INSTALLATION AND USER MANUAL CHOPPER
Contents
1. CONFIG MENU SET OPTIONS Page 19 5 3 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED In addition to the Configuration Parameter settings may be made by Zapi using standard 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 operation Pay attention to the polarity of the Console Connector Refer to Page 15 of this Manual for connection details THE PROGRAMMING CONSOLE MUST BE PLUGGED ONLY WHEN THE KEY SWITCH IS OFF The following Parameters can be modified 1 DELAY Determines the acceleration ramp DECELER DELAY Determines the deceleration ramp according to the accelerator pedal position 3 RELEASE BRAKING Determines the deceleration ramp when the travel request is released 4 INVERSION BRAKING Determines the deceleration ramp when the Direction Switch is inverted during travel 5 CUTBACK SPEED 1 First speed reduction active when H amp S is active 6 CUTBACK SPEED 2 Second speed reduction active when DIGITAL INPUT2 is active 7 MAX SPEED FORW Maximum Forward Speed obtained by weakening the Field Current after it has reache2. 14 4 Programming amp Adjustments using Digital Console 15 4 1 Adjustments vid Console 15 42 Description of Console amp 15 4 3 Description of Standard Console 16 5 SEM X Cabling and Configuration 17 2 1 Power DIAN mE oo Em 17 5 2 Description of Programmable Functions Options 18 5 3 Description of Parameters that may be Programmed 20 5 4 Table of Adj sStMenisS co nn nid nan eee ne ee de 22 55 Menu E s o Repo 24 5 6 Menu Hardware Setting nine nds 24 5 9 Menu amp 1 entre 25 5 8 SEM X Traction Standard Wiring Diagrams 26 5 9 Sequence for SEM X Traction Settings 27 6 SEM X Diagnostics mee 28 6 1 Analysis of Alarms Displayed on the Console 29 6 2 Tester Description of the 32 6 3 Description of the Console SAVE Function 34 6 4 Des
3. 11 The Display shows AN MENU 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 Page 33 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 programs 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 Flow Chart showing how to use the SAVE function of the Digital Console Press ENTER to go into the General menu The Display will show Press either ROLL UP or ROLL DOWN button until SAVE PARAM is shown The Display will show Press ENTER to go into the SAVE function If this facility has been used before the type of chopper data stored appears on the top line with a 2 digit reference the second line indicates a FREE storage facility 9 Press ENTER to commence SAVE routine 10 You can see the items that are being stored whilst the SAVE routine is happening 11 When finished t
4. 1 Opening Zapi Display DISPLAY gt SEMX ZAPI 1 0 2 Press ENTER to go into the General menu KEYBOARD gt 3 The Display will show PARAMETER CHANGE 4 Press either ROLL UP or ROLL DOWN button until RESTORE PARAM appears 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 with a Code Number 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display 9 The model is shown 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 are being stored in 1 the chopper memory whilst the RESTORE bs routine is happening n 14 When finished the Console displays MAIN MENU RESTORE PARAM 15 Press OUT to return to the Opening Zapi Display Page 35 6 5 DESCRIPTION OF ALARMS MENU The microprocessor in the chopper remembers the last five Alar
5. ELECTRONIC INDUSTRIAL DEVICES 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it INSTALLATION AND USER MANUAL CHOPPER SEM X Page LEGEND de ete ce 3 COLOUR CODES Single Colours ttc mito oot ert diente nsi nto tdnts 3 1 Introduction to the ZAPI MOS Family ss 4 2 General Characteristics sense 5 2 1 Technical 5 5 5 2 2 A NI TO SUC ING 5 2 2 0 Potentiometer ices ciucnctnadasrunabindondconnteaadmsebeenuiuninicctwmntaiadeaseannentesa 6 2 3 Safety amp Protection Features 7 2 4 Direction Orientation sentiers 7 2 0 Eesti 8 26 SEM X Chopper Diagnosis 9 2 7 Thermal Considerations 9 2 8 General Instructions and Precautions 10 3 Installation 11 3 1 Connection Cables rnm 11 2 2 tendant nier 11 3 3 FUSOS 11 3 4 Description of SEM X Connectors 12 3 5 Description of Power Connections 13 3 6 Mechanical Drawing amp
6. 29 31 34 36 39 41 44 46 49 51 WEAK DROP OUT ACN 30 35 40 45 50 55 60 65 70 75 FIELD CURR NOM FCN A 6 7 72 74 76 7 8 8 0 8 2 84 8 6 88 CREEP SPEED VBatt 1 2 1 6 2 3 2 7 3 5 3 9 47 5 1 59 63 FIELD CURR MAX A 12 8 13 2 13 6 14 1 14 5 14 9 15 3 15 7 16 1 16 6 BACKING SPEED ACC 20 23 27 31 35 39 43 47 51 55 BACKING TIME sec o 0 2 0 5 0 8 1 1 1 5 1 8 22 2 6 3 0 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 motor and the operating conditions laden unladen on plane on gradient Is a percentage of the field current which is subtracted to the value defined by the parameters MAX SPEED FORW and MAX SPEED BACK Page 22 Flow Chart showing how to make Program changes using Digital Console fitted with Eprom CK ULTRA 1 2 3 4 5 6 7 8 9 Opening Zapi Display Press ENTER to go into the General Menu The Display will show Press ENTER to go into the Parameter Change facility The Display will show the first Parameter Press either ROLL UP or ROLL DOWN to display the next parameter The names of the Parameters appear on the Display When the desired Parameter appears the Display will show a Level Number that will be between 0 and 9 press
7. TIMED AUX OUTPUT 1 ABSENT PRESENT BATTERY CHECK ON OFF SET ACCEL TYPE OPTION 1 OPTION 2 BACKING FUNCTION ON OFF HANDLE SWITCH PRESENT SEAT Page 18 The counter registers travel time only The counter registers when the key switch is Closed Quick inversion is activated while the Belly Button is pressed Quick inversion is activated while the Belly Button is pressed maximum for 3 second A11 output is not used the controller carry out monitor function as described at the paragraph 2 5 A11 output drives an electromechanical brake The controller does not carry out monitor function but locks the brake while in rest or alarm status alarm indication speed reduction and current reduction when battery charge lt 20 no alarm indication no speed and current reduction with battery discharged standard 0 5V potentiometer input 5 0V potentiometer input input A9 is used as enable backing input input A9 is a speed reduction no backing function available AA is a tiller input incorrect start if it s closed at key on no delay if it is switched off A4 is a seat input no incorrect start if it s closed at key on programmable delay if it is switched off Flow Chart showing how to make changes to Configuration Menu using Digital Console Standard Eprom CK ULTRA fitted 1 2 3 4 5 6 7 8 9 Opening Zapi Menu Press Top L
8. Page 25 5 8 SEM X TRACTION STANDARD WIRING DIAGRAMS 0 1 2 3 4 5 6 7 8 9 A FIELD 68 UO A 5 EN za D Mee C ROTOR eos x 1 SEM x r gt L FUSE D DN 22 F DIAGNOSTIC LED 8 0 as A M CN kJ S 1 p P0 4 Ae PH TILLER SW TILLER SW Bi FREE 5 BELLY SW ve 4 G LNCLRXD ag EURVARD SW A 1 PCLTXD 7 BACKWARD SW Mo _NCLTXD Ag LESS A CONSOLE 2 B5 QN 9 SM Mo H B6 10 IE B7 Alt NEB REN PC Moet i B8 12 BDI less en 7 13 LOWER Woo H 4 IMC 1 14 NM 15 CY Y o 16 KEY SW Mo CH USE 7 J THIS DRAWING 15 ZAPI s p a PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE THE REPAIRS OF ZAPI PRODUCTS SEM X FUNCTIONAL DRAWING 7 Data Date Tecnico Technician AF Serie Series Disegno n Drawing Pagina Page yh LIN NL LI s p a 28 06 00 or 1 1 1 J 42028 POVIGLIO ITALY ZC UO UY Visto Visa DE ADRZP 1 Page 26 5 9 SEQUENCE FOR SEM X TRACTIO
9. 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 The SEM X 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 disconnected and a short circuit is made between Battery Positive and Battery negative power terminals of the chopper using a Resistor between 10Q and 1000 Minimum 5 W The susceptibility and electromagnetic emission 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 between the two surfaces to permit b
10. This allows interfacing with commercially available machines Zapi can offer a range of individually designed Console Software with various features and prices SEM X 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 replacement The SEM X family of Choppers are suitable for operating on DC voltages at 24V with maximum armature current up to 110A The choppers may be used to control DC Separately Excited Motors with power ratings up to 800W Page 4 2 GENERAL CHARACTERISTICS 2 1 TECHNICAL SPECIFICATIONS Chopper for Separately Excited DC motors 0 35 0 8kW Regenerative Braking 55515 nd 24VDC Maximum Field Current all the versions 35A Armature Switching Frequency 16kHz aijek ea emissis 16kHz Maximum Ambient temperature 40 C Minimum Ambient temperature nennen 30 C Maximum temperature of Chopper e 90 C VERSIONS MAXIMUM CURRENT DoD M FULL CONDUCTION 24V 90A 3 0 14V at 35A 25 C 24V 110A 2 0 14V at 35A 25 C 2 2 CONTROL UNITS 2 2 a
11. against shortcircuit A15 PMC Line contactor coil positive supply 1 0A continuous A16 KEY Controller supply must be connected to B through a cable and a 6 3A fuse PIN REFERENCE B1 B2 NCLRXD B3 PCLTXD B4 NCLTXD B5 GND B6 12 B8 3 5 DESCRIPTION OF POWER CONNECTIONS B Positive Supply from Battery B Negative Supply from Battery VMN Negative Supply via chopper to Motor F1 F2 Connections to Drive Motor Field Winding Page 13 3 6 MECHANICAL DRAWING amp DIMENSIONS 801 _ 27 A A A f N F2 B En V l DER eN lt ZAAI sra Poviglio RE ITALY ZAPI DATA LABEL D NN IN Js 16 Ve NI Page 14 4 PROGRAMMING amp ADJUSTMENTS USING 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 B connector of the SEM X Chopper Pay attention to the polarity of the Console Connector when connecting
12. and temperature The following definition listing shows the relative measurements 1 BATTERY VOLTAGE level of battery voltage measured at the input to the key switch 2 MOTOR CURRENT the current flowing in the drive motor armature 3 FIELD CURRENT the current flowing in the drive motor field winding 4 VMN the voltage effectively dropped across the MOS It is measured between B and VMN 5 TEMPERATURE the temperature measured on the aluminum heat sink holding the MOSFET devices 6 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 7 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 8 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 9 TILLER SWITCH the level of the Handle Seat Microswitch digital entry pin A4 ON VB active entry of closed seat switch OFF GND non active entry of open seat switch 10 BELLY SWITCH the level of the digital entry from Belly Button microswitch pin A5 ON VB active entry B SW closed OFF GND non active entry B SW open 11 DIGITAL INPUT 2 A9 only with option BACKING FUNCT
13. either PARAM Top Right or SET Bottom Right buttons to change the Level value 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 ARE YOU SURE 12 Press ENTER to accept the changes or Press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters 13 The Display will show DISPLAY 0 ZAPI V1 0 AV 110A 0 000 MAIN M PARAMETER ENU CHANGE ACCELE LEVE R INVER ERS BRAKING EVEL 5 INVERS LEVEL BRAKING 6 ARE YES ENTE MAIN M PARAME ER ENU CHANGE Page 23 1 2 3 4 1 2 3 4 5 6 7 5 5 MENU SPECIAL ADJUST SET TEMPERATURE Adjusts the temperature of the chopper MAXIMUM CURRENT Software adjustment of the maximum current level of the chopper It s a password protected parameter ADJ FIELD NOM FW Software adjus
14. Alarm is generated if the Capacitors are not charged within 500ms after the Key Switch is closed Probable cause is failure inside the power block VMN NOT OK AL 32 MDI 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 Page 29 8 VFIELD NOT OK AL 15 MDI 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 75 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 relative to the field 9 VACC NOT OK AL 72 MDI 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 10 PEDAL WIRE KO AL 86 MDI This Alarm is generated if potentiom
15. ECELER DELAY 0 9 RELEASE BRAKING 0 9 NVERS BRAKING 0 9 CUTBACK SPEED 1 029 CUTBACK SPEED 2 0 9 AX SPEED FORW 0 9 SET OPTIONS MAX SP FWD FINE 0 9 JAX SPEED 0 9 MAX SP BWD FINE 0 9 COMPENSATION 0 9 AXIMUM CURRENT 029 ARMA CURR NO 0 9 WEAK DROPOUT 0 9 FIELD CURR NO 0 9 CREEP SPEED 0 9 FIELD CURR MAX 029 ADJUSTMENTS BACKING TIME 029 BACKING SPEED 0 9 SEAT MICRODELAY 0 9 TESTER BATTERY VOLTAGE V MOTOR VOLTAGE V MOTOR CURRENT A FIELD CURRENT A TEMPERATURE ACCELERATOR FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF TILLER SWITCH ON OFF BELLY INVERSION ON OFF DIGITAL INPUT 2 ON OFF HARD amp SOFT ON OFF BACKING INPUT ON OFF e BATTERY CHARGE PARAMETER RESTORE PARAMETER CODE ALARMS C PROGRAM VACC VACC SETTING MIN MAX THROTTLE Y POINT 5 SEM X CABLING AND CONFIGURATION 5 1 POWER DIAGRAM m T lt T 4 a S vem CY y ES NS 2 SWI R MICR Page 17 5 2 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 KEY ON QUICK INVERSION BELLY
16. ION PROGRAMMED OFF the level of the auxiliary microswitch when used for speed reduction ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 12 BACKING INPUT A9 only with option BACKING FUNCTION PROGRAMMED ON the level of auxiliary microswitch when used as backing enable ON VB active 13 HARD amp SOFT A8 level of the HARD amp SOFT microswitch ON VB active 14 BATTERY CHARGE battery charge indication Page 32 Flow Chart showing how to use the TESTER function of the Digital Console 1 Opening Zapi Display DISD AY gt SEMX ZAPI V 1 0 Eee 24V 110A 00000 2 Press ENTER to go into the General menu KEYBOARD 3 The Display will show MAIN MENU PARAMETER CH 4 Press either ROLL UP or ROLL DOWN button until TESTER MENU appear on the display 5 The Display shows AIN MENU TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the Display BATTERY VOLTAGE 27 8V 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display E TOR VOLTAGE 0 0 9 Next variable is shown 10 When you have finished Press OUT
17. 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 f an Electromagnetic Brake is used the Key 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 Page 5 2 2 6 Potentiometer The Potentiometer should be wired in the 3 Wire Configuration CPOT A2 signal ranges from 0 to 10V Minimum Potentiometer Resistance 5000 Maximum Potentiometer Resistance 10kQ Faults can occur if the potentiometer is out of this range O NT 21 U 3 zi PO The Procedure for automatic potentiometer signal acquisition 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 asymmetry with the mechanical elements associated with the potentiometer especially relating to the minimum level mot Va Vmot not q not A LO 10 SV 1003 2 m AV 00 AV 2 Z 7 7 ZA 2 7 0 27 4 PA 224 17 g ZA Z 1 109 41205 ay p 20 Uso A A BL FD 10 BD 100 MECHA
18. N 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 chopper 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 PROGRAM VACC 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 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 INVERSION BRAKING Operate the machine at 25 full speed Whilst traveling INVERT the Direction Switch Set a soft Level of Inversion Braking When satisfactory operate the machine at Full Speed and repeat If the machine is a Forklift repeat the tests and make adjust
19. NICAL 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 acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer Page 6 2 3 SAFETY amp PROTECTION FEATURES Connection Errors All Inputs are protected against connection errors Thermal Protection If the chopper temperature exceeds 75 C the maximum current reduces in proportion to the thermal increase The temperature can never exceed 90 C below 10 C the current is reduced to 80 Low Battery Charge When the battery charge is low lt 20 and the BATTERY CHECK option is ON the maximum current is reduced to 50 and the speed is reduced of 60 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 Line Contactor will not close if The Power Unit is not functioning The Logic is not functioning perfectly Main Line Contactor Should
20. alue 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 3 4 DESCRIPTION OF SEM X CONNECTORS 2 ASST oN Poviglio RE ITALY PIN REFERENCE A1 A2 A4 TILLER A5 BELLY A6 FW A7 REV A8 H amp S A9 DIGITAL IN A10 2 DESCRIPTION Provides a negative supply to accelerator s potentiometer the circuit is designed to provide a control against wire disconnection Accelerator s potentiometer wire input Provides a positive to supply accelerator s potentiometer protected against short to B and B Tiller seat microswitch input active high B Belly switch input used for quick inversion function active high B Forward direction switch input active high B Reverse direction switch input active high B Hard amp Soft switch input active high B Digital input free for customization Page 12 PIN REFERENCE DESCRIPTION 11 NEB electric brake driver output 1 5A continuous protected against shortcircuits A12 NLED Output to drive a led 100mA max A13 A14 NMC Line contactor driver output 1 0A continuous protected
21. 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 requires that Direction Orientation should match the following drawing CN INDIETR AVANTI BACKWARD FORWARD Page 7 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 Deceleration Braking Speed Control during descent the motor speed follows the accelerator The chopper 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 When the Key Switch is closed if the motor is rotating 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 The main co
22. cription of Console RESTORE Function 35 6 5 Description of Alarms sicscisscstsscsssccdcisciecsacasctcessaadeiceaadcindesdessnesss 36 6 6 Description of Console PROGRAM VACC Function 37 7 Recommended Spare Parts for SEM X 38 8 Periodic Maintenance to be Repeated at Times Indicated 39 Page 1 SIGNED IN APPROVAL COMPANY DEPT SERVICES MANAGEMENT EXECUTIVE ENGINEERING SECTION EXECUTIVE EXPORT MANAGER Publication n ADRZPOBA Edition June 2001 Page 2 BSW CPOT EMB FORW SW H amp S HORN HORN SW LIFT SW LOW SW NEMB NEV NHORN NMC NPC NPOT PEMB PEV PHORN PMC PPC PPOT REV SW SR1 SR2 T SW LEGEND Belly Switch Common Microswitches Wiper Potemtiometer Electromechanical Brake Lowering Valve Forward Switch Hard amp Soft Horn Horn Switch Lifting Switch Lowering Switch Main Contactor Negative Electromechanical Brake Negative Lowering Valve Negative Horn Negative Main Contactor Negative Pump Contactor Negative Potentiometer Pump Contactor Positive Electromechanical Brake Positive Lowering Valve Positive Horn Positive Main Contactor Positive Pump Contactor Positive Potentiometer Reverse Switch Speed Reduction 1 Speed Reduction 2 Tiller Switch COLOUR CODES SINGLE COLOURS The following Codes repres
23. d 100 conduction of the Armature With the Parameter set at level 0 the armature is in total conduction but the field current does not decrease below the Nominal value low speed 8 MAX SP FWD FINE Maximum forward speed Fine adjustment 9 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 decrease below the Nominal value low speed 10 MAX SP BWD FINE Maximum reverse speed Fine adjustment 11 TRACTION I MAX Maximum controller current 12 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 13 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 Page 20 14 15 16 17 18 19 FIELD NOM CURR Nominal Field Current This parameter fixes the minimum Field Current when the potentiometer is between 0 and 60 without total conduction of the Armature Adjustment should be made with reference to the Data on the Motor Label The indication of Nominal Field Current CREEP SPEED Minimum Speed This Parameter sets the minimum voltage applied to the mo
24. eft amp Top Right Buttons KEYBOARD simultaneously to enter the Config Menu The Display will show Press ROLL UP Top Left Button until SET OPTIONS appears The Display will show Press ENTER to go into this part of the menu The first Option of the menu appears on the Display Press either ROLL UP or ROLL DOWN to bring up the next the Option A new 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 Option 14 The Display now shows 15 Press OUT again Display now shows the Opening Zapi Menu SEMX ZAPI V1 0 24V 110A 0000 MENU CONFIG SET MODEL SET OPTIONS CONFIG MENU HOUR COUNTER RUNNING QUICK INVERSION BELLY QUICK INVERSION TIMED ARE YOU SURE YES ENTER NO OUT
25. ent the colours of individual wires used by Zapi unless specified otherwise Orange White BB Blue C Sky Blue G Yellow GG Grey M Brown N Black R Pink RR Red Ve Green VV 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 protection The design has been derived from High Frequency Mos Technology Real 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 program 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 increasing possibilities of interaction and expansion For this reason the Zapimos family offers a standard dialogue mode with external systems
26. eter or wiring fault is detected NPOT or PPOT are open circuit 11 FWD HIGH FIELD CURR AL 90 MDI BWD HIGH FIELD CURR AL 91 MDI NO FIELD CURR AL 58 MDI 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 12 STBY HIGH AL 53 MDI 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 13 0 EVER AL 49 MDI 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 14 CONTACTOR DRIVER AL 75 MDI DRIVER SHORTED AL 74 MDI These Alarms are generated if there is a problem with the Line Contactor Possible causes a The Contactor Coil Driver is short circuit b Defect in the wiring to the contactor or logic failure Page 30 15 20 CONTACTOR CLOSED AL 37 MDI 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 pole
27. etter heat dissipation Despite the protection provided against external agents the continuous attack of corrosive 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 correctly Ensure that suppression devices are fitted to the coils not protected by the SEM 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 10mm 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 Line Contactor designed for Continuous Operation should be installed This contactor should be fitted with a coil corresponding to the battery voltage The current absorbed by the coil must not be greater than 3A Suppression for this contactor coil is within the chopper Do not use external suppression For any Contactor using external suppression ensure that connections are made respecting 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 v
28. he Console shows 12 Press OUT to return to the Opening Zapi Display Page 34 Opening Zapi Display DISPLAY gt SEMX ZAPI V 1 24V 110A 00000 Keep pressing either ROLL UP or ROLL DOWN keys until MENU R CHANGE MAIN PARAMETE Mod 00 REE Mod 01 FREE READING ACCELER D ELAY ECC PARAM MENU 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 written over and replace with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console
29. hecked every 3 months Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requirements should be made after consulting a Zapi Agent The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual During periodic checks if a technician finds any situation that could cause damage or compromise safety the matter should be bought to the attention of a Zapi Agent immediately The Agent will then take the decision regarding operational safety of the machine Remember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER Page 39
30. ments with and without load The unladen full speed condition should be the most representative condition 10 Set MAX SPEED FORW 11 Set MAX SPEED BACK Reverse 12 Set ARMA CURR NOM NOM FIELD CURR e WEAK DROPOUT Check the parameters meaning on Chapter 5 3 Page 27 6 SEM X DIAGNOSTICS The following list shows likely problems associated with the flashing RED LED N FLASHES MESSAGE ar BP NN NN a NO DD o 32 Page 28 Watch dog EEPROM KO CHECK UP NEEDED INCORRECT START FORW BACK CAPACITOR CHARGE VMN NOT OK VFIELD NOT OK VACC NOT OK PEDAL WIRE KO NO FIELD CURR FW HIGH FIELD CUR BW HIGH FIELD CURR STBY HIGH 0 EVER CONTACTOR DRIVER DRIVER SHORTED CONTACTOR CLOSED TH PROTECTION POWER FAILURE 1 EB DRIVER SHORT EB DRIVER KO BATTERY LOW NOTES Logic board and or software failure Problem with EEPROM or Logic Check up timeout 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 in FWD direction Field wiring not OK or field current sensor not OK in BWD direction High current at the stand by sensor of armature current not OK No current sensor of armature current not OK Contactor Driver not OK Contac
31. ms 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 temperature 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 OSPLAY 210 1104 00000 2 Press ENTER to go into the General menu 3 The Display will show MAIN MEN 1 PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display i MAIN MENU 5 The Display will show ALARMS 6 Press ENTER to go into the ALARMS function 7 The Display will show the most recent Alarm 00005 402 20 C 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 ALARM NULL 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu CLEAR LOGBOOK 11 The Display will ask CLEAR LOGBOOK iem 12 Press ENTER for yes or OUT for NO 13 Press OUT to retur
32. n to the Opening Zapi Display Page 36 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 DISPLAY 2 Press ENTER to go into the General Menu KEYBOA 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 The Display will show 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 8 Press ENTER to clear these values 9 Display will show 0 0 10 Select Forward Direction close any interlock switches that may be in the system 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 Item 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 Men
33. ntactor is open after 60 seconds of stand by condition Self Diagnosis with indication of fault shown via flashing Red Led without Console 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 temperature all displayed on the Console Test Function within Console for checking main parameters See the specific Description High motor and battery efficiency due to High Frequency Switching Itis possible to connect SEM X to MDI intrument Page 8 2 6 SEM X CHOPPER DIAGNOSIS The microprocessor continually monitors the chopper and carries out diagnostic procedures 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 sensors VMN point Main Contactor Driver if the switch sequence for operation is correct and if the output of the accelerator or tiller is correct Standby Diagnosis at rest that checks VMN Point Main Contactor Driver Current Sensor Watchdog Brake Vfield NPOT Diagnosis during operation that checks Watchdog VMN Point Current field and armature Main Contactor Brake NPOT Continuos Diagnosis that checks Chopper temperature Battery Voltage Diagnosis is provided in 3 ways The Red Led connected to Connector B will flash a certain n
34. s 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 microprocessor TH PROTECTION AL 62 MDI If the temperature of the chopper rises higher than 75 C this alarm is generated The chopper current is reduced in proportion to the increase in temperature At 90 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 displayed when the chopper temperature is the same as ambient or lt 10 C a Check the connection of the temperature sensor b The temperature sensor may be defective c The logic may be defective POWER FAILURE 1 AL 73 MDI Short circuit on the brake or on the main contactor coil Possible cause a failure of the logic board b wiring error c short circuit on contactor coil EB DRIVER KO AL 2 MDI The EB driver doesn t close EB DRIVER SHORT AL 91 MDI The EB driver is shorted Check the negative of the brake it may be in short circuit with B BATTERY LOW AL 66 MDI This Alarm is generated when the battery becomes 50 discharged from the nominal value Page 31 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 voltage current
35. tment of the field nominal current in forward direction It s a password protected parameter ADJ FIELD NOM BW Software adjustment of the field nominal current in backward direction It s a password protected parameter 5 6 MENU HARDWARE SETTING SET CURRENT Armature current value used by tester menu only used to calibrate the armature current displayed in the tester menu SET FLD CURRENT Field current maximum value used to calibrate field current displayed in tester menu ADJUSTMENT 01 Adjustment of the 90 threshold of the battery discharge table ADJUSTMENT 02 Adjustment of the 20 threshold of the battery discharge table AUX FUNCTION 1 Load hour meter from MDI option ON OFF Setting this option turning off the key and connecting MDI The chopper hour meter will be overwritten by MDI hour meter CHECK UP TYPE Programmable check up function 0 no check up 1 warning after HM hours 2 warning after HM hours speed reduction after HM 10 hours 3 warning after HM hours speed reduction after HM 10 hours stop of the functions after HM 20 hours CHECK UP HOURS Sets the check up alarm if enabled time HM It s a 0 9 parameter 0 HM 200 hours 9 HM 650 hours Page 24 1 2 3 4 5 7 MENU ADJUSMENT ADJUST BATTERY Sets the correct battery voltage level THROTTLE 0 ZONE Sets the pedal curve type THROTTLE X POINT Sets the pedal curve type THROTTLE Y POINT Sets the pedal curve type
36. to the chopper The bevel on the connector should be uppermost 4 2 DESCRIPTION OF CONSOLE amp CONNECTION B CONNECTOR CHOPPER 5 DISPLAY PROGRAM IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE 2 TESTER MAX SP SPEED I SPI SPEED II 3 SAVE S P I SPEED III BYPASS FIELD WEAK 4 RESTORE Mor V POT 1 TEMP V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DA A 1 3 5 1 ROLL ENTER ARAM 4 ROLL OUT SET 4 4 6 Ameri Digital Consoles used to communicate with SEM X choppers must be fitted with Eprom CK ULTRA Page 15 4 3 DESCRIPTION OF STANDARD CONSOLE MENU NOT AVAILABLE HOUR COUNTER QUICK INVERSION AUX OUTPUT 1 BATTERY CHECK SET ACCEL TYPE BACKING FUNCTION HANDLE SWITCH KEY ON RUNNING BELLY TIMED ABSENT PRESENT ON OFF OPTION 1 OPTION 2 ON OFF PRESENT SEAT THROTTLE ZONE THROTTLE X POINT ADJUST BATTERY MOTOR DATA NOT AVAILABLE Page 16 HEADING MAIN MENU ACCELER DELAY 0 9 SET MODEL 5 D
37. tor at the start of travel FIELD CURR MAX Maximum field current The chopper reaches this field current when the armature current is at the maximum value BACKING TIME Maximum backing function time BACKING SPEED Fixed speed when the backing function is active SEAT MICRO DELAY This parameter sets the time for which the seat switch opening is ignored Page 21 5 4 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 PROGRAMMED LEVEL PARAMETERS UNT 0111 2131415 6 748 9 ACC DELAY sec 0 30 0 50 0 70 0 90 1 10 1 25 1 40 1 55 1 75 2 00 DEC DELAY 6 5 4 2 1 0 RELEASE BRAKING 01 11213141 5161713819 INVERS BRAKING 01 11213141 5161713819 CUTBACK SPEED 1 20 25 31 37 43 49 55 61 67 100 CUTBACK SPEED 2 ACC 20 25 31 37 43 49 55 61 67 100 MAX SPEED FORW 100 92 84 77 70 63 56 48 42 38 MAX SP FORW FINE 0 1 2 3 4 5 6 7 8 9 MAX SPEED BACK 100 92 84 77 70 63 56 48 42 38 MAX SP BACK FINE 0 1 2 3 4 5 6 7 8 9 TRACTION 9 72 76 79 81 84 86 90 94 96 100 ARMA CUR ACN
38. tor driver shorted Line Contactor contact not OK Temperature too much high gt 70 C or low lt 10 C Shortcircuit on EB or MC coil Shortcircuit on EB driver EB driver doesn t close Battery too low 6 1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE WATCH DOG AL 8 MDI 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 EEPROM KO AL 13 MDI 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 CHECK UP NEEDED AL 99 MDI The check up type parameter is active and the time from last check up is gt 300 hours INCORRECT START AL 79 MDI Alarm generated by an incorrect Starting Sequence Possible causes a The TILLER microswitch is stuck or failed b Error in the starting sequence from the operator c Error in the wiring FORW BACK AL 80 MDI 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 CAPACITOR CHARGE AL 60 MDI This check is made during the initial diagnosis This
39. u PARAMETER CH MAIN MENU ANGE MAIN MENU PROGRAM VAC C VACC SETTING 4 8 4 VACC MIN 0 0 MAX 0 0 ARE YOU SURE YES ENTER N Page 37 Page 38 7 RECOMMENDED SPARE PARTS FOR SEM X Part Number Description C16519 C16503 C16520 C12404 C12777 C29543 Protected 150A Fuse Protected 200A Fuse 6 3A 5x20mm Control Circuit Fuse 16 Way Molex Minifit Connector Insert for Molex Minifit Connectors SW 80 24V CO Single Pole Contactor 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 test meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound 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 c
40. umber of times for a given Alarm See Listings or the Digital Console may be used or MDI A permanent Alarm will be displayed on the Console immediately An intermittent Alarm will be recorded in the Alarm library 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 situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The 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 Never combine SCR low frequency choppers with SEM X modules The filter capacitors contained in the SEM X 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 SEM X must be completely disconnected from the battery
Download Pdf Manuals
Related Search