INSTALLATION AND USER MANUAL CHOPPER
Contents
1. B D F G H K 0 1 2 BATT 3 lt cS 4 5 OTOR TEMP OL FREE1 5 99 To L o SEAT DM GT F 20 L SE g PCLRXD SRI NCLRXD pm eal 26 PCLTXD 5 l A gt s T NCLTXD 02 o2 C s GND n 91 6 70 80 GPOT y POT 92140 7 i CM AL Gta o8 a BAC eu BACK REV 05 20 4 ENABLE SR3 BRUSH SR2 o4 B 30 4 gr SERES 8 02 50 OMM W EREE2 m Hs MED CS PAUX Qu Bo L AC1ZPAOC n 09 x o1 90 9 THIS DRAWING IS A ZAPI s p a PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE TO THE REPAIRS OF ZAPI PRODUCTS CHOPPER SEM2 WIRING DIAGRAM 7 4 D Date C Serie Number Page 5 pi 42028 26 06 97 visto SE AC1ZP40D 1 1 24 5 5 SEQUENCE FOR SEM 2 TRACTION SETTINGS When the Key Swi2. 5 The Display will show the first Parameter LEVEL 4 6 Press either ROLL UP and ROLL DOWN to display 0 the next parameter a 7 The names of the Parameters appear on the Display INVERS BRAKING LEVEL 5 8 When the desired Parameter appears the Display will show a Level Number that will be between 0 and 9 press either Top Right SET Bottom Right 2 buttons to change the Level value INVERS BRAKING 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made Press OUT 11 The Display asks YOU SURE xu A 12 Press ENTER to accept the changes or Press OUT E if you do not wish to accept the changes wish E TI to make further modifications to the parameters 13 The Display will show PARAMETER CHANGE Page 23 5 4 SEM 2 TRACTION STANDARD WIRING DIAGRAMS
3. 1 Opening Zapi Display DISPLAY 2 KEYBOARD 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until HS TESTER MENU appear on the display 5 5 Display shows MAIN MENU TESTER 6 Press ENTER to go into the TESTER function 2 7 The first variable to be tested is shown on the Display x ee 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display BATTERY CHARGE 9076 9 When you have finished Press OUT E MAIN MENU 10 The Display shows TESTER 11 Press OUT again Console now shows the Opening Zapi Display 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 Page 31 6 3 DESCRIPTION OF THE CONSOLE SAVE FUNCTION The SAVE 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 chopper 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 F
4. CONSOLE BACK BACK REV ENS BLE SR3 NAUX PAUX IIAGNUSTIC LED F N LA MEN B KEY 24 FUSE BRUSH SRE O G O P C N FW e SII O v L A SEAT DM e MOTOR TEMP REE O SEAT KEY SPEED REDUCTIDN E L7 ICROSWITCHES CONSOLE Page 18 BATT 5 1 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 2 BRUSH SWITCH PRESENT The Brush Switch provides an input signal from the motor brushes OPTION 2 The Brush Switch Input may be used as a Second Speed Reduction ENABLE SWITCH PRESENT The Enable Switch provides an input from the pedal accelerator OPTION 3 The Enable Switch input may be used as a Third Speed Heduction 4 AUX FUNCTION OPTION 1 The output on Pin B6 provides a Negative
5. SEM2 ZAPI 9 Press ENTER to commence the Restore operation 10 The Display will ask ARE YOU SURE ARE YOU SURE Press ENTER for YES or OUT for No TUN ET SUR UU 11 You can see the items that are being stored in the chopper memory whilst the RESTORE 1 routine is happening 12 When finished the Console displays MAIN MENU RESTORE PARAM 13 Press OUT to return to the Opening Zapi Display Page 33 6 5 DESCRIPTION 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 oEMZ ZAPI V 1 0 1 Opening Zapi Display 24 500 00000 2 Press ENTER to go into the General menu ier MEL 3 The Display will show
6. ELECTRONIC INDUSTRIAL DEVICES 42028 POVIGLIO R E Via Pama 59 ITALIA Tel 0522 960050 r a Tlx 530021 AINDRE I Fax 0522 960259 INSTALLATION AND USER MANUAL CHOPPER SEM2 sae 3 COLOUR CODES Single 3 1 Introduction to the ZAPI MOS family 2 4 2 Generalcharaeterislie 5 201 TECHNICA SD CCIIC ANON 5 22 OONO BRI TCR Tm 5 5 22D Fe OLS MOI CTS RP TO 6 2 3 Safety amp Protection Features 7 24 DIFECTON 2 7 25 Operational Features 8 2 6 SEM2 chopper 9 Thema SOM dTa ONS NU EO IDE 9 2 8 General Instructions and Precautions 10 ME C CULru0 eee 11 e 11 11 250220820 11 3 4 Description of SEM 2 Connectors 7 12 3 5 Description of Power Connections 14 3 6 Mechanical Drawing amp Dimensions 15 4 Programming amp Adjustments using Digital Console 16 4 1 Adjustments via Console 16 4 2 Descrip
7. the machine at 25 full speed Whilst travelling 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 PEDAL BRAKING If used Operate the machine at full Speed Press the Pedal Brake Set braking level to your requirements 12 Set MAX SPEED FORW 13 Set MAX SPEED BACK Reverse 14 Set the NOM FIELD CURR Nominal Field Current of the drive motor making reference to information given on the motor nameplate 15 Set WEAK DROPOUT Field Weakening Drop Out Level according to the require ments of the application 16 If used set the levels of SEAT MICRO DELAY HYDRO TIME BACKING TIME BACKING SPEED to levels as required Parameters are described in Page 21 Page 25 6 SEM 2 DIAGNOSTICS As described in the Chopper Diagnostics on Page 9 the following listing shows likely problems associated with the Flashing RED LED N FLASHES MESSAGE 1 LOGIC FAILURE 1 MICRO ST6215 KO 1 EEPROM KO 2 INCORRECT START 2 HANDBRAKE 2 FORW BACK 3 CAPACITOR CHARGE 3 VMN NOT OK VMN 3 VFIELD NOT OK 4 VACC NOT OK 4 PEDAL WIRE KO 5 NO FIELD CUR 5 HIGH FIELD CUR 5 STBY HIGH 5 I 0 EVER 6 CONTACTOR DRIVER 6 COIL SHORTED 6 DRIVER SHORTED 6 CONTACTOR CLOSED 7 MOTOR TEMPERAT
8. PC 24V 500A 00000 2 Press ENTER tto go into the General Menu 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until L PROGRAM VACC appears on the display 5 Display will show MAIN MENU PROGRAM VACC 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown VACC SETTING 4 0 4 8 8 Press ENTER to clear these values Display will show 0 0 9 Select Forward Direction close any interlock switches that may be in the system 10 Slowly depress the accelerator pedal or tiller butterfly to its maximum value The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction 11 Select the Reverse Direction and repeat ltem 10 12 When finished press OUT 13 The Display will ask ARE YOU SURE 14 Press ENTER for yes or OUT for NO 15 Press OUT again to return to the Opening Zapi Menu MIN VACC MAX 0 4 4 4 ARE YOU SURE YES ENTER NO OUT 5 Oc Page 35 36 7 RECOMMENDED SPARE PARTS FOR SEM 2 Part Number Description
9. C16504 Protected 300A Air Fuse C16503 Protected 200A Air Fuse C16520 6 3A 20mm Control Circuit Fuse P99060 Red LED C12373 9 Way Molex Connector C12372 8 Way Molex Connector C12371 3 Way Molex Connector C12370 2 Way Molex Connector C12769 Insert for Molex Connectors C29619 SW 180 24V CO Single Pole Contactor C29610 SW 180 48V CO single Pole Contactor 8 PERIODIC MAINTENANCE TO 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 test 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
10. DS Wes 5 xe 7 a a ES9SESE Cave Gl BB B B6 A2 All O O O O DESCRIPTION Positive of Diagnostic Red Led Negative of Diagnostic Red Led BATI NIG FAN HYDRU BRUSHZSRE Output Current is 12 for this standard type Led CMM KEY Supply into logic Downstream of 10A Fuse amp Key Switch Positive Supply to Hand Brake and Brush SR2 Microswitches Positive Supply to Main Contactor Input from motor brush switch normally open or Input from second speed reduction switch normally closed Input from Hand Brake Switch normally closed Negative Output to Fan or Power Steer Contactor Coil Negative Supply to Main Contactor Battery Negative Positive Output to Potentiometer max 25 Negative Output to Potentiometer Input from Potentiometer Wiper or output of inductive device 1 2 4 5 E6 E8 9 F1 F2 G1 G2 G3 G4 G5 G6 G7 G8 L1 L2 L3 L4 L5 L6 L7 L8 L9 CMM REV FW SR1 PB SEAT MOT THERM FREE1 BATT BATT BATT PCLRXD NCLRXD PCLT XD NCLTXD Batt VL BACK FW BACK REV ENABLE
11. Page 4 2 GENERAL CHARACTERISTIC 2 1 TECHNICAL SPECIFICATION Chopper for Separately Excited DC motors 2 5 5 5kW Hegenerative Braking Voltage Range 2 24 to 48 Volts DC Maximum Field Current all the 50 Amps Armature Switching Frequency nennen nennen nnn nnn nnn 16kHz Field Switching Frequenoy 2644 0000 1kHz Maximum Ambient nennen nnne nnns 40 Minimum Ambient 30 C Maximum temperature of 85 C Resistance of field 0 nnn to 0 6W VERSION MAXIMUM CURRENT BOOSTER CURRENT OLIAGE DROP AT TOTAL CONDUCTION 24V 500A 500A 580A 0 25V at 200A 25 36V 500A 500A 580A 0 25V at 200A 25 48V 350A 350A 400A 0 25V at 100A 25 2 2 CONTROL UNITS 2 2 4 Microswitches Microswitches should have a contact resistance lower than 0 1w and a leakage current lower than 100 UA When full load current is being drawn the voltage drop across the Key Switch con tacts must be lower than 0 1V f an Electromagnetic Brake is used the Handle Microswitch must operate the Brake Coil The Microswitches send a voltage signal to the microprocessor when an operating request running is made Page 5 2 2 0 Potentiometer Potentiometer shoul
12. 7 TH PROTECTION 32 BATTERY LOW Page 26 NOTES Problem with Logic or General Contactor Problem with the Safety circuit of Microproc essor Problem with EEPROM or logic otarting sequence for travel not correct owitch Open or Failed Double Running request Problem in Power Block Problem with Chopper Problem with Field Voltage Potentiometer Wiper Voltage too High Problem in the wiring of Foot Pedal Open Circuit Field Winding or failure of the Field Current Sensor Incorrect connection of Field Winding or fail ure of the Field Current Sensor Problem with Armature Current Sensor at rest Open circuit Armature loop or problem with Armature Current Sensor Problem with a Contactor Driver in logic Short Circuit of Contactor Coil short Circuit of Driver supplying the Main Contactor Main Contactor contacts CLOSED Contacts may be welded or mechanical failure has occoured Motor Temperature Sensor has operated Thermal Protection of the chopper has occoured Temperature was either higher than 77 C or lower than 10 C Discharged Battery 6 1 ANALYSIS ALARMS DISPLAYED ON THE CONSOLE LOGIC FAILURE 1 During the initial diagnosis the main Microprocessor performs a check of the Main Contactor s control circuit and verifies the condition If this is not correct this Alarm 5 generated MICRO ST6215 KO During the initial diagnosis the main Microprocessor tests and verifies the operation
13. 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 5 D INDIETR AVANT CBACK WARDD CF LIR W AR DD Page 7 2 5 OPERATIONAL FEATURES Speed Control Optimum sensitivity at low speeds Speed Reductions both the directions Levels can be set using Console Regenerative Braking based on deceleration ramps Three different modes of Braking Release Braking Inversion Braking Speed Limit Braking Speed Control during descent the motor speed follows the accelerator The chop 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 Self Diagnosis with indicat
14. 17 MOTOR TEMPERAT The temperature of the motor has become higher than the threshold set by the motor sensor When this Alarm is generated the motor speed is reduced If this alarm appears with cold motor a Check the connection to the temperature sensor b Check that there is no problem with the temperature sensor c Check there is no problem with the motor temperature 18 TH PROTECTION If the temperature of the chopper rises higher than 77 C this alarm is generated The chopper current is reduced in proportion to the increase in temperature At 92 C the chopper totally stops If the temperature of the chopper is lt 10 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 19 BATTERY LOW This Alarm is generated when the battery becomes 5096 discharged from the Page 29 nominal value 6 2 TESTER DESCRIPTION OF THE FUNCTIONS The most important input or 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
15. MAIN MENU 4 Press ROLL UP or ROLL DOWN button until E PARAMETER CHANGE appears on the display 2 5 The Display will show CEN 6 Press ENTER to go into the ALARMS function J 7 The Display will show the most recent Alarm 00005 20 8 Each press of the ROLL UP button brings up following Alarms 22 0 Pressing ROLL DOWN returns to the most recent Uu 9 If an Alarm has not occurred the Display will show CODE ALARM NULL 00007 03 18 10 When you have finished looking at the Alarms press OUT ES to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK CLEAR LOGBOOK YES ENTER NO OUT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi Display Page 34 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 function of the Digital Console 1 Opening Zapi Display SEM2 ZAPI V 1 0
16. SR3 2 NAUX PAUX DESCRIPTION Positive Common Feed to Rev Fwd SH1 PB and Seat Microswitches Input from Reverse Direction Microswitch Active High Input from Forward Direction Microswitch Active High Input from First Speed Reduction Switch Active Low Input from Pedal Brake Switch Active High Input from Seat Switch Active High with delay Input from Motor Thermal Switch Input from any Active High Switch Battery Negative Battery Negative Battery Negative Positive Serial Reception Negative Serial Reception Positive Serial Transmission Negative Serial Transmission Negative supply to Digital Console Positive supply to Digital Console Free Free Common Supply to Fwd amp Rev Backing Switches Motor thermal switch Speed Reduction 3 Switch and 2 spare switches Input from Forward Backing Switch Active High Input from Reverse Backing Switch Active High Input from pedal accelerator Enable Active High or Speed Re duction 3 Switch Active Low Input from Free Microswitch 1 Active High Input from Free Microswitch 2 Active High Negative Output to Auxilliary Positive Output to Auxiliary Free Entry 3 Connected to CMM if J12 2 3 or to Batt if J12 1 2 through microswitch Page 13 NOTES 1 The BRUSH SR2 and HB inputs could be connected to Battery Negative B8 It is necessary to change the internal link B from 1 2 to 2 3 In this case the
17. 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 Hemember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER Page 37
18. I MAX 100 ARMA CUR NOM ACN 58 FIELD CURR NOM FCN A 21 MAX SPEED FORW FCN 30 MAX SPEED BACK FCN 30 WEAK DROP OUT ACN 80 CUTBACK SPEED 1 ACC 80 CUTBACK SPEED 2 ACC 80 CUTBACK SPEED 3 80 CREEP SPEED 21 SEAT MICRO DELAY sec 0 2 2 5 sec 0 0 5 1 0 1 6 2 2 27 3 2 3 8 44 5 0 sec 0 05 0 2 0 3 0 5 0 8 1 0 1 5 2 0 2 5 3 0 BACKING SPEED VBatt 32 40 45 52 58 65 72 78 85 90 f the current inclines to raise then also the braking time raises in order to obtain smooth braking action Therefore the duration of the braking depends on the type of motor and the operating conditions laden unladen on plane on gradient Page 22 Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA SEM2 ZAPI V1 0 V 500A 00000 CO PLAY Opening Zapi Display KEYBOARD 2 Press ENTER to go into the General Menu MAIN MENU 3 he Display will show 1 p d 4 Press ENTER to go into the Parameter Change facility ACCELER DELAY
19. Normally Closed microswitches need to be Normally Open and the Normally Open microswitches need to be Normally Closed The REV FW 5 1 PB SEAT inputs could be connected to Battery Negative E9 It is necessary to change the internal link A from 1 2 to 2 3 In this case the Nor mally Closed microswitches need to be Normally Open and the Normally Open Microswitches need to be normally Closed The MOTOR THERM BACK FW BACK REV ENABLE SR3 FREE inputs could be connected to Battery Negative F1 or F2 It is necessary to change the internal link C from 1 2 to 2 3 In this case the Normally Closed microswitches need to be Normally Open and the Normally Open Microswitches need to be Normally Closed 3 5 DESCRIPTION OF POWER CONNECTIONS Positive Supply from Battery BATT Negative Supply from Battery VMN Negative Supply via chopper to Motor F1 F2 Connections to Drive Motor Field Winding Page 14 3 6 MECHANICAL DRAWING DIMENSIONS 150 E 147 _ 4 EN ip AL PHS SH lt 52 de S 1505 wl CIS EN PHS ep uni O 2 gt 25 15 4 PROGRAMMING amp ADJUSTMENTS USI
20. of the safety microprocessor If not correct this Alarm is generated Possible causes a Failure of the safety Microprocessor b The safety Microprocessor has established a condition of danger and has disa bled operation of the Main Contactor EEPROM KO 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 INCORRECT START Alarm generated by an incorrect Starting Sequence Possible causes a The ENABLE microswitch has welded or failed b Error in the starting sequence from the operator c Error in the wiring HANDBRAKE Hand Brake Switch operated during travel FORW BACK This check is made continually The Alarm is generated when forward and reverse directions are requested simultaneously Possible causes a Incorrect Wiring b Welding or Failure of a direction switch Incorrect operation from the operator 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 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
21. protection The design has been derived from High Frequency Mos Technology Heal time control over the internal and external components that influence the behavior 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 systems This allows interfacing with commercially available machines Zapi can offer a range of individually designed Console Software with various features and prices SEM 2 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 family of Choppers are suitable for operating on DC voltages from 24 to 48V inclusive with maximum armature current up to 350A The choppers be used to control DC Separately Excited Motors with power ratings up to 5 5kW
22. 2 BATTERY CHARGE the percentage Charge level of the battery 3 MOTOR VOLTAGE the voltage appearing across the drive motor It is measured between B4 and VMN 4 MOTOR CURRENT the current flowing in the drive motor armature 5 FIELD CURRENT the current flowing in the drive motor field winding 6 VMN the voltage effectively dropped across the MOS It is measured between BATT and VMN 7 TR CHOPPER TEMP the temperature measured on the aluminum heat sink holding the MOSFET devices 8 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 9 FORWARD SWITCH the level of the Forward direction digital entry MA pin E3 ON VB active entry of closed switch OFF GND non active entry of open switch 10 BACKWARD SWITCH the level of the Reverse direction digital entry MI pin E2 ON VB active entry of closed switch OFF GND non active entry of open switch 11 ENABLE SWITCH the level of Enable Switch digital input ON VB active entry of closed switch OFF GND non active entry of open switch 12 SEAT SWITCH the level of the Seat Microswitch digital entry pin E6 VB active entry of closed seat switch OFF GND non active entry of open seat switch 13 HAND BRAKE the level of the Handbrake Microswitch pin B5 ON VB active entry of Handbrake sw
23. EED FORW 0 9 AX SPEED BACK 0 9 WEAK DROPOUI 0 9 CUTBACK SPEED 1 0 9 CUTBACK SPEED 2 0 9 CUTBACK SPEED 0 9 CREEP SPEED 0 9 SEAT MICRO DELAY 0 9 HYDRO TIME 0 9 ADJUSTMENTS BACKING TIME 0 9 BACKING SPEED 0 9 BATTERY VOLTAGE V BATTERY CHARGE 76 OTOR VOLTAGE V OTOR CURRENT A FIELD CUIRREN A VMN V TR CHOPPER TEMP C ACCELERATO V Z FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF ENABLE SWITCH ONZ OFF SEAT SWITCH ON OFF HANDBRAKE ON OFF CUTBACK SWITCH 1 ON OFF CUTBACK SWITCH 2 ON OFF CUTBACK SWITCH 3 ON OFF BRAKE SWITCH ON OFF BACKING FUNCTION ON OFF OTOR TEMPERAT ON OFF CODE VACC SETTING MIN MAX NOT AVAILABLE NOT AVAILABLE HOUR COUNTER EY ON RUNNING BRUSHES SWITCH PRESENT OPTIONJZ2 ENABLE SWITCH PRESENT OPTION AUX FUNCTIO HYDRO CONTACTOR OPTION 1 SET BATTERY TYPE 24V 48V NOT AVAILABLE Page 17 3 Speed Reductions 5 SEM2 TRACTION Input for 3 Wire Potentiometer Input for Motor Thermal Switch Input for Tiller Switch or Seat Switch delayed Input for Brake Pedal Microswitch Management of Backing Speed Programmable
24. NG DIGITAL CONSOLE 4 1 ADJUSTMENTS VIA CONSOLE Adjustment of Parameters and changes to the chopper s configuration are made using the Digital Console The Console is connected to the connector of the SEM 2 Chopper LN 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 G G CONNECTOR l i SEM2 CONTROLLER CONSOLE CONNECTOR DISPLAY PROGRAM IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE S SP SPEED I S P SPEED 1 3 SAVE SPI SPEED 1 BYPASS FIELD WEAK 4 RESTOR EU TEMP V BATT 9 ALARMS V MOT VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DATA IT 3 ROLL ENTER PARAM BUT TONS 9 u ROLL OUT SET el Azar Digital Consoles used to communicate with SEM2 choppers
25. d wired in the 3 Wire Configuration CPOT A2 signal ranges from O 10V Minimum Potentiometer Resistance 500w Maximum Potentiometer Resistance 10kw Faults can occour if the potentiometer is out of this range oe AME FEDAL 5 WIRE TILLER MAX Ow MAX e C3 CPOT HA c3 d MIN Ik MAX c2 C C2 The Procedure for automatic potentiometer signal aquisition is carried out using the Console This enables adjustment of the minimum and maximum useful signal level in either direction This function is unique when it is necessary to compensate for asym metry with the machanical elements associated with the potentiometer especially relating to the minimum level Vrmuor Vace Voce Vict Vrat Voce Vace Vmet 109075 av 10075 aw 12222 av 100 4 ZA 20 YA 0 HOM 0 754 175 4 100 100 10055 MA 100 ANGOLO MECCANICO ANGOLO MECCANICO 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 m
26. d 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 is available via the RESTORE PARAM function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS he 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 how tto use the RESTORE function of the Digital Console 1 Opening Zapi Display DISPLAY 4220 2 Press ENTER to go into the General menu evgoagp H 9 Li 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until I B RESTORE PARAM appears on the display LU MAIN MENU 5 The Display will show 2 22 2 6 Press ENTER to go into the RESTORE PARAM function 7 Display shows the type of Model stored d with a Code Number 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display SELECT Mod 01
27. e accelera tor pedal position RELEASE BRAKING Determines the deceleration ramp when the travel request is released PEDAL BRAKING Determines the deceleration ramp when the brake pedal is operated during travel INVERSION BRAKING Determines the deceleration ramp the the Direction owitch is inverted during travel TRACTION IMAX Maximum Current of the Chopper A 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 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 MAX SPEED FORW Maximum Forward Speed obtained by weakening the Field Current after it has reached 10096 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 MAX SPEED BACK Maximum Reverse Speed obtained by weakening the Field Current after it has reached 10096 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 WEAK DROPOUT Th
28. echanical 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 The aquisition procedure is disabled if the potentiometer wiper output does not reach a minimum of 3 V If a centre tapped potentiometer is not available it is possible to use a standard 3 wire pot set in the middle of its full stroke Page 6 2 3 SAFETY amp PROTECTION FEATURES Connection Errors All Inputs are protected against connection errors Thermal Protection If the chopper temperature exceeds 80 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 85 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 necessary 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 Main Contactor will not close if Power Unit is not functioning he Logic is not functioning perfectly Main Contactor should be fitted to give protection to the chopper against reverse battery polarity and safety External Agents
29. ected from the bat tery As well as altering the charge current read by the battery charger the module can be damaged by higher than normal voltages supplied via the charger SEM2 module should only be supplied by a traction battery Do not use the outputs of convertors 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 10w and 100w Minimum 5 W he susceptibility and electromagnetic 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 Page 10 3 INSTALLATION Install the chopper baseplate onto a flat metallic surface that is clean and unpainted Apply a thin layer of thermo conductive grease betwe
30. en 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 Horn Solenoid Valves the coils of any relays and contactors not supplied by logic or the chopper 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 25 to 35mm section For the Field connections use cable of 4mm section For the optimum chopper performance the cables to the battery should be run side by side and be as short as possible 3 2 CONTACTORS A Main 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 ouppression for this contactor coil is within the chopper Do not use external suppres sion If contactors for power steer motors are supplied from the control logic the sup pression will be inside the chopper logic Fo
31. he 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 I HIGH Check the motor armature brush connections HIGH FIELD CURR NO FIELD CUR Problem detected with the field winding current Possible causes a Tailure of the field current sensor b C d e Field cables not connected or incorrectly connected Open circuit Field Winding Failure of the Field Power Unit eS 2 The Alarm No FIELD CURR could also be generated if the safety microprocessor detects a problem CONTACTOR DRIVER COIL SHORTED DRIVER SHORTED These Alarms are generated if there is a problem with the Main Contactor Possible causes a the coil of the contactor is either 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 Page 28 16 CLOSED This check is made during the initial diagnosis With the coil of the Contactor de energised the capacitors should not be charged unless there is divert resistor across the power poles Possible causes a The contactor power poles are welded b This alarm could be generated if the Main Contactor has opened but there is a problem with either the field circuit or a problem detected by the safety micro processor
32. ion of fault shown via flashing Red Led In addition to Console Display Modification of the parameters via Digital Console See the specific description nternal 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 Presence of a second microprocessor for safety that monitors the CPU that controls the motor Page 8 2 6 SEM2 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 Diagnosis on key Switch closing that checks the Watch Dog Circuits the current sensor VMN point Contactor Drivers the switch sequence for operation is correct and the output of the accelerator or tiller is correct 2 Standby Diagnosis at rest that checks VMN Point Contactor Drivers and Current Sensor 3 Diagnosis during operation that checks Watchdog VMN Point Current Contactor s and VMN when in full conduction 4 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
33. is 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 CUTBACK SPEED 1 First Speed Reduction CUTBACK SPEED 2 Second Speed Reduction This Parameter is configured in the SET OPTION Menu CUTBACK SPEED 3 Third Speed Reduction This Parameter is configured in the SET OPTION Menu Page 21 15 CREEP SPEED Minimum Speed This Parameter sets the minimum voltage applied to the motor at the start of travel 16 SEAT MICRO DELAY Delay time after Seat Microswitch has opened 17 HYDRO TIME Operating time for Steering Contactor after controller has oper ated This Parameter is configured in the SET OPTION Menu 18 BACKING TIME Operation time of the BACKING Function 19 BACKING SPEED Drive Motor Speed during the BACKING function The chart on Page 23 shows the different values to which the parameters may be adjusted 5 3 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 PARAMETERS PROGRAMMED LEVEL UNT 1 2 3 4 5 6 7 8 9 DELAY 22 0 6 0 9 133 1 6 1 9 2 8 3 1 DEC DELAY 9 RELEASE BRAKING 9 PEDAL BRAKNG 9 INVERS BRAKING 9 TRACTION
34. itch OFF GND non active entry of microswitch 14 CUTBACK SWITCH 1 the level of the Speed Reduction 1 Microswitch pin E4 ON 12 active entry of speed reduction microswitch OFF GND non active entry of microswitch 15 CUTBACK SWITCH 2 the level of the Speed Reduction 2 Microswitch pin B4 ON 12 active entry of speed reduction microswitch OFF GND non active entry of microswitch Page 30 16 CUTBACK SWITCH 3 the level of the Speed Reduction 3 Microswitch Pin L4 ON 12 active entry of speed reduction microswitch OFF GND non active entry of microswitch 17 BRAKE SWITCH the level of the Pedal Brake Microswitch pin E5 VB active entry of Brake pedal microswitch OFF GND non active entry of microswitch 18 BACKING FUNCTION the level of the Backing Microswitch inputs pins L2 or L3 VB active switch entry OFF GND non active switch entry 19 MOTOR TEMPERAT the level of the Motor Temperature Sensor pin E7 ON VB temperature of the motor is too high OFF GND temperature of the motor within the limits Sensor is not operating Flow Chart showing how to use the TESTER function of the Digital Console
35. low Chart showing how to use the SAVE function of the Digital Console 1 Opening Zapi Display DISPLAY SEM ZAPI 1 0 2 Press to go into the General menu KEYBOARD gt 9 M 3 Ihe Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the display 2 5 Display will show MAIN MENU SAVE PARAM 6 Press ENTER to go into the SAVE function of chopper data stored appears on the top Main with a 2 digit reference 7 If this facility has been used before the type 8 Keep pressing either ROLL UP or ROLL DOWN keys until the second Main indicates a FREE storage facility QO 2 SELECT Mod OO FREE SELECT Mod O1 FREE 9 Press ENTER to commence SAVE routine 10 You can see the items that are being stored whilst the SAVE routine is happening READING ACCELER DELAY ECC 11 When finished the Console shows MAIN MENU SAVE PARAM 13 Press OUT to return to the Opening Zapi Display Page 32 6 4 DESCRIPTION OF CONSOLE RESTORE FUNCTION The RESTORE PARAM function allows transfer of the Console s store
36. 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 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 he thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle Page 9 2 8 GENERAL INSTRUCTIONS AND PRECAUTIONS 7 Never combine SCR low frequency choppers with SEM2 modules The filter capaci tors contained in the SEM2 module will change the SCR chopper operation 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 SEM2 must be completely disconn
37. must be fitted with Eprom CK ULTRA Page 16 4 3 DESCRIPTION STANDARD CONSOLE MENU G AMETE HANGE SAVE PA AME T AJ ALARMS ROG AM VACC MOTOR DATA FADING MAIN MENU ACCELER DELAY 0 9 SET MODEL DECELER DELAY 0 9 RELEASE BRAKING 0 9 PEDAL BRAKING 0 9 VERS BRAKING 0 9 RACTIO MAX 0 9 ARMA CU NOM 0 9 OPTIONS FIELD CURR NOM 0 9 SP
38. of safety SIGNED IN APPROVAL COMPANY DEPT SERVICES MANAGEMENT EXECUTIVE EXPORT MANAGER ENGINEERING SECTION EXECUTIVE BEEN Publication No AC1ZPOCA Edition Aprile 1998 Page 2 BACK FW BIG CMM CPOT FORW HB KEY NAUX NPOT PAUX PB PPOT HEV SH1 SR2 TG VMN LEGEND Inching forward direction switch Inching reverse direction switch Main Contactor Coil Common Feed to Microswitches Potentiometer Wiper Forward switch Handbrake switch Key switch input Negative supply for auxiliary load Potentiometer Negative supply Positive supply for auxiliary load Brake pedal switch Potentiometer Positive supply Reverse switch input Speed Reduction 1 Microswitch Speed Reduction 2 Microswitch Main Contactor Voltage to Negative of Motor COLOUR CODES SINGLE COLOURS The following Codes represent the colours of individual wires used by Zapi Unless specified otherwise A B BB Orange White Blue Sky Blue Yellow Grey Brown Black Pink Red Green Purple Page 3 1 INTRODUCTION TO 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
39. r SET Bottom Right button to change the configuration 11 The new Configuration for the selected Option appears on the Display a G 12 Press OUT to exit the Menu a 13 Press to accept the changes ARE YOU SURE or Press OUT if you do not accept the YES ENTER NO OUT changes and wish to make further modifications to the particular Option E H 2 14 The Display now shows 15 Press OUT again Display now shows e z the Opening Zapi Menu If any changes are made to the Configuration it is necessary to Open and Re Close the Key Switch before the Display will show the new stored changes Page 20 5 2 DESCRIPTION PARAMETERS THAT MAY 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 Parameters be modified in real time during opera tion Pay attention to the polarity of the Console Connector Refer to Page 16 of this Manual for connection details The following Parameters can be modified 1 2 10 11 12 13 14 ACC DELAY Determines the acceleration ramp DECELER DELAY Determines the deceleration ramp according to th
40. r any Contactor using external suppression ensure that connections are made re specting correct polarity 3 3 FUSES Use a 6 3A Fuse for protection of the auxiliary circuits For protection of the power unit refer to diagrams The Fuse value shown is the maximum allowable For special applications or requirements these values can be reduced For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow Page 11 VMN EI UJ PIN A1 A2 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 PLED NLED KEY CMM PIG BRUSH SR2 HB FAN HYDRO NIG BATT PPOT NPOT CPOT Page 12 3 4 DESCRIPTION OF SEM 2 CONNECTORS be G7 Iu btt b3 Ge G1 Fe r1 O O O O O O O O O O O Q 0 OC O O V gt i L ku dus CU I x ox d XxX Ld dd v f J D da dud lt d lt lt I lt Y IT Y Y p ub xe WE t Ju du
41. supply to a fan HYDRO The output on Pin B6 provides a Negative supply to the coil of a steering Contactor 5 SET BATTERY TYPE This option allows selection of the Nominal Battery Volt age Page 19 Flow Chart showing how to make changes to Configuration Menu using Digital Con sole Standard Eprom CK ULTRA fitted SEM2 ZAPI V1 0 DISPLAY 24V 500A 0000 1 Opening Zapi Menu 2 Press Top Left amp Top Right Buttons E 2 simultaneously to enter the Config Menu L L 3 The Display will show 2 4 Press ROLL UP Top Left Button until OD Uc SET OPTIONS appears E 5 The Display will show SEL ORTON Tr 6 Press ENTER to go into this part of the menu I 7 The first Option of the menu appears BATTERY CHECK on the Display OFF 8 Press either ROLL UP or ROLL DOWN to bring 2 up the next the Option 2 9 new Option appears on the Display HOUR COUNTER 10 When the desired Option is displayed press gu 6 PARAM Top Right o
42. tch 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 1 Select the Options required Page 19 2 Select and set the Battery Voltage 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the accelerator signal aquisition procedure using the Console PROGRAM Procedure is detailed on Page 36 5 Setthe TRACTION IMAX Current taking into account any Boost requirements Use Table on Page 23 6 Set the Acceleration Delay requirements for the machine Test the parameters in both directions 7 Set the CREEP level starting from level 0 The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 8 Set the Speed Reductions as required Make adjustments to 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 9 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
43. 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 Frame fault of motor to chassis C Defect in the power unit Page 27 9 10 11 12 13 14 15 VFIELD NOT This test is made at standby with the Main Contactor open this condition the voltage 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 a Frame fault on the motor to chassis b Incorrect connection of the field winding to the chopper C Failure of the chopper in the section 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 Possible causes a The track of the potentiometer has become open b The potentiometer is not wired correctly d The values set in PROGRAM routine have not remained or made cor rectly 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 c The potentiometer itself is defective a Defective current sensor b Logic failure First replace t
44. tion of Console amp Connection 16 4 3 Description of Standard Console 17 S OEM ra CUO 18 5 1 Description of Programmable Functions Options 19 5 2 Description of Parameters that may be Programmed 21 2202 Table Ol 22 5 4 SEM 2 Traction Standard Wiring Diagrams 23 5 5 Sequence for SEM 2 Traction Settings 222 24 6 m inean 26 6 1 Analysis of Alarms displayed on the Console 27 6 2 Tester Description of the Functions 30 6 3 Description of the Console SAVE 32 6 4 Description of Console RESTORE Function 33 6 5 Description of Alarms MenU popuU APR UEM EG 34 6 6 Description of Console PROGRAM function 35 Page 1 7 Recommended Spare parts for SEM 2 36 8 Periodic Maintenance to be repeated at times indicated 37 AN The information contained in the paragraphs marked with this symbol is essential for the purpose
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