ACLZP0CB - SEM-ZERO - User manual Page 1 of 38
Contents
1. 35 6 6 Description of Console PROGRAM VACC function 36 7 Recommended Spare parts for SEM Zero 37 8 Periodic Maintenance to be repeated at times indicated 38 ACLZPOCB SEM ZERO User manual Page 1 of 38 SIGNED IN APPROVAL COMPANY DEPT SERVICES MANAGEMENT EXECUTIVE ENGINEERING SECTION EXECUTIVE EXPORT MANAGER Pubblication n ACLZPOCB Edition December 2006 ACLZPOCB SEM ZERO User manual Page 2 of 38 LEGEND BSW Belly Switch CM Common Microswitches CPOT Wiper Potemtiometer EMB Electromechanical Brake EV Lowering Valve FORW SW Forward Switch H amp S Hard amp Soft HORN Horn HORNSW Horn Switch LIFT SW Lifting Switch LOW SW Lowering Switch MC Main Contactor NEMB Negative Electromechanical Brake NEV Negative Lowering Valve NHORN Negative Horn NMC Negative Main Contactor NPC Negative Pump Contactor NPOT Negative Potentiometer PC Pump Contactor PEMB Positive Electromechanical Brake PEV Positive Lowering Valve PHORN Positive Horn PMC Positive Main Contactor PPC Positive Pump Contactor Positive Potentiometer REV SW Reverse Switch SR1 Speed Reduction 1 SR2 Speed Reduction 2 T SW Tiller Switch COLOUR CODES SINGLE COLOURS The following Codes represent the colours o2. MIN VACC MAX 0 0 0 0 emas Ny 10 Select Forward Direction close any interlock switches that may be in the system Slowly depress the accelerator pedal butterfly to its maximum value The new minimum and maximum voltages will be displayed on 9 Display will show 0 0 the Console plus an arrow indicating the direction J MIN VACC MAX 0 6 4 4 11 Select the Reverse Direction and repeat 10 12 When finished press OUT 13 The Display will ask ARE YOU SURE 2 wae ERI E 14 Press ENTER for yes or OUT for NO 15 Press OUT again to return to the Opening Zapi Menu ACLZPOCB SEM ZERO User manual Page 36 of 38 7 RECOMMENDED SPARE PARTS FOR SEM ZERO Part Number Description C16519 Protected 150A Fuse C16503 Protected 200A Fuse C16520 10 A 5x20mm Control Circuit Fuse P99060 Red LED C12372 8 Way Molex Connector C12416 6 Way Molex Connector C12371 3 Way Molex Connector C12769 Insert for Molex Connectors C29543 SW 80 24V CO Single Pole Contactor ACLZPOCB SEM ZERO User manual Page 37 of 38 8 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors moving and fixed contacts Electrical Contacts should be checked every 3 months Check the Foot pedal or Tiller microswitch Using a suitable tes
3. u Sues 21 02126 4 SLONGOYd ldvz 30 Suivd3M 3HL 01 3ALVI3H SI 3SN Q3MOTIV AINO JHL NOLLVZINOHLOV NALUYM Y 303 1d30X3 SI NOLLOnGONd3N SU ALH3dOHd 098 V SI TAS SUE 3 33419 9 t ays 02 8 33841 4 4 9 ju 8313N8nH O 9 I e AS AE t Aad o9 1178 9 5 in Ui uM AST OH 3 y B 9d xs P Os 1 Ov x113N MS ON 53 Ov H o 1 AS A38 d 2 x113d4 4 OWN oe imag 9 r0 1 AS NAOH 3 1OdN mena 538 9 1093 RUNI 4 WO 4 asn4 3814 asna 3 OW Liva i 3A WA HILIAS AS L 339388 1 0373 3AILVO3N AWN g 0119 03 43385 eas YOLIVLNOO dW d I NOILOAGSY 03385 145 3019914050 NIVW OW 3 V 3 SIDLON H H 1 ip ILIAS S Ada 31IAS ONIS3AU AS AU 59 83130113104 3AILISDd HOLIAS AS 1311 2 019 91 05 3AILISUd HSLIMS NaOH YOLOVLNOO NIVN 3AILISUd NaOH NaOH 3AILISUd 1305 NV S H JAWA GIUN32US DNIS3AD 3AILISUd A3d HOLIMS GNVASDA AS ANDA 3 33938 1 2313 3AILISUd
4. LEGEND mec 3 COLOUR CODES Single Colours 3 1 Introduction to the ZAPI MOS family 4 2 General characteristicCS Uul nanctus s Enid kk i 5 21 Technical Specification itineri reta nuni iita i 5 22 eee ceci eade 5 MIGEOSWICIIBS que 5 2 2 b 6 23 Safety amp Protection Features 7 2 4 Direction Orientation 7 2 5 Operati nal FOaltr S a 8 26 SEM Zero chopper diagnosis uuce rentrer ene teint 9 2 7 Thermal Considerations 9 2 8 General Instructions and Precautions 10 Installation u 11 3 1 Connection Cables RR 11 32 u 11 33 FUSES me 11 3 4 Description of SEM Zero Connectors 12 Description of Power Connections 13 3 6 Mechanical Drawing amp Dimensions
5. 14 4 Programming amp Adjustments using Digital Console 15 41 Adjustments Console 15 42 Description of Console amp Connection 15 4 3 Description of Standard Console 16 5 SEM Zero cabling and configuration 17 Ee ce NE EEEE 17 5 2 ee omen renter 18 5 3 Description of Programmable Functions Options 19 5 4 Description of Parameters that may be Programmed 21 5 5 Table or e 23 5 4 SEM Zero Traction Standard Wiring Diagrams 25 5 5 Sequence for SEM Zero Traction 26 6 SEM Zero Diagnostics 27 6 1 Analysis of Alarms displayed on the Console 28 6 2 Tester Description of the Functions 31 6 3 Description of the Console SAVE Function 33 64 Description of Console RESTORE Function 34 65 Description of Alarms Menu
6. JAYA 5 0199109 dWnd 24 33938 TWIINVHOSWOYLI373 83 S313ADILN3IUd S3I3ADILNGIUd X3dIM 1099 y SOLIVLNOD NIVN 3AIIVO3N IWN HOLIMSOSIIW NOWWOI Wo 3ALLV93N HOlIAS 1738 AS 8 37871 NUILVIA3S8S8V 8 Page 25 of 38 ACLZPOCB SEM ZERO User manual 5 5 SEQUENCE FOR SEM ZERO TRACTION SETTINGS When the Key Switch is Closed if no Alarms or Errors are present the Console Display will be showing the Standard Zapi Opening Display If the chopper is not Configured to your requirements follow the Sequence detailed on Page 20 Remember to re cycle the Key Switch if you make any changes to the chop per s Configuration Otherwise follow the sequence detailed below Select the options required Chapter 5 3 Select and set the Battery Voltage Confirm correct installation of all wires Use the Console s TESTER function to assist Perform the accelerator signal acquisition procedure using the Console PRO GRAM Set the TRACTION IMAX Current taking into account any Boost requirements Use Table on Chapter 5 5 Set the Acceleration Delay requirements for the machine Test the parameters in both directions Set the CREEP level starting from level 0 The machine should just move when the accelerator microswitch is closed Increase the Level accordingly Set the Speed Reductions as required Make adjustments to
7. the switch sequence for operation is correct and the output of the accelerator or tiller is correct Standby Diagnosis at rest that checks VMN Point Contactor Drivers and Current Sensor Diagnosis during operation that checks Watchdog VMN Point Current Contactor s and VMN when in full conduction Continuos Diagnosis that checks Chopper temperature Battery Voltage Diagnosis is provided in 2 ways The Red Led connected to Connector A will flash a certain number of times for a given Alarm See Listings or the Digital Console may be used A permanent Alarm will be displayed on the Console immediately and the RED LED will flash An intermittent Alarm will be recorded in the Alarm library but the RED LED will only flash at the time of the Alarm 2 7 THERMAL CONSIDERATIONS The heat generated by the power block must be dissipated For this to be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system should be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situa tions where either ventilation is poor or heat exchange is difficult forced air ventila tion should be used The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle ACLZPOCB SEM ZERO User manual Page 9 of 38 2 8 GENERAL INSTRUCTIONS AND PRECAUTIONS A Never combine SCR lo
8. b Error in the starting sequence from the operator c Error in the wiring 5 FORW BACK This check is made continually The alarm is generated when forward and reverse direction are requested simultaneously Possible causes a Error in Wiring b Welding or Failure of a direction switch c Error in the starting sequence from the operator 6 CAPACITOR CHARGE This check is made during the initial diagnosis This Alarm is generated if the Ca pacitors are not charged within 500ms after the Key Switch is closed Probable cause is failure inside the power block 7 VMN NOT OK This test is performed at rest with the general Contactor Closed and also during operation At rest if VMN is lower than battery voltage this Alarm is generated During operation this Alarm is generated if VMN doesn t follow the duty cycle of the chopper Possible causes a Incorrect Motor connection b Short circuit motor windings to chassis c Defect in the power unit ACLZPOCB SEM ZERO User manual Page 28 of 38 10 11 12 13 14 VFIELD NOT OK This test is made at standby with the Line Contactor open In this condition the voltages on both the connections of field must be to around 1 2 VBatt This alarm is generated if the field voltage is different from this value Possible causes d Frame fault on the motor to chassis Incorrect connection of the field winding to the controller f Failure of the controller in the section
9. motor and the operating conditions laden unladen on plane on gradient The values in the table indicate how much the brakings release inversion deceleration are reduced while H amp S function is active The values in the table indicate how much the acceleration is reduced while H amp S function is active Is a percentage of the field current which is subtracted to the value defined by the parameters MAX SPEED FORW and MAX SPEED BACK Indicates the percentage of the armature current while the machine is at con stant maximum speed that is subtracted to the field current ACLZPOCB SEM ZERO User manual Page 23 of 38 Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA DISPLAY gt Opening Zapi Display KEYBOARD MAIN MENU PARAMETER CHANGE 2 Press ENTER to go into the General Menu 3 The Display will show 4 Press ENTER to go into the Parameter Change facility 5 The Display will show the first Parameter 6 Press either ROLL UP or ROLL DOWN to display the next parameter 7 The names of the Parameters appear on the Display 8 When the desired Parameter appears the Display will show a Level Number that will be between 0 and 9 press either PARAM Top Right or SET Bottom Right buttons to change the Level value 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made Pre
10. of open seat switch 11 QUICK INVERSION the level of the digital entry from Belly Button microswitch pin B5 ON VB active entry B SW closed OFF GND non active entry B SW open 12 CUTBACK SWITCH 1 the level of the Speed Reduction 1 Microswitch SR1 ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 13 CUTBACK SWITCH 2 the level of the Speed Reduction 2 Microswitch SR2 ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch ACLZPOCB SEM ZERO User manual Page 31 of 38 Flow Chart showing how to use the TESTER function of the Digital Console Opening Zapi Display SEMZERO ZAPI 1 0 24V 150A 00000 2 Press ENTER to go into the General menu KEYBOARD 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press either ROLL UP or ROLL DOWN button until TESTER MENU appear on the display 5 The Display shows MAIN MENU TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the Display wa ss 27 8V 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display 9 Next variable is shown MOTO
11. relative to the field VACC NOT OK This Alarm is generated if the accelerator output voltage differs more than 2V from the acquired minimum during the PROGRAM VACC Possible causes a the track of the potentiometer has become open b the potentiometer is not wired correctly c the potentiometer itself is defective d the values set in PROGRAM VACC routine have not remained or made correctly PEDAL WIRE KO This Alarm is generated if potentiometer or wiring fault is detected NPOT or PPOT are open circuit STBY HIGH This test is made during the initial diagnosis and at standby The test verifies that the current is zero This Alarm disables the machine Possible causes a defective current sensor b logic failure First replace the logic If fault remains replace the power unit EVER This check is made during travel If the current is not higher than a preset minimum value this Alarm is generated and the machine disabled Possible causes see STBY HIGH Check the motor armature brush connections HIGH FIELD CUR NO FILD CUR Problem detected with the field winding current Possible causes a Failure of the field current sensor b Field cables not connected or incorrectly connected c Failure of the Field Power Unit CONTACTOR DRIVER COIL SHORTED DRIVER SHORTED These Alarms are generated if there is a problem with the General or Line Contac tor Possible causes a The coil of the contactor is eithe
12. ACCELER DELAY 0 9 SET MODEL NOT AVAILABLE DECELER DELAY 0 9 RELEASE BRAKING 0 9 INVERS BRAKING 0 9 SOFT BRAKING 0 9 SOFT ACCELERATION 0 9 CUTBACK SPEED 1 0 9 SET OPTIONS HOUR COUNTER CUTBACK SPEED 2 0 9 QUICK INVERSION H amp S CUTBACK 029 AUX OUTPUT 1 MAX SPEED FORW 0 9 MAX SP FORW FINE 0 9 MAX SPEED BACK 0 9 MAX SP BACK FINE 0 9 COMPENSATION 0 9 MAXIMUM CURRENT 0 9 ARMA CURR NOM 0 9 WEAK DROPOUT 0 9 ADJUSTMENTS ADJUST BATTERY FIELD CURR NOM 0 9 CREEP SPEED 0 9 TESTER BATTERY VOLTAGE MOTOR VOLTAGE V MOTOR CURRENT FIELD CURRENT VMN V TEMPERATURE ACCELERATOR V Z FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF HANDLE SEAT SWITCH ON OFF QUICK INVERSION ON OFF CUTBACK SWITCH 1 ON OFF CUTBACK SWITCH 2 ON OFF HARD amp SOFT ON OFF SAVE PARAMETER RESTORE PARAMETER CODE ALARMS h Nt C PROGRAM VACC VACC SETTING MIN MAX MOTOR DATA NOT AVAILABLE ACLZPOCB SEM ZERO User manual Page 16 of 38 5 SEM ZERO CABLING AND CONFIGURATION 5 1 POWER DIAGRAM BAT ACLZPOCB SEM ZERO User manual 7 LJ DE Z gt GL Y Que i IY 1 uut Y W
13. CUTBACK SP 1 2 Check the performance with the accelerator pedal totally depressed If the machine is a forklift check the performance with and without load RELEASE BRAKING Operate the machine at full speed Release the accelerator pedal Adjust the level to your requirements If the machine is a forklift check the performance with and without load 10 INVERSION BRAKING Operate the machine at 25 full speed Whilst traveling INVERT the Direction Switch Set a soft Level of Inversion Braking When satisfac tory operate the machine at Full Speed and repeat If the machine is a Forklift repeat the tests and make adjustments with and without load The unladen full speed condition should be the most representative condition 11 Set MAX SPEED FORW 12 Set MAX SPEED BACK Reverse 13 Set ARMA CURR NOM NOM FIELD CURR e WEAK DROPOUT Check the parameters meaning on Chapter 5 4 ACLZPOCB SEM ZERO User manual Page 26 of 38 6 SEM ZERO DIAGNOSTICS The following list shows likely problems associated with the flashing RED LED N FLASHES MESSAGE 1 OI A CG N O O O ACLZP0CB SEM ZERO User manual Logic failure 1 Watch dog EEPROM KO INCORRECT STARTS FORW BACK CAPACITOR CHARGE VMN NOT OK VFIELD NOT OK VACC NOT OK PEDAL WIRE KO NO FIELD CUR HIGH FIELD CUR STBY HIGH l 0 EVER CONTACTOR DRIVER COIL SHORTED CONTACTOR CLOSED TH PROTECTION BATTERY LOW NOTES Proble
14. ENTER to go into the SAVE function 7 If this facility has been used before the type of chopper data stored appears on the top line with a 2 digit reference SELECT Mod 00 FREE 8 Keep pressing either ROLL UP or ROLL DOWN keys until 8 the second line indicates a FREE storage facility J SELECT Mod 01 FREE 9 Press ENTER to commence SAVE routine 10 You can see the items that are being stored whilst READING the SAVE routine is happening DETAY ECC o MAIN MENU 11 When finished the Console shows SAVE PARAM 12 Press OUT to return to the Opening Zapi Display ACLZPOCB SEM ZERO User manual Page 33 of 38 6 4 DESCRIPTION OF CONSOLE RESTORE FUNCTION The RESTORE PARAM function allows transfer of the Console s stored data into the memory of the chopper This is achieved in a fast and easy way using the method previously used with the SAVE PARAM function The data that are available via the RESTORE PARAM function are as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The level of the Battery ADJUST BATTERY ATTENTION When the RESTORE operation is made all data in the chopper memory will be writtten over and replace with data being restored Flow Chart showing ho
15. LUGGED ONLY WHEN THE KEY SWITCH IS OFF The following Parameters can be modified 1 DELAY Determines the acceleration ramp 2 DECELER DELAY Determines the deceleration ramp according to the accelera tor pedal position 3 RELEASE BRAKING Determines the deceleration ramp when the travel request is released 4 INVERSION BRAKING Determines the deceleration ramp the the Direction Switch is inverted during travel 5 SOFT BRAKING Determines how much the brakings are reduced when the H amp S function is active 6 SOFT ACCEL Determines how much the acceleration ramps are reduced when the H amp S function is active CUTBACK SPEED 1 First speed reduction CUTBACK SPEED 2 Second speed reduction H amp S CUTBACK Speed reduction active when the H amp S function is active 0 MAX SPEED FORW Maximum Forward Speed obtained by weakening the Field Current after it has reached 100 conduction of the Armature With the Parameter set at level 0 the armature is in total conduction but the field current does not de crease below the Nominal value low speed 11 MAX SP FORW FINE Maximum forward speed Fine adjustement 12 MAX SPEED BACK Maximum Reverse Speed obtained by weakening the Field Current after it has reached 100 conduction of the Armature With the Parameter set at level 0 the armature is in total conduction but the field current does not de crease below the Nominal value low speed 13 MAX SP BACK FINE Ma
16. NT BOOSTER CURRENT FULL CONDUCTION 24 36V 180A 10 0 23V at 50A 25 C 24 36V 230A 10 0 23V at 50A 25 C 2 2 CONTROL UNITS 2 2 a Microswitches Microswitches should have a contact resistance lower than 0 10 and a leakage current lower than 100 pA When full load current is being drawn the voltage drop across the Key Switch con tact must be lower than 0 1V If an Electromagnetic Brake is used the Handle Microswitch must be able to operate the Brake Coil The Microswitches send a voltage signal to the microprocessor when an operating request running is made ACLZPOCB SEM ZERO User manual Page 5 of 38 2 2 6 Potentiometer The Potentiometer should be wired in the 3 Wire Configuration CPOT B1 signal ranges from 0 to 10V Minimum Potentiometer Resistance 500Q Maximum Potentiometer Resistance 10kQ Faults can occur if the potentiometer is out of this range 3 WIRE PEDAL 3 WIRE TILLER B3 PPOT B3 PPOT MAX O gt Sy 1 MIN B1 CPOT d MIN MAX B2 B2 The Procedure for automatic potentiometer signal aquisition is carried out using the Console This enables adjustment of the minimum and maximum useful signal level PROGRAM VACC function in either direction This function is unique when it is necessary to compensate for asymmetr
17. O a Li RE uiu Ow aH c oo Page 17 of 38 5 2 CONNECTIONS 1 HDURMETER 2 Ho KEY D LNMC MCC EMB LNEMB PEMB A 5 or o SW i 5 gt BBS SV teur gr REV SV i 5 Po B SW i Mo FORW SW i M FN 2 O 59 SRI 3 OQ REG SIGNAL PHORN HORN SWI HORN 5 ORN LIFT Sw D D ae 5 D EV LOW SW LPCLRXD Mo 8 CLRXD 2 8 CLTXD CLTXD D E N E E S 5 GND L i 12 EREE a ACLZPOCB SEM ZERO User manual Page 18 of 38 5 3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS OPTIONS Using the CONFIG MENU of the console it is possible to select from the following options SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING The counter registers travel time only KEY ON The counter registers when the key switch is Closed The A1 output for external hourmeter operates according to internal hourmeter If the pump contactor is connected D4 hourmeter output A1 is activated during lifting as well 2 QUICK INVERSION BELL
18. OGRAMMED LEVEL PARAMETERS UNIT 0 1 2 3 4 5 6 7 8 9 DELAY sec 0 30 0 50 0 70 0 90 110 1 25 1 40 1 55 1 75 2 00 DEC DELAY 9 8 7 6 5 4 3 2 1 0 RELEASE BRAKING 0 1 2 3 4 5 6 7 8 9 INVERS BRAKING 0 1 2 3 4 5 6 7 8 9 SOFT BRAKING 50 40 33 28 25 22 20 18 16 15 SOFT ACCELERATION 50 40 33 28 25 22 20 18 16 15 CUTBACK SPEED 1 30 38 45 51 57 64 72 80 90 100 CUTBACK SPEED 2 30 38 45 51 57 64 72 80 90 100 H amp S CUTBACK 30 38 45 51 57 64 72 80 90 100 SPEED FORW FCN 100 90 80 71 62 53 45 40 36 33 SP FORW FINE FCN 0 1 2 3 4 5 6 7 8 9 MAX SPEED BACK FCN 100 90 80 71 62 53 45 40 36 33 SP BACK FINE 0 1 2 3 4 5 6 7 8 9 COMPENSATION 0 5 10 16 22 27 33 38 44 78 MAXIMUM CURRENT 82 84 86 88 90 92 94 96 98 100 ARMA CUR ACN 45 47 50 52 54 56 58 61 63 65 WEAK DROP OUT ACN 40 44 48 52 57 62 66 70 75 80 FIELD CURR FCN A 7 5 8 1 8 7 9 3 10 10 6 11 2 11 8 12 5 13 1 CREEP SPEED N Batt 4 5 6 7 8 9 10 11 12 13 RRR If the current inclines to raise then also the braking time raises in order to obtain a smooth braking action Therefore the duration of the braking depends on the type of
19. R VOLTAGE 0 0V 10 When you have finished Press OUT 11 The Display shows MAIN MENU TESTER 12 Press either ROLL UP or ROLL DOWN button to show other MENU or press OUT to finish Remember it is not possible to make any changes using TESTER All you can do is measure as if you were using a pre connected multimeter ACLZPOCB SEM ZERO User manual Page 32 of 38 6 3 DESCRIPTION OF THE CONSOLE SAVE FUNCTION The SAVE PARAM function allows the operator to transmit the Parameter values and Configuration data of the chopper into the Console memory It is possible to load 64 different programmes The information saved in the Console memory can then be reloaded into another chop per using the RESTORE function The data that is available via the SAVE function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The Level of the Battery ADJUST BATTERY Flow Chart showing how to use the SAVE function of the Digital Console 1 Opening Zapi Display EE 2 Press ENTER to go into the General menu KEYBOARD gt 3 The Display will show J PARAMETER CHANGE 4 Press either ROLL UP or ROLL DOWN button until 2 PARAM is shown 2 MAIN MENU 5 The Display will show SAVE PARAM 6 Press
20. Y Quick inversion is activated while the Belly Button is pressed TIMED Quick inversion is activated while the Belly Button is pressed maximum for 2 second 3 AUX OUTPUT 1 FREE A4 output is not used the controller carry out monitor function as described at the paragraph 2 5 BRAKE A4 output drives an electromechanical brake The con troller does not carry out monitor function but locks the brake while in rest or alarm status ACLZPOCB SEM ZERO User manual Page 19 of 38 Flow Chart showing how to make changes to Configuration Menu using Digital Con sole Standard Eprom CK ULTRA fitted 1 Opening Zapi Menu 2 Press Top Left amp Top Right Buttons simultaneously to enter the Config Menu 3 The Display will show 4 Press ROLL UP Top Left Button until SET OPTIONS appears 5 The Display will show 6 Press ENTER to go into this part of the menu 7 The first Option of the menu appears on the Display 8 Press either ROLL UP or ROLL DOWN to bring up the next the Option 9 Anew Option appears on the Display 10 When the desired Option is displayed press PARAM Top Right or SET Bottom Right button to change the configuration 11 The new Configuration for the selected Option appears on the Display 12 Press OUT to exit the Menu 13 Press ENTER to accept the changes or Press OUT if you do not accept the changes and wish to make further modifications to the particular Optio
21. cessary before the machine will start Operation cannot commence if these operations are not carried out correctly Requests for drive must be made after closing the key Switch Protection against uncontrolled movements The Line Contactor will not close if The Power Unit is not functioning The Logic is not functioning perfectly Main Line Contactor Should be fitted to give protection to the chopper against reverse battery polarity and safety External Agents The chopper is protected against dust and the spray of liquid to a degree of protection meeting IP54 2 4 DIRECTION ORIENTATION Machines fitted with Tillers Belly Switches and Pulse Control Systems providing rapid reversal should conform to the requirements of Directive prEN 1175 This Directive re quires that Direction Orientation should match the following drawing INDIETR AVANTI CBACKWARD2 FORWARD ACLZPOCB SEM ZERO User manual Page 7 of 38 2 5 OPERATIONAL FEATURES Speed Control Optimum sensitivity at low speeds Speed Reductions in both the directions Levels can be set using Console Regenerative Braking based on deceleration ramps in every condition Three different modes of Braking Release Braking Inversion Braking Speed Limit Braking Speed Control during descent the motor speed follows the accelerator The cho
22. ening Zapi Display ACLZPOCB SEM ZERO User manual Page 34 of 38 6 5 DESCRIPTION OF ALARMS MENU The microprocessor in the chopper remembers the last five Alarms that have occurred Items remembered relative to each Alarm are the code of the alarm the number of times the particular Alarm occurred the Hour Meter count and the chopper tempera ture This function permits a deeper diagnosis of problems as the recent history can now be accessed Flow Chart showing how to use the ALARMS function via the Digital Console 1 Opening Zapi Display DISPLAY M SEMZERO V1 0 2 2 Press ENTER to go into the General menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display 5 The Display will show J 6 Press ENTER to go into the ALARMS function I CODE 7 The Display will show the most recent Alarm 00005 02 20 8 Each press of the ROLL UP button brings up following Alarms Pressing ROLL DOWN returns to the most recent 9 If an Alarm has not occurred the Display will show J CODE 00007 18 C ALARM NULL 10 When you have finished looking at the Alarms press OUT to ex
23. ered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER ACLZPOCB SEM ZERO User manual Page 38 of 38 1 ELECTRONIC INDUSTRIAL DEVICES 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 0522 960050 r a Tlx 530021 AINDRE I Fax 0522 960259 INSTALLATION AND USER MANUAL CHOPPER SEM ZERO
24. f individual wires used by Zapi unless specified otherwise A Orange M Brown B White N Black Blue Sky Blue RR Red G Yellow V Green GG Grey VV Purple ACLZPOCB SEM ZERO User manual Page 3 of 38 1 INTRODUCTION THE ZAPI MOS FAMILY The ZAPIMOS chopper family represents ZAPI s answer to the needs of the 90 s To ensure that products remain on the market without running the risk of becoming technically obsolescent the ZAPIMOS family offers the following features Advanced technology Economical costs Maximum safety Maximum flexibility Open to future technical innovations Optimum level of protection The design has been derived from High Frequency Mos Technology Real time control over the internal and external components that influence the be haviour of the machine with self diagnosis of the checking circuits themselves Stored Program Machine SPC where the hardware is completely separate from the functions to be configured The programme is parametric and can easily be modified by the end user Various chopper configurations can be selected by the user without the need for hardware modifications Future technological updates are made easy for the user The communication protocol will continue to evolve thereby offering increas ing possibilities of interaction and expansion For this reason the Zapimos family offers a standard dialogue mode with external syste
25. figuration are made using the Digital Console The Console is connected to the E connector of the SEM Zero Chopper A Pay attention to the polarity of the Console Connector when connecting to the chopper The bevel on the connector should be uppermost 4 2 DESCRIPTION OF CONSOLE amp CONNECTION 3 E CONNECTOR CHOPPER SEM ZERO CONSOLE CONNECTOR DISPLAY PROGRAM 4 IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE SP SPHED I S P 1 SPEED 3 SAVE S P SPEED BYPASS _ FIELD WEAK 2 RESTORE I MOT V POT TEMP V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DATA 1 5 ROLL ENTER PARAM BUTTONS 4 ROLL OUT SET uu Digital Consoles used to communicate with SEM Zero choppers must be fitted with Eprom CK ULTRA ACLZP0CB SEM ZERO User manual Page 15 of 38 HEADING 4 3 DESCRIPTION OF STANDARD CONSOLE MENU KEY ON RUNNING BELLY TIMED FREE BRAKE MAIN MENU Ropa
26. he cables to the battery should be run side by side and be as short as possible 3 2 CONTACTORS A Line Contactor designed for Continuous Operation should be installed This contac tor should be fitted with a coil corresponding to the battery voltage The current ab sorbed by the coil must not be greater than 3A Suppression for this contactor coil is within the chopper Do not use external suppres sion For any Contactor using external suppression ensure that connections are made respecting correct polarity 3 3 FUSES Usea 10 A Fuse for protection of the auxiliary circuits For protection of the power unit refer to diagrams The Fuse value shown is the maxi mum allowable For special applications or requirements these values can be reduced ForSafety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow ACLZPOCB SEM ZERO User manual Page 11 of 38 3 4 DESCRIPTION OF SEM ZERO CONNECTORS pr O 1 Cc c VMN IAN 6 8 1 8 U O ki PIN REFERENCE DESCRIPTION HOURMETER Output hourmeter it controls a load to BATT Maximum output current 200mA A2 KEY Supply into logic downstream of 10A fuse amp key switch NMC Negative main contactor coil 4 Negative elect
27. it the ALARMS menu 11 The Display will ask CLEAR LOGBOOK xis K 12 Press ENTER for yes or OUT for 13 Press OUT to return to the Opening Zapi Display ACLZPOCB SEM ZERO User manual Page 35 of 38 6 6 DESCRIPTION OF CONSOLE PROGRAM VACC FUNCTION This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function Flow Chart showing how to use the PROGRAM VACC function of the Digital Console 1 Opening Zapi Display KATL Ta 2 Press ENTER to go into the General Menu KEYBOARD 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 Tthe Display will show MAIN MENU PROGRAM VACC 6 Press ENTER to go into the PROGRAM VACC routine 2 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown 8 Press ENTER to clear these values
28. m with Logic or Line Contactor Logic board and or software failure Problem with EEPROM or Logic Starting sequence for travel not correct Double running requests Problem in Power Block Problem with Chopper Problem with Field Voltage Potentiometer Wiper Pedal wire not OK Field wiring not OK or field current sensor not OK Field wiring not OK or field current sensor not OK High current at the stand by sensor of arma ture current not OK No current sensor of armature current not OK Contactor Driver not OK Coil contactor shorted Line Contactor contact not OK Temperature too much high gt 70 C or low lt 10 Battery too low Page 27 of 38 6 1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE 1 LOGIC FAILURE 1 This test is carried out at the start up Possible cause failure of the logic board 2 WATCH DOG The test is executed at the key turn on at the stand by and on running Possible causes a Watch dog hardware circuit not OK b Software not OK 3 EEPROM OK Fault in the area of memory where the adjustment parameters are stored This Alarm inhibits machine operation If the fault continues when the Key Switch is re cycled replace the logic If the fault disappears the previously stored Parameters will have been replaced by the default parameters 4 INCORRECT START Alarm generated by an incorrect Starting Sequence Possible causes a The ENABLE microswitch has welded or failed
29. ms This allows interfacing with commercially available machines Zapi can offer a range of individually designed Console Software with various features and prices SEM Zero meets the requirements of IP54 This provides excellent protection against spray water acid and against the ingress of dust or small foreign particles Access to the control logic is very simple and allows simple substitution or replace ment The SEM Zero family of Choppers are suitable for operating on DC voltages from 24 to 36V inclusive with maximum armature current up to 200A The choppers may be used to control Separately Excited Motors with power ratings up to 2 0kW ACLZPOCB SEM ZERO User manual Page 4 of 38 2 GENERAL CHARACTERISTICS 2 1 TECHNICAL SPECIFICATION Chopper for Separately Excited DC 0 5 2 0kW Regenerative Braking Voltage FN Ss uu ROT 24 36VDC Maximum Field Current all the 35A Armature Switching Frequency onis uoto peu RUSO 16kHz Field Switching Frequency 1kHz Maximum Ambient 40 C Minimum Ambient temperature 30 C Maximum temperature Of Chopper 80 C VOLTAGE DROP IN VERSIONS MAXIMUM CURRE
30. n 14 The Display now shows 15 Press OUT again Display now shows the Opening Zapi Menu ACLZPOCB SEM ZERO User manual DISPLAY 3 SEMZERO ZAPI V1 0 24V 150A 0000 KEYBOARD CONFIG MENU SET MODEL CONFIG MENU SET OPTIONS HOUR COUNTER RUNNING QUICK INVERSION BELL QUICK INVERSION TIMED e ARE YOU SURE YES ENTER OUT CONFIG MENU SET OPTIONS Page 20 of 38 5 4 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED In addition to the Configuration Parameter settings may be made by Zapi using stand ard default settings settings to Customer Specifications or the customer may make changes according to the application using a Digital Console During the setting up procedure on the machine the Console can remain connected to the chopper during travel The Parameters can be modified in real time during opera tion Pay attention to the polarity of the Console Connector Refer to Page 15 of this Manual for connection details THE PROGRAMMING CONSOLE MUST BE P
31. netic emmission levels are seriously influenced by installation conditions Take particular care with the length of cables and wires types of electrical connections and braided screened wires Zapi declines any responsibility for incorrect or bad operation that can be attributed to the above circumstances Above all the manufacturer of the machine must ensure that the requirements of EN 50081 2 are met ACLZPOCB SEM ZERO User manual Page 10 of 38 3 INSTALLATION Install the chopper baseplate onto a flat metallic surface that is clean and unpainted Apply a thin layer of thermo conductive grease between the two surfaces to permit better heat dissipation Despite the protection provided against external agents the continuous attack of corro sive elements and substances may cause oxidization of connector contacts resulting in bad operation Remember this point when deciding the installation position on the vehicle Fix the chopper using the special holes located on the baseplate Verify that the wiring of the cable terminals and connectors has been carried out cor rectly Ensure that suppression devices are fitted to the coils not protected by the SEM Zero itself 3 1 CONNECTION CABLES For the auxiliary circuits use cables better or equal to 0 5mm section For power connections to the motor armature and battery use cable of 16mm section For the Field connections use cable of 4mm section For the optimum chopper performance t
32. output signals can be measured in real time using the TESTER function of the console The Console acts as a multimeter able to read volt age current and temperature The following definition listing shows the relative meas urements 1 BATTERY VOLTAGE level of battery voltage measured at the input to the key switch 2 MOTOR VOLTAGE the voltage appearing across the drive motor It is measured between B and VMN 3 MOTOR CURRENT the current flowing in the drive motor armature 4 FIELD CURRENT the current flowing in the drive motor field winding 5 VMN the voltage effectively dropped across the MOS It is measured between B and VMN 6 TEMPERATURE the temperature measured on the aluminum heat sink holding the MOSFET devices 7 ACCELERATOR the voltage of the accelerator potentiometer wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 8 FORWARD SWITCH the level of the Forward direction digital entry MA pin B6 ON VB active entry of closed switch OFF GND non active entry of open switch 9 BACKWARD SWITCH the level of the Reverse direction digital entry MI pin B4 ON VB active entry of closed switch OFF GND non active entry of open switch 10 HANDLE SEAT SWITCH the level of the Handle Seat Microswitch digital entry pin 5 ON VB active entry of closed seat switch OFF GND non active entry
33. p per automatically brakes if the motor speed overcomes the accelerator set point This provides optimum performance on a gradient Starts on a Ramp without roll back even without an electric brake Programmable Anti Roll Back When the Key Switch is closed if the motor is rotat ing the chopper controls the speed and automatically brakes and keeps the motor at a very low speed during descent on a gradient This is a very useful safety feature and is not driver dependent Output for Hourmeter The main contactor is open after 45 seconds of stand by condition Self Diagnosis with indication of fault shown via flashing Red Led In addition to Console Display Modification of the parameters via Digital Console See the specific description Internal Hour Meter that is displayed on the Console Memory of the last 5 Alarms with relative Hour meter count and chopper tempera ture all displayed on the Console Test Function within Console for checking main parameters See the specific De scription High motor and battery efficiency due to High Frequency Switching ACLZPOCB SEM ZERO User manual Page 8 of 38 2 6 SEM ZERO CHOPPER DIAGNOSIS The microprocessor continually monitors the chopper and carries out diagnostic proce dures on the main functions The diagnosis is made in 4 points 1 2 3 4 Diagnosis on key Switch closing that checks the Watch Dog Circuits the current sensor VMN point Contactor Drivers
34. r short circuit open circuit or not connected b The Contactor Coil Driver is short circuit c Defect in the wiring to the contactor or logic failure ACLZPOCB SEM ZERO User manual Page 29 of 38 15 CONTACTOR CLOSED This check is made during the initial diagnosis With the coil of the line contactor de energized the capacitors should not be charged unless there is divert resistor across the power poles Possible causes a The line contactor power poles are welded b This alarm could be generated even if the line contactor has opened but there is a problem with either the field circuit or a problem detected by the safety micro processor TH PROTECTION If the temperature of the chopper rises higher than 70 C this alarm is generated The chopper current is reduced in proportion to the increase in temperature At 80 C the chopper totally stops If the temperature of the chopper is lt 10 C this Alarm is also generated and the current is reduced by 80 If this alarm is dis played when the chopper is temperature is the same as ambient or better than zero degrees a Check the connection of the temperature sensor b The temperature sensor may be defective c The logic may be defective BATTERY LOW This Alarm is generated when the battery becomes 50 discharged from the nomi nal value ACLZPOCB SEM ZERO User manual Page 30 of 38 6 2 TESTER DESCRIPTION OF THE FUNCTIONS The most important input or
35. ro brake A5 TILLER Tiller micro switch A6 BATT BATT A7 PMC Positive main contactor coil and common positive supply for REV FORW B SW HORN LIFT LOW microswitches A8 H amp S Hard amp Soft function input It should be connected to A7 through the H amp S switch Active high 4 VB B1 CPOT Accelerator s potentiometer wiper or output of inductive device B2 NPOT Provides a negative supply to accelerator s potentiometer B3 Provides a positive supply to accelerator s potentiometer B4 REV Reverse direction input it should be connected to A7 by a micro switch Active HIGH VB B5 BSW Quick inversion input it should be connected to belly button Active HIGH VB B6 FORW Forward direction input It should be connected to A7 by a micro switch active HIGH VB ACLZPOCB SEM ZERO User manual Page 12 of 38 PIN REFERENCE DESCRIPTION Ci CM Common positive supply for micro switch SR1 SR2 BATT C2 SRI Input for 1 speed reduction It should be connected to C1 by micro switch active LOW C3 SR2 Input for 2 speed reduction It should be connected to C1 by micro switch active LOW D1 REGSIGNAL Regenerative braking status Normally high low while regenerating D2 PHORN Positive horn it should be connected to A7 by the horn micro switch D3 NHORN Negative horn it is BATT D4 PPC Positive pump contactor it should be connected to A7 by lifting micro switch LIFT which provides the positive s
36. ss OUT 11 The Display asks ARE YOU SURE SEMZ ERO ZAPI V1 0 24V 150A 00000 ACCELER DELAY LEVEL 4 INVERS BRAKING LEVEL 5 2 INVERS BRAKING LEVEL ARE YOU SURE YES ENTER NO OUT 12 Press ENTER to accept the changes or Press OUT Z if you do not wish to accept the changes and wish QO to make further modifications to the parameters 13 The Display will show ACLZPOCB SEM ZERO User manual MAIN MENU PARAMETER CHANGE Page 24 of 38 5 4 SEM ZERO TRACTION STANDARD WIRING DIAGRAMS SA 82027 3097 2v W3S WVNDVIT DNISIA U83Z W3S 86720787 ses
37. t meter confirm that there is no electrical resistance between the contacts by measuring the volt drop be tween the terminals Switches should operate with a firm click sound Microswitches should be checked every 3 months Check the Battery cables cables to the chopper 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 imme diately The Agent will then take the decision regarding operational safety of the ma chine Remember that Battery Pow
38. upply to the pump contactor s coil 05 NPC NEV Negative supply for pump contactor 06 Positive electro valve for lowering E1 PCLRXD Positive serial reception E2 NCLRXD Negative serial reception PCLTXD Positive serial transmission E4 NCLTXD Negative serial transmission E5 GND Negative console power supply E6 VL Positive console power supply E7 Free E8 Free 3 5 DESCRIPTION OF POWER CONNECTIONS BATT Positive Supply from Battery BATT Negative Supply from Battery VMN 9 Negative Supply via chopper to Motor F1 F2 Connections to Drive Motor Winding ACLZPOCB SEM ZERO User manual Page 13 of 38 3 6 MECHANICAL DRAWING amp DIMENSIONS 85 58 6 68 6 AQ M6 X 5 VITI Gp A UG OG l e D 4 1 3Cis B 1 s A 1j WF C 000000000 L L U DO BATT BATT 6 128 6 T ND AL T 140 7 0 SEM ZERO User manual Page 14 of 38 4 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 4 1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the chopper s con
39. w frequency choppers with SEM Zero modules The filter capacitors contained in the SEM Zero module will change the SCR chopper opera tion and subject it to excessive workload If it is necessary to use two or more control units eg Lift traction the choppers must be of the High Frequency Zapi family Do not connect the chopper to a battery with a different nominal voltage to the value indicated on the chopper A higher battery voltage may cause MOS failure and a lower voltage may prevent the logic operating During battery recharge the SEM Zero must be completely disconnected from the battery As well as altering the charge current read by the battery charger the mod ule can be damaged by higher than normal voltages supplied via the charger The SEM Zero module should only be supplied by a traction battery Do not use the outputs of converters or power supplies For special applications please contact the nearest Zapi service centre Start the machine the first time with the drive wheel s raised from the floor to ensure that any installation errors do not compromise safety After operation even with the Key Switch open the internal capacitors may remain charged for some time For safe operation we recommend that the battery is discon nected and a short circuit is made between Battery Positive and Battery negative power terminals of the chopper using a Resistor between 100 and 1000 Minimum 5 W The susceptibility and electromag
40. w to use the RESTORE function of the Digital Console 1 Opening Zapi Display DISPLAY p 2 Press ENTER to go into the General menu 3 The Display will show Bx ae 4 Press either ROLL UP or ROLL DOWN button until RESTORE PARAM appears on the display MAIN MENU 5 The Display will show RESTORE PARAM 6 Press ENTER to go into the RESTORE PARAM function 7 The Display shows the type of Model stored SELECT Mod 00 with a Code Number 8 Keep pressing either ROLL UP and ROLL DOWN buttons C until the desired model appears on the Display 9 The model is shown J 2 O 10 Press ENTER to commence the Restore operation 11 The Display will ask ARE YOU SURE ARE YOU SURE Press ENTER for YES or OUT for No YES ENTER NO OUT 12 Press ENTER to confirm OUT to not confirm 13 You can see the items that being stored the chopper memory whilst the RESTORE ae routine is happening 14 When finished the Console displays MAIN MENU RESTORE PARAM 15 Press OUT to return to the Op
41. ximum reverse speed Fine adjustement 14 COMPENSATION Speed compensation when load is present It reduces the difference between maximum speed laden and unladen 15 MAXIMUM CURRENT Maximum controller current 16 ARMA NOM CURR Nominal Armature Current This parameter fixes a limit for the armature current above which the Field Current is at least the Nominal Value FIELD NOM CURR regardless of accelerator position ACLZPOCB SEM ZERO User manual Page 21 of 38 17 WEAK DROPOUT This Parameter fixes a limit on the Armature Current above which the Field Current is increased linearly up to the Nominal Field Current in proportion to the armature current 18 FIELD NOM CURR Nominal Field Current This parameter fixes the minimum Field Current when the potentiometer is between 0 and 60 without total conduc tion of the Armature Adjustment should be made with reference to the Data on the Motor Label The indication of Nominal Field Current 19 CREEP SPEED Minimum Speed This Parameter sets the minimum voltage applied to the motor at the start of travel ACLZPOCB SEM ZERO User manual Page 22 of 38 5 5 TABLE OF ADJUSTMENTS The following Table shows the different values that the SEM2 Parameters may be adjusted to A suitable acceleration performance assumes FIELD CURR NOM is set to level 5 and MAX SPEED Fwd or Rev is set to level 9 PR
42. y with the machanical elements associated with the potentiometer especially relating to the minimum level Vmot Vmot Vmot Vmot A A A A A 100 100 J 5V_ 100 100 _ av 20 1A 20 10 0 L 0 J 1 108 100 BD FD 100 100 BD O FD 100 MECHANICAL ANGLE MECHANICAL ANGLE The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal aquisition being made The Right Hand Graph shows the same relationship after signal aquisition of the potentiometer ACLZPOCB SEM ZERO User manual Page 6 of 38 2 3 SAFETY amp PROTECTION FEATURES Connection Errors All Inputs are protected against connection errors Thermal Protection If the chopper temperature exceeds 70 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 80 C below 10 C the current is reduced to 80 Low Battery Charge When the battery charge is low the maximum current is reduced proportionally to the battery discharge Protection against accidental Start up A precise sequence of operations are ne
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