4Q CONTROLLER OPERATING AND USER MANUAL
Contents
1. RI SET MODEL MODEL TYPE OPTIONJH OPTION 2 CHANGE DECELER DELAY 0 9 ELEASE BRAKING 0 9 VERS BRAKING 0 9 CUTBACK SPEED 1 5 9 A V CUTBACK SPEED 2 0 9 gt AX SPEED FORW 0 9 _ HOUR COUNTER EY ON RUNNING SET OPTIONS SPEED BACK 0 9 i BATTERY CHECK ON OFF A A TRACTION MAX 0 9 NI QUICK INVERSION BELLY TIMED V CREEP SPEED 0 9 NVERSION MODE OPTION 1 OPTION 2 AUXILIARY TIME 0 9 SET BATTERYT TYPE 24V 36V HIDRO TIME 0 9 AUTOMATIC FUNT ON2. O 1 e 3 4 zi 6 Z 8 9 RACT ION gt UR AN NI FUSE i B A AG F 2221 A1 P Ac AA SW Y W R 5 4 na i XL A6 F WARD SW A 5 is 7 BACKWARD SW Mo Ra SPEFD PED SND m a SPEED RED Z 5 7 s EV 10 VO 87 R 11 PEV 4 1 K Ale o 13 E Vl YS PER 14 15 x EB AND EVe ARE MUTUALLY EXCLUSIVE KEY SW 2 16 Mo FUSE TED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THIS DRAWING IS A s p a PROPERTY ITS REPRODUCTION IS PROHIB AT RELATIVE TO THE REPAIRS OF ZAPI
3. y DON T USE THE gt HOUR COUNTER EY ON RUNNING BATTERY CHECK ON OFF AUX OUTPUT 1 FREE BRAKE OPTION 1 OPTION 2 QUICK INVERSION BELLY TIMED BACKING FUNCTION ON OFF HANDLE SWITCH PRESENT ABSEN N N AUX OUTPUT 2 OPTION 1 OPTION 2 SET INPUT 2 OPTION 1 OPTION 2 INVERSION MODE OPTION 1 OPTION 2 AUX FUNCTION 42 OPTION 1 OPTION 2 SET BATTERY TYPE 24V 36V m gt ROTTLE O ZONE ADJUSTMENTS OE Y ZONE L9 ROTTLE Y ZONE ADJUST BATTERY V A WITH THIS TWO BUTTONS THE USER CAN SET Y THE AVAILABLE OPTION HARDWARE gt SET CURRENT A SETTING J ADJUSTMENT 01 V ADJUSTMENT 02 V AUX FUNCTION 1 ON OFF CHECK UP DONE ON OFF VW CHECK UP TYPE NONE OPTION 1 OPTIONZ2 SPECIAL gt SET TEMPERATURE ADJUST MAXIMUM CURRENT N ZA s gt gt DON T USE IF NOT NECESSARY DIV OTHER SUBMENU S Sp 3 2 b Floor washer HEADING AN N
4. ACCELER DELAY 0 9 DECELER DELAY 0 9 RELEASE BRAKING 0 9 VERS BRAKING 0 9 CUTBACK SPEED 1 0 9 CUTBACK SPEED 2 0 9 MAX SPEED FORW 0 9 MAX SPEED 0 9 MAX 0 9 CREEP SPEEU 0 9 BACKING TIME 0 9 BACKING SPEED 059 SEAT MICRO DELAY 0 9 HIDRO TIME 0 9 A V gt BATTERY VOLTAGE V p VMN V OTOR CURRENT A TEMPERATURE gs ACCELERATOR FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF TILLER SWITCH ON OFF CUTBACK SWITCH 1 ON OFF V CUTBACK SWITCH 2 ON OFF BELLY SWITCH ON OFF BACKING INPUT ON OFF TOGGLE INPU ON OFF BATTERY CHARGE z SAVE gt i PARAMETER A MN BESTORE gt MODEL N PARAMETER AIV gt ALARM gt ALARMS h b I gt SETTINGS ROGRAM VACC v uv gt MOTOR DATA NOT AVAILABLE Page 14 SET MODE T AW MODEL OPTIONJH OPTION 2
5. ELECTRONIC INDUSTRIAL DEVICES 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 39 0522 960050 Fax 39 0522 960259 e mail zapi zapispa it 4Q CONTROLLER OPERATING AND USER MANUAL Main features 3 1 1 Field Of APDUCANOM 3 Jo Ore aire ESI 4 VZAME OSNO NEO exstet uuu MU EINE D dE TN MU FK PEINE 4 1 2 D TOTO DUO TIO OE ee 4 1 2 Safety EE 5 1 4 Operating TUNCIONS u uuu uu na 6 To CGoniollerd rO SIS omo 6 16 Thermal COM SIGS FANOINS uuu o TM 7 1 7 General warnings precautions A 7 5 CAN eg u nuan 8 2 1 Choice Of connecting cables 8 22 EI MA eee 8 2 3 Description of connectors ener 9 ZF Dle pi u uu au O a 10 11 VY u en eee 11 DAO IO u A 12 Console 13 3 1 Programming with the console 13 o CON SOIS Uem 14 J j el TIC A aaa nara 14 uuu uuu eo a EE aaa bo eG 15 teser MENU serrer EE EAE 16 j PO UI Cu x E ERU DEDE 16 sie Was
6. 16 3 4 Parameter Change Menu 17 Pall IL C VREME RE AE 17 SD FO WOON renina 17 JO Set Model uu u 18 9 6 ODIO MENU u u u u u uu uu 18 JO jo 18 DODANO 20 AG II MONU 21 3 8 Hardware Setting Menu 22 9 9 pecial Men uu k u 23 Clear EBDIOIn Ment uuu uuu u u uu u u a ae eee 23 PI lil PRETERITO 24 DIAGNOSIS TETTE 24 Recommended spare parts for the 40 27 Regular maintenance at set intervals 28 Page 1 ZN The informations included into the marked paragraphs by this symbol essential for the safety SIGNATURES TABLE COMPANY DEPT SERVICES MANAGEMENT EXECUTIVE Publication N ADMZPODA Edition November 2001 Page 2 1 MAIN FEATURES The 40 is the smallest permanent magnet motor controller it is designed for use at 24Vor 36V with a maximum armed current of 70A or 90 The controller is constructed with a full bridge no changeover necessary 1 1 FIELD OF APPLICATION Power 500W 800W Voltages 24V 36V Max current TOA 90A Continuos current 30A The
7. Adjust Battery Page 23 1 2 3 4 9 6 7 4 ALARMS 4 1 DIAGNOSIS POWER FAILURE 1 AL 73 MDI 1 LED FLASH Short circuit on main relay or on auxiliary outputs NEV1 NEV2 CAPACITOR CHARGE AL 60 MDI 3 LED FLASHES This alarm is signalled if the capacitors have not begun re charging after a certain amount of time has lapsed Possible causes fault in the potentiometer unit DRIVER SHORTED AL 74 MDI 6 LED FLASHES Short circuit on driver of main relay VMN NOT OK AL 32 MDI 3 LED FLASHES Test at rest with the main relay open and running If the VMN is very low and the main relay is open the chopper goes into alarm When running an alarm is signalled if the VMN does not move from the half battery value according to the direction of the duty cycle for forward running the VMN value should go from Vbaitt 2 to zero in reverse the VMN should go from Vbatt 2 to Vbatt Possible causes a incorrect motor connection b motor leak to earth fault in power unit STBY HIGH AL 53 MDI 5 LED FLASHES Test during initial diagnosis and at rest with main relay open Check to ensure that current signals are nil If not the chopper goes into alarm and prevents machine functions Possible causes a faulty current sensor b fault in the feedback circuit in the logic or in the power board LOW BATTERY AL 66 MDI 32 LED FLASHES Reduces the traction current to Imax 2 The low battery alarm is activated when th
8. OFF N AUT FUNCTION ON OFF ANNI AUX FUNCTION 2 gt 1 2 OPTION 3 gt BATTERY VOLTAGE V lt VMN V OTOR CURRENT A gt MPE i ROTILE O ZONE d ADJUSTMENTS A ACCELERATO V Z 2 RO E X ONE FORWARD SWITCH ON OFF VW BACKWARD SWITCH ON OFF ADJUST BATTERY 22 HYDRO SPEED REQ ON OFF CUTBACK SWITCH 1 ON OFF NV N CUTBACK SWITCH 2 ON OFF v BELLY SWITCH ON OFF A BATTERY CHARGE 2 WITH THIS TWO BUTTONS THE USER CAN SET THE AVAILABLE OPTION Y SAVE gt HARDWARE 3 SET CURRENT A PARAMETER 7 SETTING ADJUSTMENT 401 ADJUSTMENT 402 5 AIV AUX FUNCTION 1 ON OFF gt CHECK UP DONE ON OFF V RESTORE ENE CHECK UP TYPE NONE OPTION 1 MODEL N PARAMETER A V 2 OPTION 3 w gt ALARM gt SPECIAL gt SET TEMPERATURE A n ADJUST MAXIMUM CURRENT V gt gt LN PROGRAM VACC ds DON T USE IF NOT NECESSARY N VW NOT AVAILABLE MOTOR DATA DONT USE THE OTHER SUBMENU AN S Page 15 3 3 a Pallet truck BATTERY VOLTAGE VMN MOTOR CURRENT TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH TILLER SWITCH CUTBACK SWITCH 1 CUTBACK SWITCH 2 BELLY SWITCH BACKING INPUT TOGGLE INPUT BATTERY CHARGE 3 3 b Floor washer BATTERY VOLTAGE VMN MOTOR CURRENT TEMPERATURE ACCELERATOR FORWARD SWITCH BACKWARD SWITCH HYDRO SPEED REO CUTBACK SWITCH 1 CUTBACK SWITCH
9. PRODUCTS 40 FUNCTIONAL DRAWING FOR TRANSPALLE V A Data Date Tecnico Technician SD Serie Series Disegno n Drawing n Pagina Page V4 77 S D O bdi 42028 20 03 00 Visto Visa ui ADMZPTAB 1 1 Page 11 2 5 b Floor washer O 1 E 4 5 6 8 2 A IRACTILN B 9 NIA 2 d FUSE D A E WA A A o DOO 1 Ac A3 G V HYDRO SPEED REG met BELLY SW B1 d RE E 5 Ko C RWARD SW po
10. Quick inversion is active while the button remains Timed inversion set duration The quick inversion input is configured as normally open The quick inversion input is configured as normally closed To be defined The NEV2 output is active during running and is disengaged with a programmable delay time The output is always disengaged when a low battery alarm is present The tiller seta switch is not used by cleaning machine so the input can be used for other purpose Option 1 Option 2 Page 20 The Tiller Seat input is a switch that activates the NEV1 output When the switch is opened the output is disengaged with a delay time that is programmed by the Hydro Time parameter The Tiller Seat input is a button that activates the NEV1 output when pressed once Pressing a second time disengages the output with a delay time that is programmed by the Hydro Time parameter Option 3 If the Tiller Seat input is activated without traction it activates NEV1 for a duration that is programmed by the Hydro Time parameter If the input is activated with traction then the NEV1 output is permanently active lf traction stops NEV1 remains active for a certain length of time that can be programmed by the Hydro Time parameter If the Tiller Seat input is disengaged NEV1 disengages immediately The low battery alarm disengages NEV1 used to drive brushes Set battery type Sets the battery nominal value
11. acts as a hydro it is active during running and is set at rest with a programmable delay time after running The NEV1 output is activated when a thermal alarm is present e s can be used to activate a fan The Aux output 2 and Backing function options can be used The Aux output 2 and Backing function options have no effect The RV2 input is not a speed reduction but is used as a button Toggle the NEV1 output is activated by an RV2 impulse and disengaged by a second impulse The quick inversion input is configured as normally open The quick inversion input is configured as normally closed The potentiometer is configured with an electric range of OV 5V Forward and backward micros are present The potentiometer is configured with an electric range of OV 2 5V 5V 2 5V is the at rest value Forward and backward micros are not used the direction is given by the voltage on the potentiometer unit 2 5V BV backward Page 19 Set battery type Sets the battery nominal value 24V 36V 3 6 b Floor washer Hour counter Running Key on Battery check Off On Quick inversion Belly Timed Inversion Mode Option 1 Option 2 Automatic function Off On Aux function 2 24V 36V battery The hour counter is active during running only The hour counter is active at all times Battery alarm disengaged Low battery alarm enabled plus current limiting device
12. following inputs are foreseen tiller seat microswitch quick inversion forwards reverse potentiometer with 3 wires speed reduction 1 speed reduction 2 The controller has 2 outputs EV1 solenoid valve EV2 electric brake The main contactor relay is internal The 4Q controller can be configured in two different ways Pallet truck Model 1 Floor washer Model 2 The parameters tester and options may vary according to the model chosen with ZAPI console Page 3 1 2 CONTROL UNITS 1 2 a Microswitches A contact resistance of less than 0 10 and a current leakage of less than 1001 is required Thekey contact must be able to take all the current of the loads without causing a voltage drop of more than 01 V between contacts Send voltage signal to the microchip when a function is requested e g start running 1 2 b Potentiometer Potentiometer configured with 3 wires The CPOT range varies from 0 to 10V Minimum resistance 500 Q Maximum resistance 10KQ 3 WIRES e Wikes LH B3 PPOT B3 PPOT MAX MAX _ _ T 5 ia O B1 CPOT O lt O B1 CPOT d MIN MAX B2 NPOT C B2 NPOT Automatic minimum and maximum signal acquisition must be carried out PROGRAM VACC function usin
13. taken into consideration when choosing where to install the chopper on the vehicle Secure the chopper using the pre drilled holes on the aluminium fixing plate Check to make sure that the cable terminals and connectors are wired correctly Remember to install a snubber circuit on the horn relays solenoid valves and electromagnetic switches not connected to the chopper such as the motor pump contactor 2 1 CHOICE OF CONNECTING CABLES Use cables with a cross section of 0 5mm for auxiliary circuits Use 6mm cables for power connections to the motor and to the battery The cables connecting the chopper to the battery should be laid side by side and be as short as possible 2 2 FUSES Use a GA fuse to protect auxiliary circuits Use a 50A fuse to protect the power unit The values given are the maximum permitted values and can be reduced for special applications or requirements For safety purposes is it advisable to use shielded fuses to prevent molten particles being scattered in the event of a blowout Page 8 pin A1 A2 A3 A4 5 A8 A9 A10 A11 A12 A13 A14 A15 A16 B1 B2 B3 B4 B5 B6 B7 B8 function CPOTT NPOTT PPOTT TILLER BELLY FORWARD BACKWARD RV1 RV2 NEV1 NEB NEV2 PEV2 PEV1 PEB CM KEY PCLRXD NCLRXD PCLTXD NCLTXD GND 12 2 3 DESCRIPTION OF CONNECTORS description Potentiometer unit connect to the cursor of the accelerator potentiometer Negativ
14. 2 BELLY SWITCH BATTERY CHARGE Page 16 3 3 TESTER MENU battery voltage VMN voltage motor current chopper temperature accelerator forward input reverse input tiler switch input speed reduction 1 input speed reduction 2 input if configured guick inversion input backing input if configured toggle input if configured charge status of battery battery voltage VMN voltage motor current chopper temperature accelerator forward input reverse input reguest exclusive hydro if configured speed reduction 1 input speed reduction 2 input if configured guick inversion input charge status of battery 3 4 a Pallet truck ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERS BRAKING CUTBACK SPEED 1 CUTBACK SPEED 2 MAX FORW SPEED MAX BACK SPEED TRACTION IMAX CREEP SPEED BACKING TIME BACKING SPEED SEAT MICRO DELAY HYDRO TIME 3 4 b Floor washer ACCELER DELAY DECELER DELAY RELEASE BRAKING INVERS BRAKING CUTBACK SPEED 1 CUTBACK SPEED 2 MAX FORW SPEED MAX BACK SPEED TRACTION IMAX CREEP SPEED AUXILIARY TIME HYDRO TIME 3 4 PARAMETER CHANGE MENU Acceleration time 9 lt maximum time Deceleration time 9 lt maximum time Release braking time 9 lt max braking power minimum time Inversion braking time 9 max braking power minimum time Speed reduction 1 Speed reduction 2 Maximum forward speed Maximum reverse speed Maximum current it s a function of the par
15. 24V 24V battery 36V 36V battery 3 7 ADJUSTMENT MENU Throttle 0 zone This parameter is used to set the dead zone of the traction potentiometer See graph below Throttle X zone This parameter is used to adjust the characteristic of the traction potentiometer signal Throttle Y zone This parameter is used to adjust the characteristic of the traction potentiometer signal MAX SPEE IRUTTLE 0 RUTTEE X VALC MIN ZUNE PLIN MAX Adjust battery Fine adjustment of the battery voltage Page 21 Set current Adjustment 01 Adjustment 02 Aux function 1 On Off Check up done On Off Page 22 3 8 HARDWARE SETTING MENU ADJUSTMENT LEVEL 9 ADJUSTMENT LEVEL 0 ADJUSTMENT LEVEL 9 ADJUSTMENT LEVEL 05 Adjust the bottom of the scale setting of the current reading visualised on the console Adjust the maximum value of the low battery curve Adjust the minimum value of the low battery curve The hour counter of the chopper loads the hour counter If the hour counter of the chopper and the have different values alarm 98 is displayed for one minute if the option is not set to On within the minute then the chopper hour counter overwrites the
16. FLASHES Test both at rest and running this is an internal self diagnosis of the logic If this alarm is signalled replace the logic 12 CHECK UP NEEDED AL 99 MDI 0 LED FLASH Indicates that it is time to carry out programmed maintenance this alarm is activated 300 hours after the last time maintenance was carried out unless the Check up type option is set to None cancel by setting Check up done to ON 13 FORW BACK AL 80 MDI 2 LED FLASHES Test carried out continuously The alarm is activated when 2 running requests are given simultaneously The alarm is reset if one of the two requests is cancelled Possible causes a check wiring b if fault persists replace the logic 14 VACC NOT OK AL 78 MDI 4 LED FLASH This alarm indicates that the traction accelerator voltage is 1V higher that the minimum programmed voltage at key on and when at rest Possible causes a a potentiometer wire is disconnected b the potentiometer is not wired correctly the potentiometer is faulty d potentiometer programming has not been carried out correcily Page 25 15 INCORRECT START AL 79 MDI 2 LED FLASHES Forwards reverse tiller guick inversion present at key on traction running reguest given before tiller seat 16 THERMAL PROTECTION AL 62 MDI 7 LED FLASHES Temperature alarm activated if the temperature is gt 75 in which case the maximum armature current is reduced linearly until it reaches nil at a threshold te
17. MDI hour counter 0 hours if the chopper is new the programmed check up has been carried out the maintenance hour counter and the Check up needed alarm are reset checkup not done Check up type None Option 1 Option 2 Option 3 Set temperature Maximum Current Programmed maintenance function disengaged no alarm no reduction no shut down Programmed maintenance function enabled an alarm message is visualised after 300 hours Programmed maintenance function enabled an alarm message is visualised after 300 hours and a speed reduction is enabled after 340 hours Programmed maintenance function enabled an alarm message is visualised after 300 hours speed reduction is enabled after 340 hours and the traction is blocked after 380 hours 3 9 SPECIAL ADJUST MENU Fine adjustment of chopper temperature the chopper temperature is calibrated by Zapi during testing and should not be modified by the client Adjust the maximum chopper current A password is reguired in order to modify this setting and remains active until the key is turned off 3 10 CLEAR MENU Clear EEprom can be effected from this menu this virtually resets the plant and cancels the settings entered up to that moment At the end of the Clear EEprom operation the original settings default values are reloaded Clear EEprom has no effect on the following settings Model Type Maximum Current Set temperature
18. MR 6 Mo PCL 7 BACKWARD SW Mo i PEED RED i ei AS T SND m UNS EE FEED RED 2 5 7 S 1 118 10 Eve 87 11 CREE EYE BS R A12 Rap EVI A14 x A15 EY SW po J A16 gt Mo FUSE IS DRAWING IS_A ZAPI s p a PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS AT RELATIVE TO THE REPAIRS OF ZAPI PRODUCTS 420 FUNCTIONAL DRAWING FOR CLEAN MACHINE 2 Data Date Tecnico Technician SD Serie Series Disegno n Drowing n Pagina Page A D 42028 POVIGLIO ITALY 20 03 00 Visto Visa HF ADM 1 1 12 3 CONSOLE MENU 3 1 PROGRAMMING WITH THE CONSOLE The Zapi console can be used to program various 40 chopper functions is therefore possible to adapt the truck performance to suit the clients requirements The console can be left connected to the controller when it is in use and the parameters can be modified in real time In this case if you wish to save the new data entries get into rest mode and save the data in the controller memory E prom before turning the key off This section describes the functions of the Zapi console The console has six push buttons that can be used to modify or visualise the chopper parameters as described below 1 Roll up press to scroll sub menus or parameters upwards 2 press to scroll sub menus or parameters downwards 3 Ente
19. T SET INTERVALS Check the pedal microswitch use a tester to check for the absence of resistance on the contact by measuring the voltage drop at the terminals also check that the switch clicks u ER RE IRMA ARE EVERY 3 MONTHS Check the power cables to the battery and to the motor both cables and sheathing must be in good condition u uuu u u u EVERY 3 MONTHS Check the efficiency of the pedal springs EVERY 3 MONTHS All work must be carried out by qualified staff and original spare parts only should be used Follow the assembly diagrams carefully when installing the machine any modifications must be agreed to with the supplier The supplier declines all responsibility for problems caused by failure to comply to the proposed solutions Any cause for concern that is visible or apparent to the average technician when carrying out the regular check ups on the equipment and that could result in damage or faults to the equipment itself must be reported to ZAPI technicians or to the technical sales network who are responsible for any decisions concerning the safety of the electric vehicle THE USER IS PROHIBITED FROM USING THE VEHICLE SHOULD THERE BE ANY FAULTS IN THE ELECTRICAL EQUIPMENT THAT REPRESENT A HAZARD
20. adjusted using the programming console Regenerative braking based on deceleration ramps release braking inversion braking Speed control in descent the motor speed is controlled by the accelerator pedal and regenerative braking is activated automatically if the motor speed exceeds the reguired speed this results in excellent ramp performance Even without the use of an electric brake anti roll back Electric brake control optional Diagnosis with optional led to indicate type of fault Parameter adjustment using console Internal hour counter displayed on the console The last 5 alarms are recorded together with the relative hour counter reading and chopper temperature Tester function using the console to check in real time inputs motor voltage battery etc Good motor and battery efficiency thanks to high freguency switching Watchdog circuit to check the uC operations An MDI indicator can be connected to display software version hour counter alarms speed reduction and battery charge 1 5 CONTROLLER DIAGNOSIS The uC diagnoses the main chopper functions Diagnosis consists of 4 main stages and includes the following tests 1 2 3 4 Key turned on test current sensor test VMN test main relay test presence of start command test accelerator high test potentiometer connection test watchdog test power devices At rest test VMN test main relay test current sensor test potentiometer connect
21. ameter MAXIMUM CURRENT Initial step voltage Backing time Fixed speed during backing function Seat microswitch release delay time if the Handle Switch option is configured as Seat or delay between direction request and tiller if the Handle Switch option is configured as Present Delayed disengaging of hydro output Acceleration time 9 maximum time Deceleration time 9 lt maximum time Release braking time 9 lt max braking power minimum time Inversion braking time 9 lt max braking power minimum time opeed reduction 1 opeed reduction 2 Maximum forward speed Maximum reverse speed Maximum current it s a function of the parameter MAXIMUM CURRENT Initial step voltage Delayed disengaging of auxiliary output NEV2 Delayed disengaging of hydro output NEV1 Page 17 Model Type Option 1 Option 2 3 6 a Pallet truck Hour counter Running Key on Battery check Off On 3 9 SET MODEL MENU The 40 is configured as a transpallet The 40 is configured as a floor washer 3 6 SET OPTION MENU The hour counter is active during running only The hour counter is active at all times Battery alarm disengaged Low battery alarm engaged plus current limiting device Aux output 1 NEV2 NEB output Free Brake Option 2 Option 3 Quick inversion Belly Timed Backing function Unused output Output used to control an electric brake that receives the posit
22. e residual charge falls to 10 If the alarm is activated with the battery fully charged check the battery value reading in the TESTER menu on the console if the reading is incorrect carry out fine adjustment in the CONFIG MENU ADJUSTMENT menu This alarm be present only with battery check option ON CONTACTOR CLOSED AL 37 MDI 6 LED FLASHES Test before closing the main relay only if the VMN is at approx Vbatt 2 Check that the contact of the main electromagnetic switch is open and has not jammed Page 24 8 CONTACTOR DRIVER AL 75 MDI 6 LED FLASHES Test with the main relay closed check that the driver is not open Possible causes a driver open b fault in the feedback circuit of the main relay coil voltage 9 1 0 EVER AL 49 MDI 5 LED FLASHES Test whilst running Check that the current value is higher than the minimum threshold value If not the chopper will go into alarm and prevent machine functions Possible causes a faulty current sensor b fault in the feedback circuits in the logic or in the power board 10 EB DRIVER KO AL 02 MDI 8 LED FLASHES The alarm is activated when a problem in the driver of the electric brake is detected only for transpallets with brake present and diagnosis enabled Possible causes a shorted driver b the driver is faulty and cannot control the electric brake fault in the feedback circuit of the electric brake coil voltage 11 WATCHDOG AL 08 MDI 1 LED
23. e pole of accelerator potentiometer Positive pole of accelerator potentiometer Tiller seat switch signal input or hydro request input if the chop per is configured as a floor washer Ouick inversion switch input Forward switch input Reverse switch input Cutback switch 1 input Cutback switch 2 input Negative pole of solenoid valve 1 Negative pole of electric brake or solenoid valve 2 Positive pole of solenoid valve 2 Positive pole of solenoid valve 1 Positive pole of electric brake Common switch voltage output using battery potential Key input Serial reception positive Serial reception negative Serial transmission positive Serial transmission negative Negative for powering console Positive for powering console Page 9 2 4 DIMENSIONS OE OH 7 1510 50 OROROROROAORORO us M N N FON A QEL 07 1122 Page 10 2 5 CONNECTIONS 2 5 a Pallet truck
24. g the programming console and in both directions This function is indispensable when compensating an eventual asymmetry in the mechanical components of the potentiometer and for minimum level adjustment in particular Vmot Vacc VEG Voce Ymar MO 5V 100 OV 100 av 100 4v Ye CA 202 YA 2402 0 0 4 RN 100 MI O 100 120 MI O MA 100 MECHANICAL ANGLE MECHANICAL ANGLE The above graphs show the output voltage of a potentiometer that has not been calibrated compared to the mechanical zero of the tiller Knob MI and MA indicate the closing points of the microswitches 0 represents the mechanical angle of rotation of the throttle The first graph shows the corresponding motor voltage without acquisition the second graph shows the corresponding voltage after potentiometer signal acquisition Page 4 1 3 SAFETY FEATURES Inverted battery polarity Connections must be made as indicated in the wiring diagrams to avoid damaging the power unit Connection errors All the inputs are protected against wrong connection Thermal protection If the temperature of the 4Q exceeds 75 C the maximum current is automatically reduced in proportion to the temperature increase The temperature cannot exceed 90 C at this temperature the maximum curre
25. ion test watchdog test accelerator up in absence of start microswitch Running test VMN test main relay test current sensor test negative wire of potentiometer test watchdog test electric brake if configured Permanent check temperature and battery voltage Diagnostic messages are coded by counting the number of times the led flashes or by a 2 digit code on the MDI The full alarm message can be visualised using the programming console Page 6 1 6 THERMAL CONSIDERATIONS Since the heat generated by the controller must be dissipated it is important to install itin a well ventilated area with adeguate cooling surfaces The cooling system must be scaled according to the use reguired of the machine forced ventilation may be necessary in some cases if air circulation is insufficient and heat exchange is limited by the type of materials used The power dissipated by the module varies according to the current and the duty cycle 1 7 GENERAL WARNINGS AND PRECAUTIONS ZN Do not connect the 40 module to a battery with a different rated voltage to the one indicated on the module s rating plate A higher battery voltage can cause irreparable damage the MOSFETs With a lower battery voltage the module will not work The 4Q module must be disconnected when the battery is being charged as the module can be damaged by overvoltages generated by the battery charger and ripple currents generated in the capacitors if a low frequency batter
26. ive from the tiller switch with relative diagnosis Output used to control an electric brake that does not receive the positive from the tiller switch diagnosis disengaged Output used to enable the electric brake during release braking The brake is controlled as in the option brake Quick inversion active while the belly button remains pressed Timed quick inversion fixed duration This option is effective only if the Set input 2 is set to Option 1 Off On Page 18 The backing function is disengaged the RV2 input is a speed reduction The backing function is enabled the RV2 input is used to activate the backing function the direction is chosen using the gears Handle switch Present Seat Tiller present incorrect start if pressed at key on and movement jammed if released during running A maximum delay time between selecting the running direction and selecting the tiller can be programmed using the Seat micro delay parameter Seat present no incorrect start is pressed at key on delay if released during running program the delay time using the Seat micro delay parameter The seat running sequence is compulsory Aux output 2 NEV1 output This option is only effective if Set input 2 is set to Option 1 Option 1 Option 2 Set input 2 Option 1 Option 2 Inversion Mode Option 1 Option 2 Aux function 2 Option 1 Option 2 The NEV1 output
27. mperature of 90 C the speed is reduced to 60 the alarm is reset only if the temperature drops to below 70 C If the temperature falls to below 10 C the maximum armature current is reduced by 20 17 EEPROM OK AL 13 MDI 1 LED FLASH Fault in memory area where configuration parameters are recorded If the fault persists when the key is turned off and turned on again replace the EEPROM and check the connections between the EEPROM and the pP If the alarm no longer occurs remember that the previously recorded parameters have now been cancelled and replaced with default values PEDAL WIRE KO AL 86 MDI 4 LED FLASHES Indicates that the negative wire of the potentiometer is disconnected Possible causes a one of the potentiometer wires is disconnected b the potentiometer is not wired correctly the potentiometer is faulty 18 w 19 CURR PROTECTION AL 96 MDI 5 LED FLASHES Current protection if for any reason the current exceeds the calibrated values the microprocessor disengages the functions until the current drops to the required value AL 98 on MDI MDI and chopper have different counter Page 26 5 RECOMMENDED SPARE PARTS FOR THE 40 ITEM CODE DESCRIPTION C12404 16 way Molex Minifit female connector C12777 Molex Minifit female crimp terminal C00077 Console connector plug C18556 Outer gasket for Molex Minifit connector C18557 Inner gasket for Molex Minifit connector Page 2 6 REGULAR MAINTENANCE A
28. nt is zeroed If the temperature drops to below 10 C the maximum current is reduced by 20 Battery low When the battery runs down lt 10 the maximum current is reduced by 50 This function can be excluded using the console Battery Check option External agents The chopper has 54 protection Protection against accidental starting A precise sequence of operations is required to start the machine if the sequence is not carried out correctly the machine will not start The start running command must be given after key on and activating the seat microswitch if configured If on the other hand the tiller is configured it must be activated with a predefined minimum delay time compared to the activation of a start running microswitch Protection against uncontrolled movement The electromagnetic switch does not close if the power unit is not in function the output voltage of the accelerator does not drop to below the recorded minimum value increased by 1V the potentiometer negative is disconnected the logic is not in good working order one of the start microswitches is closed the controller fulfil the requirements specified on the EN1175 point 5 9 4 The requirements specified on point 5 9 5 have to be fulfil by external solutions Page 5 1 4 OPERATING FUNCTIONS Speed control Excellent sensitivity at low speeds Maximum speed reduction the maximum speed in both directions can be
29. r press to access sub menus Also used to confirm a new parameter 4 Out press to exit sub menus Also used for non confirmation of a new parameter 5 Set Up press to increase the value of a parameter 6 Set Down press to decrease the value of a parameter N B When a parameter has been modified the new value can be recorded by pressing key 4 Out followed by key 3 Enter By pressing key 4 Out twice the new value is not recorded The numbers printed in the triangles on the following console map correspond to the numbers on the keyboard of the console shown in the diagram below The position of the triangle indicates to which sub menu or parameter the key refers tl 3 Fit ROLL ENTER BUT TONS ROLL OUT 4L zam 2 Important THE CONSOLE SHOULD ONLY BE CONNECTED AND DISCONNECTED WITH THE PLANT TURNED OFF Page 13 3 2 a Pallet truck HEADING gt 3 2 CONSOLE gt T AN NY
30. y charger is used The 4Q module should be powered by batteries for traction only Do not use rectifier outputs or power supply units For special applications contact the nearest ZAPI technical service centre When starting the machine for the first time keep the wheels raised to avoid hazardous situations due to possible connection errors When the key is turn off the filter capacitors in the module can stay charged for several minutes For safety purposes it is advisable to disconnect the battery and short circuit the positive and negative power lines of the chopper for a few seconds using a resistor of between 10Q and 1000 The electromagnetic susceptibility and emission is strongly influenced by the method of installation particular attention should be paid to the length and lay out of electrical connections and to shielding Zapi declines all responsibility for malfunctions caused by the above mentioned factors particularly if the machine manufacturer fails to carry out the tests required by current legislation Page 2 INSTALLATION If possible assemble the chopper with its base on flat metal surface that has not been painted or cleaned It is advisable to spread a layer of thermo conductive grease between the two surfaces to improve the transmission of heat Although the chopper is protected against external agents the connector contacts may become oxidised due to the presence of corrosive substances This factor should be
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