Products

1
 Applications Overview

OPERATOR CONTROL
- joystick
- fingertips

DISPLAY: ZAPI GRAPHIC SMART

PUMP CONTROLLER: ZAPI ACE-3

2
 TRACTION CONTROLLERS: ZAPI ACE-2 + ACE-2

VEHICLE CONTROL MASTER: ZAPI VCM

VALVE CONTROLLER: ZAPI MHYRIO CB

3
 ZAPI Technology
Inverter for asynchronous motors
As the pioneer of AC motor controller technology, ZAPI has 20 years of experience in developing a full line of AC controllers.
These units feature a multi-plex communications platform, with unmatched flexibility. ZAPI AC controllers offer enhancements
in vehicle control, operation, performance and efficiency. The ZAPI family of AC controllers represent the widest range of
AC products currently available in the low voltage electric vehicle market. The power capabilities of these systems range
from 0.5kW to over 30kW. ZAPI is leader in development of control systems for battery powered vehicles. As a result of
continuous investment in new technology, ZAPI remains the market leader in high performance AC applications.

Inverter ACE-X & ACE-X PW - 2µC Technical details

The Inverter ACE-X is suitable for pedestrian, small Power section
stacker trucks, fitted with asynchronous traction Power supply: 24V, 36V, 48V
Maximum current:
motors up to 2.0kW. Double microcontroller redundant - ACE-X: 24V 165Arms (2’)
architecture. - ACE-X: 36-48V 140Arms (2’)
- ACE-X PW: 24V 240Arms (2’)
- ACE-X PW: 36-48V 210Arms (2’)
Sensorless/Sense Coil version Ambient Temperature range: -40° +40° C
Same as above but with ZAPI patented sensorless/sense coil Maximum heatsink temperature:
85°C (starts to reduce current)
control algorithm to be used with encoderless AC motor. Mechanics
Dimensions: 138x180x87 mm
Connector: Ampseal 35 poles
Protection: IP65
Available with Al base plate or finned heatsink
I/O
11 Digital inputs (input range - Batt ÷ + Batt)
2 Analog inputs (input range 0 ÷ 12V)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
6 Outputs driving to - Batt:
1 Output driving to - Batt: Proportional EV, current controlled
2 LED outputs
Other features
CAN-BUS Interface

Technical details
Inverter ACE-0 & ACE-0 PW - 2µC
Power section
The ACE-0 Inverter is suitable for pedestrian, small Power supply: 24V 36V 48V 80V 120V
stacker trucks and order pickers fitted with asynchronous Maximum current:
- ACE-0: 24V 220 Arms (2’)
motors up to 2.5kW. Double microcontroller redundant - ACE-0: 36-48 V: 180 Arms (2’)
architecture. - ACE-0 PW: 24V: 350 Arms (2’)
- ACE-0 PW: 36 - 48V: 320 Arms (2’)
Sensorless/Sense Coil version - ACE-0 PW: 80V: 200 Arms (2’)
- ACE-0 PW: 120V: 100 Arms (2’)
Same as above but with ZAPI patented sensorless/sense coil Ambient temperature range: -40° +40°C
Maximum heatsink temperature: 85°C
control algorithm to be used with encoderless AC motor. (starts to reduce current)
Mechanics
Dimensions 150x200x79 mm
Connector: Ampseal 35 poles
Protection: IP65
Available with Al base plate or finned heatsink
I/O
13 Digital inputs (input range - Batt ÷ + Batt )
2 Analog inputs (input range 0 ÷ 12V )
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
2 Output driving to - Batt: Proportional EV, current controlled
8 Outputs driving to - Batt
Other features
CAN-BUS Interface

4
 Technical details
Inverter AC-X
The AC-X Inverter is suitable for pedestrian, small Power section
Power supply: 24V 36V 48V 80V
stacker trucks and cleaning machines fitted with Maximum current:
asynchronous motors up to 1.2kW. - 24, 36V 100 Arms (2’)
- 48V 80 Arms (2’)
- 80V 100Arms (2’)
Sensorless/Sense Coil Version Continuous output power: 900W
Ambient Temperature range: -30° +40° C
Same as above but with ZAPI patented sensorless/ Maximum heatsink temperature: 78°C
(starts to reduce current)
sense coil control algorithm to be used with Mechanics
encoderless AC motor. Dimensions: 120x150x54 mm
Connector: Molex Minifit
Protection: IP54
I/O
9 Digital inputs (input range -Batt ÷ + Batt)
2 Analog inputs (input range 0 ÷ 12V)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
4 Outputs driving to - Batt:
1 Output driving to + Batt (optional)
Other features
CAN-BUS Interface
Serial Interface

Inverter AC-0 Technical details

The AC-0 Inverter is suitable for pedestrian, small Power section
stacker trucks and cleaning machines fitted with Power supply: 24V 36V 48V
Maximum current: 200 Arms (2’) (125Arms @48V)
asynchronous motors up to 2.0kW. Current booster: 10% Imax 10’’
Continuous output power: 1800W
Sensorless/Sense Coil Version Ambient Temperature range: -30° +40°C
Maximum heatsink temperature: 78°C
Same as above but with ZAPI patented sensorless/ (starts to reduce current)
Mechanics
sense coil control algorithm to be used with Dimensions: 140x180x58 mm
encoderless AC motor. Connector: Molex Minifit
Protection: IP54
I/O
9 Digital inputs (input range - Batt ÷ + Batt)
2 Analog inputs (input range 0 ÷ 12V)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
4 Outputs driving to - Batt:
1 Output driving to + Batt
Other features
CAN-BUS Interface
Serial Interface

5
 ZAPI Technology
Inverter for asynchronous motors
Inverter ACE-2 & ACE-2 PW - 2µC Technical details
The ACE2 Inverter is suitable for reach and counterbalanced trucks Power section
Power supply: 24V 36V 48V 80V 96V
with single or twin drive motors, high level order pickers and Maximum current:
tow tractors fitted with asynchronous motors up to 9kW. Double - ACE2 24V 450 Arms (2’)
- ACE2 36V, 48V 400 Arms (2’)
microcontroller redundant architecture. Double CAN interface. - ACE2 80V 250 Arms (2’)
- ACE2 96V 215 Arms (2’)
- ACE2 PW 24V 550 Arms (2’)
Sensorless/Sense Coil version - ACE2 PW 36V, 48V 500 Arms (2’)
- ACE2 PW 80V 350Arms (2’)
Same as above but with ZAPI patented sensorless/sense coil control - ACE2 PW 96V 300Arms (2’)
algorithm to be used with encoderless AC motor. Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 85°C
(starts to reduce current)
Mechanics
ACE2 dimensions: 150x200x95 mm
ACE2 PW dimensions: 185x200x95 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or with fitted heatsink
I/O
3 Digital Inputs (input range - Batt ÷ + Batt )
4 Analog inputs (input range 0 ÷ 12V )
2 Outputs driving to - Batt:
1 Output driving to - Batt: Proportional EV, current controlled
1 Incremental Encoder Interface
1 Analog input: Motor Temperature Sensor
Other features
CAN-BUS Interface
Serial Interface

Inverter ACE-3 & ACE-3 PW - 2µC Technical details

The ACE3 Inverter is suitable for reach and counterbalanced trucks Power section
Power supply: 36/48V 72/80V 96V 120V
with single or twin drive motors and tow tractors or Electric Maximum current:
Vehicles fitted with asynchronous motors up to 20kW. - ACE-3 36/48V: 600 Arms (2’)
- ACE-3 80V: 450 Arms (2’)
Double microcontroller redundant safety architecture. - ACE-3 PW 36-48V: 650 Arms (2’)
Single or double CAN architecture interface. - ACE-3 PW 72/80V: 550 Arms (2’)
Ambient temperature range: -40° +40°C
Available both in standard or expanded I/O (premium). Maximum heatsink temperature: 85°C (starts to reduce current)
Mechanics
Dimensions: 200x230x103 mm
Connector: Ampseal 23 poles (2 x 23 poles in premium version)
Protection: IP65
Available with Al base plate or finned heatsink
I/O
5 Digital inputs
2 Analog inputs
2 Outputs driving to - Batt:
1 Output driving to - Batt: Proportional EV, current controlled
1 Incremental Encoder Interface
1 Analog input: Motor Temperature Sensor
I/O Premium Version
10 Digital inputs
5 Analog inputs
7 Outputs driving to - Batt: pwm or ON/OFF, voltage controlled
1 Output driving to - Batt: Proportional EV, current controlled
1 Incremental Encoder Interface
1 Analog input: Motor Temperature Sensor
Different speed sensors can be connected: Incremental Encoder,
3-hall sensors (BLDC), Sin/cos sensor
Other features
CAN-BUS Interface (2 lines in Premium version)

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Inverter AC-2 Technical details
The AC-2 Inverter is suitable for reach and counterbalanced Power section
trucks with single or twin drive motors, high level order pickers, Power supply: 24V 36V 48V 72V 80V 96V 120V
Maximum current:
and tow tractors fitted with asynchronous motors up to 9kW. AC-2 24, 36V 550 Arms (2’) - 36, 48V 550 Arms (2’)

Inverter AC-3 2µC 72-80V 500 Arms (2’) - 96V 350 Arms (2’)
AC-3 36V 600 Arms (3’) - 48V 600 Arms (3’)
The AC-3 Inverter is suitable for tow tractors and counterbalanced 72V 600 Arms (3’) - 80V 600 Arms (3’)
96V 500 Arms (3’) - 120V 500 Arms (3’)
trucks fitted with asynchronous motors up to 20kW. Continuous output power:
AC-2 24V 5000W - 48V 6500W - 80V 9000W
AC-3 48V 10000W - 80V 20000W
Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
AC-2 Dimensions: 200x230x111 mm
AC-3 Dimensions: 250x300x111 mm
AC-2 Connector: Molex Minifit
AC-3 Connector: Molex Minifit / Amp Saab / Ampseal
Protection: IP54 / IP65 (AC-3 only)
Available with Al base plate or with fitted heatsink
I/O
8 Digital inputs (input range - Batt ÷ + Batt)
2 Analog inputs (input range 0 ÷ 12V)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
2 Outputs driving to - Batt:
Other features
CAN-BUS Interface

Inverter ACE4 - 2µC Technical details I/O

5 Digital Inputs (input range - Batt ÷ + Batt )
The ACE4 Inverter is suitable for counterbalanced Power section 2 Analog inputs (input range 0 ÷ 12V )
Power supply: 36V 48V 80V 96V 120V 2 Outputs driving to - Batt:
trucks up to 8 tons, Tow Tractors and Airport Maximum current: 1 Output driving to - Batt: Proportional EV,
Ground Support Vehicles, Aerial (telescopic boom - 36V 1000Arms (2’) current controlled
- 48V 875Arms (2’) 1 Incremental Encoder Interface
and scissor lift) access equipment, fitted with - 80V 700 Arms (2’) 1 Analog input: Motor Temperature Sensor
asynchronous motors up to 20kW. - 96V 500 Arms (2’) I/O Premium
- 120V 400 Arms (2’) 11 Digital Inputs (input range - Batt ÷ + Batt )
Double microcontroller redundant architecture. Ambient Temperature range: -40° +40°C 4 Analog inputs (input range 0 ÷ 12V )
Available both in standard or expanded I/O Maximum heatsink temperature: 85 °C 6 Outputs driving to - Batt:
(starts to reduce current) 1 Output driving to - Batt: Proportional EV,
(premium). Mechanics current controlled
Dimensions: 204 x 235 x 103 mm 1 Incremental Encoder Interface
Connector: Ampseal 23 poles 1 Analog input: Motor Temperature Sensor
(35 poles for Premium version) Other features
Protection: IP65 CAN-BUS Interface
Available with Al base plate or with fitted heatsink

Technical details
Inverter ACE5 - 2µC
Power section
The ACE5 Inverter is suitable for road vehicles, Power supply: 48V 72V 80V 96V 120V
I/O
8 Digital inputs (input range - Batt ÷ + Batt)
large tow tractors and counterbalanced trucks Maximum current: 2 Analog inputs (input range 0 ÷ 12V)
- 48V 1000 Arms (3’)
fitted with asynchronous motors up to 30kW. - 72V 1000 Arms (3’) - 80V 1000 Arms (3’)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
Double microcontroller redundant architecture. - 96V 800 Arms (3’) - 120V 750 Arms (3’) 2 Outputs driving to - Batt:
Continuous output power: Other features
(48V) 18000W - (80V) 30000W CAN-BUS Interface
Ambient Temperature range: -40° +40° C Serial Interface
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
Dimensions: 370x300x144 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or fitted heatsink

7
 ZAPI Technology
Combi inverter for asynchronous motors
The COMBI is an inverter for an AC traction motor with an integrated pump motor controller.

Combi AC-X & Combi AC-X PW - 2µC

The COMBI AC-X CONTROLLER is suitable for pedestrian, Technical details
small stacker trucks, fitted with asynchronous traction
Power section
motors up to 2.0kW, and DC series pump motors up to 5kW. Power supply: 24V 36V 48V
Double microcontroller redundant architecture. Maximum current:
- Combi AC-X: 24V 165Arms (2’) + 270Adc pump
- Combi AC-X: 36-48V 140Arms (2’) + 240Adc pump
Sensorless/Sense Coil version - Combi AC-XPW: 24V 240Arms (2’) + 270Adc pump
Same as above but with ZAPI patented sensorless/sense - Combi AC-XPW: 36-48V 210Arms (2’) + 240Adc pump
Ambient Temperature range: -40° +40° C
coil control algorithm to be used with encoderless AC motor. Maximum heatsink temperature:
85°C (starts to reduce current)
Mechanics
Dimensions: 138x180x87 mm
Connector: Ampseal 35 poles
Protection: IP65
Available with Al base plate or finned heatsink
I/O
11 Digital inputs (input range - Batt ÷ + Batt)
2 Analog inputs (input range 0 ÷ 12V)
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
6 Outputs driving to - Batt
1 Output driving to - Batt: Proportional EV, current controlled
2 LED outputs
Other features
CAN-BUS Interface

Combi AC-0 & Combi AC-0

Technical details
PW Controller - 2µC
The COMBI AC-0 Controller is suitable for pedestrian, small Power section
Power supply: 24V 36V 48V 80V
stacker trucks, and order pickers fitted with asynchronous Maximum current:
motors up to 2.5kW, and DC series pump motor up to 5kW. - Combi AC-0: 24 V: 220 Arms (2’) + 400 A DC pump
- Combi AC-0 36 - 48 V: 180 Arms (2’) + 300 A DC pump
Double microcontroller redundant architecture. - Combi AC-0 PW 24 V: 350 Arms (2’) + 400 A DC pump
- Combi AC-0 PW 36 - 48 V: 320 Arms (2’) + 300 A DC pump
- Combi AC-0 PW 72 - 80 V: 200 Arms (2’) + 200 A DC pump
Ambient Temperature range: -40° +40°C
Sensorless/Sense Coil version Maximum heatsink temperature: 85°C
(starts to reduce current)
Same as above but with ZAPI patented sensorless/sense Mechanics
coil control algorithm to be used with encoderless AC Dimensions: 150x200x79 mm
Connector: Ampseal
motor. Protection: IP65
Available with Al base plate or finned heatsink
I/O
13 Digital inputs (input range - Batt ÷ +Batt )
2 Analog inputs (input range 0 ÷ 12V )
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
2 Outputs driving to - Batt: Proportional EV, current controlled
8 Outputs driving to - Batt
Other features
CAN-BUS Interface

8
Combi AC-1 Controller - 2µC Technical details
The COMBI AC-1 Controller is suitable for pedestrian, small stacker Power section
Power supply: 24V 36V 48V 80V
trucks, and order pickers fitted with asynchronous traction motors Maximum current:
up to 3.5kW, and DC series pump motors up to 7.5kW. - 24V 350 Arms (2’) + 350 A DC pump
- 36V 350 Arms (2’) + 350 A DC pump
Double microcontroller redundant architecture. - 48V 300 Arms (2’) + 300 A DC pump
- 80V 225 Arms (2’) + 225 A DC pump
Sensorless/Sense Coil version Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 85°C
Same as above but with ZAPI patented sensorless/sense (starts to reduce current)
coil control algorithm to be used with encoderless AC motor. Mechanics
Dimensions: 150x230x125 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or with finned heatsink
I/O
10 Digital inputs (input range - Batt ÷ +Batt )
2 Analog inputs (input range 0 ÷ 12V )
1 Analog input: Motor Temperature Sensor
1 Incremental Encoder Interface
8 Outputs driving to - Batt:
1 Output driving to - Batt: Proportional EV, current controlled
Other features
CAN-BUS Interface (also with CAN tiller card)
Serial Interface

Technical details
Inverter Combi AC-2 & Combi AC-2 PW Power section
COMBI AC-2 POWER Inverter is suitable for counterbalanced trucks Power supply: 24V 36V 48V 72V 80V
Maximum current:
and reach trucks with single traction motor and AC pump in the 4 to Combi AC-2 24V 350+350 Arms (3’)
8kW power range. 36V, 48V 330+330 Arms (3’)
72V, 80V 320+320 Arms (3’)
Combi AC-2 PW 24V 500+500 Arms (3’)
36V, 48V 450+450 Arms (3’)
72V, 80V 400+400 Arms (3’)
Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
Dimensions: 250x340x129 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or with finned heatsink
I/O
6 Digital inputs (input range - Batt ÷ + Batt )
3 Analog inputs (input range 0 ÷ 12V )
3 Outputs driving to - Batt:
2 Incremental Encoder Interface
2 Analog input: Motor Temperature Sensor
Other features
2 microcontrollers
CAN-BUS Interface
Serial Interface

9
 ZAPI Technology
Inverters for dual asynchronous motor applications
This controller is suitable for medium and large electric vehicles fitted with dual AC traction motors up to 8kW each
(counterbalanced truck, tow tractor), used in high performance applications. General features: MOSFET Technology,
microprocessor logic, faults memory, digital programming via console, regenerative braking.

Inverter Dual AC-2 & Dual AC-2 PW Technical details

The inverter is suitable for counterbalanced trucks, reach Power section
Power supply: 24V 36V 48V 72V 80V
trucks, and tow tractors with twin traction motors in the 3 to Maximum current:
8kW power range. - Dual AC-2 24V 350+350 Arms (3’)
- Dual AC-2 36V, 48V 330+330 Arms (3’)
- Dual AC-2 72V, 80V 300+300 Arms (3’)
- Dual AC-2 PW 24V 500+500 Arms (3’)
- Dual AC-2 PW 36V, 48V 450+450 Arms (3’)
- Dual AC-2 PW 72V, 80V 500+500 Arms (3’)
Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
Dimensions Dual AC-2: 200x322x129 mm
Dimensions Dual AC-2 PW: 250x340x129 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or with finned heatsink
I/O
6 Digital inputs (input range - Batt ÷ + Batt)
3 Analog inputs (input range 0 ÷ 12V)
3 Outputs driving to - Batt:
2 Incremental Encoder Interface
2 Analog input: Motor Temperature Sensor
Other features
2 microcontrollers
CAN-BUS Interface
Serial Interface

Inverter Dual AC-2 & HP / Technical details

Inverter Dual AC-2 & HP PW Power section

Power supply: 24V 36V 48V 72V 80V
The inverter is suitable for counterbalanced trucks, reach trucks Maximum current:
- Dual AC-2 & HP 24V 350+350 Arms+500 A DC pump (3’)
and tow tractors with twin traction motors in the 3 to 8kW - Dual AC-2 & HP 36V, 48V 330+330 Arms+450 A DC pump (3’)
- Dual AC-2 & HP 72V, 80V 300+300 Arms+400 A DC pump (3’)
power range. The unit has an integrated chopper for the control - Dual AC-2 & HP PW 24V 500+500 Arms+500 A DC pump (3’)
of a DC pump motor. - Dual AC-2 & HP PW 36V, 48V 450+450 Arms+450 A DC pump (3’)
- Dual AC-2 & HP PW 72V, 80V 500+500 Arms+400 A DC pump (3’)
Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
Dimensions Dual AC-2 & HP: 200x400x129 mm
Dimensions Dual AC-2 & HP PW: 250x420x129 mm
Connector: Ampseal
Protection: IP65
Available with Al base plate or with finned heatsink
I/O
12 Digital inputs (input range - Batt ÷ + Batt)
4 Analog inputs (input range 0 ÷ 12V)
3 Outputs driving to - Batt:
2 Incremental Encoder Interface
2 Analog input: Motor Temperature Sensor
Other features
2 microcontrollers
CAN-BUS Interface
Serial Interface

10
 Inverters for high voltage applications
The High Voltage is a controller capable of operating with a voltage up to 720V and suitable for AC induction, BLDC and
PMAC motors, in the range from 15 to 30 Kw continuous power, for traction, pump and auxiliary functions of electric/hybrid
vehicles. Thanks to this characteristic it can operate both with battery packs which are common in electric/hybrid markets
(lithium types) and with an high voltage dc-link stabilized by a generator.

High Voltage Inverter Technical details

Power section
Nominal DC voltage: 650 V DC
Maximum DC voltage: 720 V DC
Logic supply: 12, 24V
Maximum current : 70 A (60 sec);
Continuous output current: 45 A
Maximum output power: 55 kVA (60 sec)
Continuous output power : 35 kVA
Switching frequency: 2-8 KHZ, fixed, auto-adjusted
Ambient temperature range: -40° +85°C
Maximum power section temperature: 90°C (starts to reduce current
@ 60°C)
Mechanics
Dimensions: 250x200x87 mm
Mass: 4,5 Kg
Liquid cooling dissipation: 600W (6l/min; Tinliquid=60°C);
Also available in forced air cooled version.
Connector: Molex CMC 48 poles
Protection: IP6K9K
I/O
5 Digital inputs; connection: active to +12 / 24V.
1 Resolver Interface (1output / 2input). Can be used also for SIN / COS
sensor or as analog input (range 0-12V)
1 Incremental Encoder Interface + index. These can be customized to
be used for Hall sensor (BLDC motor control), upon request
2 Insulated analogue motor thermal sensor input
1 Analog input general purpose
1 Output driving to low voltage negative, 2,5 A continuous, PWM
voltage control.
2 Outputs driving to low voltage negative, 1 A continuous, PWM
voltage control, ON/OFF control
Communication
2 X canbus port
Communication speed up to 500 Kbit/sec
Opto-insulated can transceiver, esd protected
11 and 29 bits communication supported
Compatible with different standard CAN protocol
Other features
FOC motor control for ACIM and PMAC motors with field weakening
6 step motor control for BLDC motors
Resolver, Sin-Cos, Encoder Feedback
Fully automated self-check at start-up
Automatic protection against over heating
HVIL - High Voltage Connection Supervision

11
 ZAPI Technology
PMAC & DC Brushless controllers
With a well proven reliability on the market these units feature a multiplex communication platform with unmatched
flexibility. Zapi family of BLAC and BLDC controllers covers the range from 0.5kW to 15kW applications.

BL-X Controller Technical details

The BL-X controller is suitable for Brushless AC and DC Power section I/O
Power supply: 24V 36V 48V 8 Digital inputs (input range - Batt ÷ + Batt)
motors up to 1kW. Maximum current: 130 Arms (2’) 2 Analog inputs (input range 0 ÷ 12V)
Continuous output power: 900W 3 Digital Hall sensor inputs
Ambient Temperature range: -30° +40° C 4 Outputs driving to - Batt:
Maximum heatsink temperature: 78°C 1 Output driving to +Batt (optional)
(starts to reduce current) 1 Incremental Encoder Interface
Mechanics 1 Analog input: Motor Temperature Sensor
Dimensions: 120x150x54 mm Other features
Connector: Molex Minifit CAN-BUS Interface
Protection: IP54 Serial Interface

BLE-X & BLE-X PW Controller - 2µC Technical details

The BLE-X controller is suitable for Brushless AC and Power section I/O
DC motors up to 2kW. Double microcontroller redundant Power supply: 24V, 36V, 48V 9 Digital inputs (input range - Batt ÷ +
Maximum current: Batt)
architecture. - BLE-X: 24V 165Arms (2’) 2 Analog inputs (input range 0 ÷ 12V)
- BLE-X: 36-48V 140Arms (2’) 1 Analog input: Motor Temperature
- BLE-X PW: 24V 240Arms (2’) Sensor
- BLE-X PW: 36-48V 210Arms (2’) 1 Incremental Encoder Interface + Index,
Ambient Temperature range: -40° +40° C 1 Sin/Cos Interface, 3 Digital Hall Sensors
Maximum heatsink temperature: Interface (with reduction of digital input
85°C (starts to reduce current) number)
Mechanics 1 PWM position signal input
Dimensions: 138x180x87 mm 7 Outputs driving to - Batt
Connector: Minifit or Ampseal 1 Output driving to - Batt: Proportional EV,
Protection: IP54/IP65 current controlled
Available with Al base plate or 2 LED Outputs
finned heatsink 1 Analog input: Motor Temperature
Sensor
Other features
CAN-BUS Interface

BLE-0 & BLE-0 PW Controller - 2µC Technical details

The BLE-0 controller is suitable for Brushless AC and Power section I/O
Power supply: 24V 36V 48V 80V 120V 9 Digital inputs (input range - Batt ÷ + Batt)
DC motors up to 2.5kW. Double microcontroller Maximum current: 2 Analog inputs (input range 0 ÷ 12V )
redundant safety architecture. - BLE-0: 24V 220 Arms (2’) 1 Analog input:Motor Temperature Sensor
- BLE-0: 36-48 V: 180 Arms (2’) 1 Incremental Encoder Interface + Index,
- BLE-0 PW: 24V: 350 Arms (2’) 1 Sin/Cos Interface,3 Digital Hall sensors
- BLE-0 PW: 36 - 48V: 320 Arms (2’) Interface (with reduction of digital input
- BLE-0 PW: 72 - 80V: 200 Arms (2’) number)
- BLE-0 PW: 120V: 100 Arms (2’) 2 Outputs driving to - Batt: Proportional EV,
Ambient temperature range: -40° +40°C current controlled
Maximum heatsink temperature: 85°C 8 Outputs driving to - Batt
(starts to reduce current) 1 PWM position signal input
Mechanics Other features
Dimensions 150x200x79 mm CAN-BUS Interface
Connector: Ampseal
Protection: IP65
Available with Al base plate or
finned heatsink

12
BLE-2 & BLE-2 PW Controller - 2µC Technical details
Power section Connector: Ampseal
The BLE-2 controller is suitable for Brushless AC and Power supply: 24V 36V 48V 80V 96V Protection: IP65
DC motors up to 8kW. Double microcontroller redundant Maximum current: Available with Al base plate or with finned heatsink
architecture. Double CAN interface. - BLE-2 24V 450 Arms (2’) I/O
- BLE-2 36V, 48V 400 Arms (2’) 3 Digital Inputs (input range - Batt ÷ + Batt )
- BLE-2 80V 250 Arms (2’) 2 Analog inputs (input range 0 ÷ 12V )
- BLE-2 96V 215 Arms (2’) 2 Outputs driving to - Batt:
- BLE-2 PW 24V 550 Arms (2’) 1 Output driving to - Batt: Proportional EV, current
- BLE-2 PW 36V, 48V 500 Arms (2’) controlled
- BLE-2 PW 80V 350 Arms (2’) 1 Incremental Encoder Interface, 1 Sin/Cos Interface,
- BLE-2 PW 96V 300 Arms (2’) 3 Digital Hall Sensors Interface (with reduction of
Ambient Temperature range: -40° +40°C digital input number)
Maximum heatsink temperature: 85°C 1 Incremental Encoder Interface
(starts to reduce current) 1 Analog input: Motor Temperature Sensor
Mechanics Other features
BLE-2 dimensions: 150x200x95 mm CAN-BUS Interface
BLE-2 PW dimensions: 185x200x95 mm Serial Interface

BLE-3 & BLE-3 PW Controller - 2µC Technical details

Power section I/O Premium version
The BLE-3 controller is suitable for Brushless AC and DC Power supply: 36/48V 72/80V 96V 120V 10 Digital inputs
motors up to 20kW. Double microcontroller redundant Maximum current: 5 Analog inputs
architecture. Single or double CAN interface. - BLE-3 36/48V: 600 Arms (2’) 7 Outputs driving to - Batt:
- BLE-3 80V: 450 Arms (2’) 1 Output driving to - Batt: Proportional EV, current
- BLE-3 PW 36-48V: 650 Arms (2’) controlled
- BLE-3 PW 72/80V: 550 Arms (2’) 1 Incremental Encoder Interface
Ambient temperature range: -40° +40°C 1 Analog input: Motor Temperature Sensor
Maximum heatsink temperature: 85°C 1 Sin/Cos Interface, 3 Digital Hall Sensors Interface
(starts to reduce current) (with reduction of digital input number)
Mechanics Other features
Dimensions: 200x230x103 mm CAN-BUS Interface (2 lines in Premium version)
Connector: Ampseal 23 poles
(2 x 23 poles in premium version)
Protection: IP65
Available with Al base plate or
finned heatsink I/O
5 Digital Inputs (input range - Batt ÷ + Batt )
2 Analog inputs (input range 0 ÷ 12V )
Technical details
BLE-4 Controller - 2µC Power section
2 Outputs driving to - Batt: pwm or ON/OFF, voltage
controlled
The BLE-4 Controller is suitable for counterbalanced Power supply: 36V 48V 80V 96V 120V 1 Output driving to - Batt: Proportional EV, current
Maximum current: controlled
trucks up to 8 tons, Tow Tractors and Airport Ground 1 Incremental Encoder Interface, 3 Digital Hall Sensors
- 36V 1000 Arms (2’) - 48V 875 Arms (2’)
Support Vehicles, Aerial (telescopic boom and scissor - 80V 700 Arms (2’) - 96V 500 Arms (2’) Interface (with reduction of digital input number)
lift) access equipment, fitted with Brushless AC and - 120V 400 Arms (2’) 1 Analog input: Motor Temperature Sensor
Ambient Temperature range: -40° +40°C I/O Premium
DC motors up to 20kW. Double microcontroller Maximum heatsink temperature: 85 °C 11 Digital Inputs (input range - Batt ÷ + Batt )
redundant architecture. (starts to reduce current) 4 Analog inputs (input range 0 ÷ 12V )
Mechanics 6 Outputs driving to - Batt:
Available both in standard or expanded I/O (premium). Dimensions: 204 x 235 x 103 mm 1 Output driving to - Batt: Proportional EV, current
Connector: Ampseal 23 poles controlled
(35 poles for Premium version) 1 Incremental Encoder Interface, 1 Sin/Cos Interface, 3
Protection: IP65 Digital Hall Sensors Interface (with reduction of digital
Available with Al base plate or input number)
Other features
with fitted heatsink
Flash memory embedded
BLE-5 Controller - 2µC CAN-BUS Interface
The BLE-5 controller is suitable for Brushless AC and Technical details
DC motors up to 30kW. Double microcontroller Power section
redundant safety architecture. Power supply: 48V 72V 80V 96V 120V Available with Al base plate or fitted heatsink
Maximum current: I/O
- 48V 1000 Arms (3’) 8 Digital inputs (input range - Batt ÷ + Batt)
- 72V 1000 Arms (3’) - 80V 1000 Arms (3’) 2 Analog inputs (input range 0 ÷ 12V)
- 96V 800 Arms (3’) - 120V 750 Arms (3’) 1 Analog input: Motor Temperature Sensor
Continuous output power: 1 Sin/Cos interface
48V 18000W - 80V 30000W 1 Incremental Encoder Interface, 1 Sin/Cos Interface,
Ambient Temperature range: -40° +40° C 3 Digital Hall Sensors Interface (with reduction of
Maximum heatsink temperature: 75°C digital input number)
(starts to reduce current) 2 Outputs driving to - Batt
Mechanics Other features
Dimensions: 370x300x144 mm CAN-BUS Interface
Connector: Ampseal Serial Interface
Protection: IP65
13
 ZAPI Technology
Electronic power steering
The electronic power steering unit provides CB trucks, reach trucks, order pickers, man-up VNA trucks and similar vehicles with a
“steer by wire” system. ZAPI offers the system controller, stepper motor (tacho-generator) and the motor/gearbox combination for
a complete, integrated solution.
The electronic power steering with wire guidance controls the steering for vehicles operating in narrow aisles. Vehicle mounted
sensors (Smart antenna) detect the magnetic field from a cable embedded in the floor, and guide the vehicle, without steering input
from the operator. ZAPI offers a system that will operate in a wide range of current and frequencies in the cable (from 30mA AC up
to 100mA AC at frequencies of 5.2, 6.25, 7, 9.1, 10 KHz). All electronic power steering comply with ISO EN 13849-1 CAT. 3 PL.D.

EPS AC0 AMPSEAL EPS AC

This is a compact and cost effective steer by wire controller Steer by wire controller for AC steering motors (EPS-AC).
for trucks fitted with AC steering motors (ACIM, BLAC). It ZAPI started the development of DC Electronic Power Steering
is suitable for steering wheel, handlebar and tiller trucks. systems for lift truck applications in 1992. The EPS-AC system
Microprocessor technology, combined with the CAN Bus reflects ZAPI’s experience in the initial DC products together with
communication system, provides an effortless steering state of the art asynchronous technology. The EPS-AC is suitable
command facility, with several advanced features: for asynchronous steering motors between 200W and 1kW.
• Steering sensitivity reduces when the truck speed increases.
• Truck speed reduces in proportion to the angle of the steered EPS AC+WG
wheel. Steer by wire controller for AC motors with wire-guidance
• Force feedback device control with high and low side drivers. option (EPS-AC + WG). The EPS-AC + WG controls two
• A non-linear relationship between the handle bar position distinct control area networks (CAN) and performs a redundant
and the steered wheel angle can be made. control of the CAN communication system (by using two
• On request, the steering command may originate from a on board microprocessors). The first CAN communication
remote unit via CAN Bus. system is used for the connection with the pick up devices
(smart antennae). The second CAN communication system is
EPS AC0 AMPSEAL TORQUE compatible with different standard CAN protocol.
ASSISTED WIRE GUIDANCE
Same as EPS AC0 Ampseal but for torque assisted applications.
All above controllers have wire guidance capabilities if
connected to Zapi Smart Antennas.

Technical details Technical details

Nominal voltage: 24V 36V 48V 72V 80V Nominal voltage: 24V 36V 48V 72V 80V
Maximum current: Maximum current (1’): 70A (50A@72V-80V)
- 24V, 36V 85 Arms Dimensions: 150x210x74 mm
- 36V, 48V 70 Arms CAN BUS (2 indipendent in WG version only)
- 72V, 80V 40 Arms Dual Microprocessors
Dimensions: 120x150x55 mm Internal hour meter
CAN-BUS Interface Environmental protection: IP54
Dual Microprocessors, both CAN Bus connected
Environmental Protection: IP54 or IP65 (with Ampseal
connector)

Smart antenna
The smart antenna is a microprocessor based unit, able to detect signal data for wire-
guidance applications. It picks up the magnetic field from an embedded wire in the floor;
amplifies the signal, and then transfers the information to the EPS-AC + WG through the
dedicated CAN BUS communication system.

14
 EPS BLI - EPS ACW Integrated steering system
Integrated Plug & Play steering system available in CB (counterbalanced) and Wharehouse configuration. The integration
between the electronic controller and the steering mechanichs permit an easier installation with associated cost reduction.
Due to the dual microcontroller architecture both connected to CAN bus it fulfills the Category 3 PL.D of ISO EN 13849-1 also
in applications with steering command via CAN bus.

EPS BLI
- Wide range of command sensors (stepper motor, twin
pot, double PWM, double encoder).
- Wire Guidance compatible.

Technical details
Nominal voltage: 24V 36V 48V 72V 80V
Maximum current:
- 24V, 36V 70 Arms
- 36V, 48V 70 Arms
- 72V, 80V 50 Arms
CAN-BUS Interface
Dual Microprocessors, both CAN Bus connected
Environmental Protection: IP65

EPS ACW Warehouse Version

- Wide range of command sensors (stepper motor, twin
pot, double PWM, double encoder).
- Wire Guidance compatible.

Technical details
Nominal voltage: 24V 36V 48V 72V 80V
Maximum current:
- 24V, 36V 70 Arms
- 36V, 48V 70 Arms
- 72V, 80V 50 Arms
CAN-BUS Interface
Dual Microprocessors, both CAN Bus connected
Environmental Protection: IP65

EPS ACW CB Version

- Absolute and redundant contactless sensors onboard.
- High power saving compared to hydraulic version.
- Less noisy then hydraulic version.

Technical details
Nominal voltage: 24V 36V 48V 72V 80V
Maximum current:
- 24V, 36V 70 Arms
- 36V, 48V 70 Arms
- 72V, 80V 50 Arms
CAN-BUS Interface
Dual Microprocessors, both CAN Bus connected
Environmental Protection: IP65

15
 ZAPI Technology
Series motor controllers
The ZAPI family of series controllers are designed to perform with standard DC Series wound traction and pump motors.
Microprocessor based, these controllers incorporate the latest in solid state Mosfet technology, high frequency switching,
microprocessor logic, digital adjustment, and diagnostic and fault code storage.

Traction controllers
MAIN MODELS 24V 36V 48V 80V 96V 120V
HO - 24 230A 230A
H1DN 1Q 300A
H2 600A 600A 600A 600A 600A
H3D 1000A 1000A 1000A 800A
B1S (Dual) 330+330A 330+330A 330+330A
Combi C1 350+350A 350+350A
* other models available
Pump Controllers
MAIN MODELS 24V 36V 48V 80V 96V
HP 350A 350A
H2P 600A 600A
HP CAN 500A 500A 450A 500A
HPRC 500A 500A 500A 500A
PPC 500A 350A

* other models available

HP Can Pump Controller Technical details

This equipment is suitable for operations on medium and large Power section
capacity trucks, such as counter balance, order picker, reach and Power supply: 24V 36V 48V 80V
Maximum current:
3 wheel trucks, with DC series wound motors from 2kW to 20kW. - (24V, 36V) 500 A DC
- (36V, 48V) 450 A DC
- (80V) 500 A DC
Ambient Temperature range: -40° +40°C
Maximum heatsink temperature: 75°C
(starts to reduce current)
Mechanics
Dimensions: 110x200x127 mm
Connector: Ampseal 35 poles
Protection: IP65
Available with Al base plate or finned heatsink
I/O
8 Digital inputs to + B
1 Digital input to - B
2 Analog inputs (input range 0 ÷ 12V )
1 Incremental encoder port
2 Outputs driving to - Batt:
1 Output for proportional EV, current control
2 Outputs driving to - Batt
(optional if the encoder is not used)
Other features
CAN-BUS Interface
Serial Interface

16
 Controllers for separately excited motors
After recognising the significant advantages of separately excited motors (SEM) for traction applications, ZAPI was the
leader in developing this technology for industrial electrical vehicles. Since the start of production in the early 1990’s, ZAPI
has continued to improve the control algorithms and the design of the SEM family of controllers. Incorporating full bridge
field control in all of the SEM models, ZAPI has not only eliminated the need for direction contactors, but also provides
inherent features such as speed control and regenerative braking. All SEM controllers feature high frequency operation,
microprocessor control, Mosfet power technology, digital adjustment, programmable logic, solid-state direction reversal,
fault code storage, anti-roll down, anti-roll back, speed control, regenerative braking, hour meter and battery level sensing.
Single Controllers
MAIN MODELS 24V 36V 48V 72V 80V 96V
SEM-X 110A 110A
SEM-0 200A 200A
SEM-1 C 300A 300A 330A
SEM-1 CAN 400A
SEM-2 D 500A 500A 350A 280A 280A
SEM-3 D 350A 550A 550A

* other models available

Dual/Combi/Tri Controllers
MAIN MODELS 24V 36V 48V 80V 96V
DUAL SEM-0 200+200A 200+200A
DUAL SEM-2 500+500A 350+350A 350+350A
DUAL SEM-3 500+500A 500+500A
Combi SEM-0 150+150A 150+150A
Combi SEM-1 400+300A 250+180A
Combi SEM-2 500+350A 500+500A 350+350A
Combi SEM-3 600+500A 500+500A
TRIPLAT 250+250+250A 180+180+200A
TRIPLO 330+330+350A 330+330+350A

* other models available

Controllers for Permanent Magnet motors

The ZAPI family of PM motor controllers new release now include also the new Dual traction and Dual traction & HPpump versions
developed from a well proven and reliable hardware architecture. All new released controllers are CAN based this permitting the use
both as stand alone or with a can based on board vehicle controller.

Single Controllers Dual Controllers

MAIN MODELS 24V 36V 48V MAIN MODELS 24V 36/48V

4Q 90A 70A 50A DUAL PMX 80+80A 70+70A

MX 90A 70A DUAL PMX PW 120+120A 105+105A

PMX 165A 140A DUAL PMX &HP 80+80A+280A 70+70A+240A

PMX PW 240A 210A DUAL PMX &HP PW 120+120A+280A 105+105A+240A

PMO 220A 180A DUAL PMO 110+110A 90+90A

PMO PW 320A 280A DUAL PMO PW 160+160A 140+140A * other models available
* other models available DUAL PMO &HP 110+110A+270A 90+90A+220A
DUAL PMO &HP PW 160+160A+270A 140+140A+220A 17
 ZAPI Technology
Display
Smart display Technical details
This electronic module is an intelligent operator interface.
Power Supply
The display informs the operator of the truck status in 15-100V
Control
real time (BDI, HCs, operating modes, fault control). The -- 64 kbyte eeprom to record:
membrane keypad is an interactive interface for operators -- operator adjustable parameters
and service engineers to customise truck setups and
-- truck fault logs
-- truck hour counters
calibrate truck sensors. -- operator password
-- service password
-- maintenance features
-- BDI profiles
Communication
-- CAN
-- RS232 - current loop only for handset and laptop
Display Alphanumeric
-- 2 lines
-- 20 characters each line
-- backlight
Leds 6, red colour
Dashboard membrane, 6 buttons
Input
8 DIGITAL
-- Input range - Batt ÷ + Batt
-- Input Impedance max 47 KOhm
-- Threshold level 10 V
Output
2 ON-OFF NPN type 1,5 A
1 ON-OFF NPN type 100 mA
Connectors Ampseal
Protection IP65

Sicos
This electronic module is an intelligent operator interface.
The graphic display informs the operator of the truck status
in real time (BDI, HCs, operating modes, fault control). The
membrane keypad is an interactive interface for operators Technical details
and service engineers to customise truck setups and Input
calibrate truck sensors. 18 DIGITAL
-- PNP Type VBatt
-- Input Impedance 10 KOhm
-- Threshold level 10V
4 DIGITAL
-- NPN Type +5
-- Input Impedance 4,7 KOhm
-- Threshold level Analogue Input
5 ANALOGUE
-- 0-5V
-- Input Impedance > 100 KOhm
Normally used for finger tips
3 ANALOGUE
-- 0-7,5V
-- Input Impedance > 100 KOhm
Normally used for potentiometer (traction, brake...)
Output
3 ON-OFF NPN type 500 mA - 48V

18
Eco smart display Technical details
This electronic module is an intelligent operator interface. The
Power Supply
display informs the operator of the truck status in real time 15-100V
Control
(BDI, HCs, operating modes, fault control). The Navipad is the -- operator adjustable parameters
interactive interface for operators and service engineers to interact -- truck fault logs
with truck, setup and calibrate truck sensors.
-- truck hour counters
-- operator password
-- service password
-- maintenance features
-- BDI profiles
Communication
-- CAN-BUS Interface
Display
-- Graphic LCD
-- 128x64 pixel resolution
-- backlight
Leds 5, red colour
Dashboard 5 buttons Navipad
Connectors Minifit with rubber protection
Protection IP65

Graphic smart display

This electronic module is an intelligent operator interface similar to ECO SMART but more important in dimension and
with a larger view area. The graphic display informs the operator of the truck status in real time (BDI, HCs, operating
modes, fault control). The 6 push buttons permit operators and service engineers truck interaction, setup and calibrate
truck sensors.
Technical details Communication
-- CAN
Power Supply -- RS232 - current loop only for
24-80V handset and laptop
Control Display
-- operator adjustable parameters -- Graphic LCD 70x46,50 mm view area
-- truck fault logs -- 240x160 pixel resolution
-- truck hour counters -- backlight
-- operator password Diagnostic Leds 6, red colour
-- service password Dashboard 6 push buttons
-- maintenance features Connectors Minifit with rubber protection
-- BDI profiles Protection IP54
I/O
4 Analog / Digital Inputs
1 Output driving to - Batt, 2,0A continuous
Available with calendar function (optional)

Multifunction Digital Indicator Technical details

This indicator provides three main functions: battery state of charge MDI Features:
Supply voltage: 12V
indication, hour meter count, and information on the alarm status of Dimensions: Ø52x35 mm
the system. The MDI PRC indicator incorporates all functions of the MDI CAN Features:
Supply voltage: 12V
MDI. In addition it is able to drive two proportional valves and two ON/ Dimensions: Ø52x63 mm
OFF valves. One unit provides single mudule indicator functions plus CAN-BUS Interface
Backlighted
control of an electrohydraulic distributor. MDI PRC Features:
Supply voltage: 12V
Dimensions: Ø52x63 mm
2 outputs for proportional valves: 2A continuous
(current control)
2outputs for ON/OFF valves: 2A continuous
(PWM control)

19
 ZAPI Technology
Hydraulic Valves Controller
Technical details
Mhyrio CB Power Supply 15-100V
Control
Mhyrio CB is an electronic module specifically designed for the -- eeprom to record operator adjustable control
control of hydraulic electrovalves. Typically it is one of the nodes in an parameters
Communication
intelligent distribution system in which different modules are connected -- CAN
together via CAN Bus. The Mhyrio CB unit has the advantage that it can -- RS232 - current loop only for handset and laptop
Input
easily be located near to the actuators (hydraulic valves) thus reducing 3 DIGITAL
and optimising wiring layout.
-- Voltage range VBatt
-- Input Impedance max 47 KOhm
-- Threshold level 6V
1 ANALOGUE
-- 0-10V, 3 wires
-- Input Impedance > 100 KOhm
Output
3 ON-OFF NPN 1,5 A
9 PROPORTIONAL 1,5 A
-- EVP 1-2 function 1
-- EVP 3-4 function 2
-- EVP 5-6 function 3
-- EVP 7-8 function 4
-- EVP 9 function 5
Dimension 82x197x59 mm
Connector Ampseal
Protection IP65

Technical details
Power Supply 15-56V
Mhyrio flash Control
-- eeprom to record operator adjustable control parameters
Mhyrio flash is an electronic module specifically designed to Communication
control hydraulic electrovalves. Typically it is one of the nodes -- CAN
-- RS232 - current loop only for handset and laptop
in an intelligent distribution system in which different modules Input
are connected together via CAN Bus. The Mhyrio flash unit has 8 DIGITAL
-- PNP Type VBatt
the advantage that it can easily be located near to the actuators -- Input Impedance 10 KOhm
(hydraulic valves) thus reducing and optimising wiring layout. -- Threshold level 6V
2 ANALOGUE
-- 0-10V, 3 wires
-- Input Impedance > 100 KOhm
Encoder
-- A and B 12V
-- PNP or NPN type open collector or push-pull
-- Threshold 2,5V
-- Max Frequency 500 Hz
-- Supply 12 V< 50 mA
Output
3 ON-OFF NPN 1,5 A
8 PROPORTIONAL 1,5 A
-- EVP 1-2 function 1
-- EVP 3-4 function 2
-- EVP 5-6 function 3
-- EVP 7-8 function 4
Function 3 and 4 are mutually exclusive
Dimension 125x215x55 mm

20
 HVC - Hydraulic valves control
HVC is an electronic module specifically designed to control hydraulic electrovalves. Typically it is one of the nodes in
an intelligent distribution system in which different modules are connected together via CAN Bus. The HVC unit has the
advantage that it can easily be located near to the actuators (hydraulic valves) thus reducing and optimising wiring layout.

Technical details
Power Supply
12-24V
Control
-- eeprom to record operator adjustable control parameters
Communication
-- CAN
-- RS232 - current loop only for handset and laptop
Input
3 DIGITAL
-- Voltage range VBatt
-- Input Impedance max 10 KOhm
-- Threshold level 7V
2 DIGITAL
-- 0-12 Volt
-- Input Impedance 10 KOhm
1 ANALOGUE
-- 0-10V
-- Input Impedance > 100 KOhm
Output
4 ON-OFF NPN 1,5 A
1 PROPORTIONAL NPN 0-1,5 A
Dimension 82x107x47 mm

ZAPI VCM - Vehicle Control Master

The VCM family is a group of I/O and valve controlles also including the vehicle control software capability. Depending on final
application requirements different sets of I/O are available. Also available in double micro and/or double CAN architecture.

General Characteristics
Power supply: 24V 36V 48V 72V 80V I/O
Dimensions: 225 x 90 x 49 mm 7 Digital inputs
Connector: Ampseal 35 poles (35 + 23 poles in double connector 2 Analog inputs
version) 2 Outputs driving to - Batt:
Protection: IP65 8 Outputs driving to - BATT proportional EV, current controlled
Real Time Clock 2 CAN-BUS Interfaces
Built-in freewheeling diodes +12V Output Power Supply (up to 500mA)
Ambient temperature range: -40° +40°C +5V Output Power Supply (up to 150mA)
Other features
Serial Interface
I/O double connector version
11 Digital input
10 Analog inputs
3 Outputs driving to - Batt:
9 Outputs driving to - BATT proportional EV, current controlled
2 Incremental Encoder Interface
2 CAN-BUS Interfaces
+12V Output Power Supply (up to 500mA)
+5V Output power Supply (up to 150mA)

21
 ZAPI Technology
Accessories
Smart console Technical details
With this console it is possible to interact with the controller via CAN or 3.2’’ TFT Color Display
Serial communication in order to monitor the real time operation and to ARM Cortex 32bit Microcontroller
Connection via CAN or serial line (compatibility mode)
change the software parameters in order to better fit the application. Power supply from truck battery (24V to 80V) or from onboard
The console onboard USB port permits also to import/export controller NiMh AA batteries
Improved Navigation and Tester Menu
operational data using an external flash drive. Interchangeable cable
3 user programmable buttons
USB connection to flash drives
In addition to this Smart Console, other ZAPI tools are available, either Dimension: 100x190x60 mm
serial or CAN based, permitting to operate on controllers using external
Man-machine interface details
devices such as personal computers.
Tester
Real time display of the analogue and digital measurements
in the controllers (battery voltage, motor voltage, motor
current, temperature, potentiometer voltage, …).

Programming Parameters
Multilevel password protected access to the controllers
parameters.

Save&Restore
Possibility to save in an external memory a set of parameters
in order to program multiple controllers with the same set in
an automated way.

Alarms display
last 5 faults/warnings.

Advanced functions
CAN messages real time data-logging on USB for system
analysis
Real time data-logging of I/O values shown in the tester menu
Sw download for firmware upgrade.

Can tiller & Can encoder Technical details

Designed to collect inputs and make data available via CAN Bus, CAN I/O - CAN TILLER
Tiller and CAN Encoder are essential to minimize wiring layout. 12 Digital inputs (input range: - Batt ÷ + Batt)
6 Analog inputs (input range: o ÷ 12V)
Analog inputs can be used also
as Digital inputs
Command devices supply 5V or 12V

I/O - CAN ENCODER

2 Encoder inputs
6 Analog inputs (input range: o ÷ 12V)
Analog inputs can be used also
as Digital inputs
Command devices supply 5V or 12V

OTHER FEATURES
CAN Bus interface
Sw download via CAN Bus
Potted version available on request

22
Topo foot pedals Technical details
These units are complete with cable, connector, and one or two
pedals. A sensor provides a variable output voltage according to pedal Dimension
(levers included) 115x160x195 mm
angle. Microswitches for forward, reverse and bypass are also fitted.

Joystick and fingertip

ZAPI philosophy is, and always has been, to co-operate with the customer for the development of every kind of electric
vehicle. Our technical consultation is well appreciated by most of the world’s important electric vehicle manufacturers.
Joystick and Fingertip control elements are becoming more and more strategic components for ZAPI. We can provide
the most advanced joysticks currently present in the international market. As a result of our strong experience in material
handling, boom lift, scissors lift, and crane markets, ZAPI is able to give technical consultation on the most sophisticated
joysticks. ZAPI co-operates with high profile joystick manufacturers such as Penny & Giles, Gessmann, and ITT Cannon.
ZAPI Technical Department is able to develop specific solutions for any customer requirement.

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