing it to be used across systems with varying battery voltages. This design simplifies the machine's wiring, reducing costs and installation time, as it only requires a "point-to-point" connection from the indicator to the chopper.

The device integrates three core internal functions:

1. Battery State of Charge Indication: The MDI-CAN provides an accurate indication of the battery's state of charge using an advanced algorithm. This algorithm considers dynamic conditions such as braking or high acceleration current demands from the drive motor. The state of charge is displayed on the LCD via ten notches, each representing 10% of the battery charge. As the battery discharges, these notches progressively turn off. When a "BATTERY LOW" alarm is triggered on the controller, the battery symbol beneath the notches blinks to alert the operator.
2. Operating Hour Meter: The unit includes an hour meter that records the vehicle's operating hours. This value is displayed alphanumerically on the liquid crystal display. The hour meter value is retained in the MDI-CAN's internal EEPROM memory, allowing it to be transferred to other controllers if a replacement is necessary, thus preserving the machine's hour meter record.
3. System Alarms Indication: The MDI-CAN signals system alarms generated by the connected controllers. When an alarm occurs, a red LED blinks, and a corresponding alarm code is displayed on the LCD. The "Monkey Wrench" symbol also appears, indicating a maintenance request or an alarm state. The display shows "XXAYY," where "XX" represents the alarmed node and "AYY" is the alarm code. The meaning of these codes can be found in the relevant controller's user manual.

Usage Features

The MDI-CAN's display is backlighted for clear visibility. Upon initial closure of the Key Switch, the display performs a general test, illuminating all liquid crystals, the LED, and the backlight. It then shows the Eprom Version (e.g., EPXXX) for the MDI-CAN, followed by the traction controller's Eprom Version, each for two seconds. Simultaneously, the "Monkey Wrench" symbol appears.

The device also provides additional operational information through three distinct symbols:

• Turtle Symbol: This symbol is normally off. When it appears fixed, it indicates that the "soft" mode of the truck is active, meaning maximum speed and acceleration are reduced.
• Monkey Wrench Symbol: Normally off, this symbol appears fixed when programmed maintenance is requested or an alarm state is present. The corresponding alarm code is displayed, offering valuable information for operators or service technicians to quickly identify and resolve issues.
• Hourglass Symbol: This symbol is normally off. It blinks when the Hour Meter is actively working.

The MDI-CAN supports both standard and non-standard communication protocols. If a non-standard protocol is used, the traction controller dictates how icons, LED, and backlight are managed, and what information is written to the MDI-CAN's memory.

Maintenance Features

The hour meter memory service is a key maintenance feature. The MDI-CAN stores the hour meter value in its EEPROM. This allows for the transfer of the machine's hour meter value to a new controller if the original needs replacement, ensuring that the operational history is not lost.

To transfer the hour meter value:

1. Open the Key Switch.
2. Connect the ZAPI Console to the controller.
3. Close the Key Switch.
4. Navigate to the "ADJUSTMENTS Menu" (or "AUX FUNCTION1" in some versions) and set the "LOAD HM FROM MDI" function to ON.
5. Open and close the Key Switch.

The replacement controller will then receive and retain the hour meter value from the previous controller.

It is important to note that the "LOAD HM FROM MDI" parameter is set to OFF by default. If this function is not activated, the hour meter memory will be lost upon turn-on. To prevent accidental loss of data, if the operator forgets to set this parameter, the MDI-CAN will signal an "A98" alarm for one minute, during which traction is disabled. This alarm serves as a warning about the imminent cancellation of the hour meter memory. If no intervention occurs after one minute, the MDI-CAN's hour meter will be rewritten with the value from the new controller (or Zero Hours if the controller is new).

The alarm decoding feature also aids in maintenance. By referring to the alarm codes displayed on the MDI-CAN and cross-referencing them with the relevant controller's manual, operators can often resolve minor issues themselves. For more serious problems, the alarm information provides valuable diagnostic data to the Service Centre, helping to reduce downtime and associated costs. For instance, the "16A06" alarm specifically indicates a "NO COMMUNICATION" problem between the MDI-CAN and the traction controller, prompting a check of the connections. It's crucial to remember that while the provided alarm tables refer to Zapi standard coding, customized software or special products might have variations in alarm indications.

Zapi MDI-CAN Specifications