Zapi Sem-X Manual
Zapi Sem-X Manual
Zapi Sem-X Manual
INSTALLATION AND
USER MANUAL
CHOPPER SEM-X
INDEX
Page
LEGEND .............................................................................................................. 3
COLOUR CODES (Single Colours) ...................................................................... 3
1 Introduction to the ZAPI-MOS Family .......................................................... 4
2 General Characteristics ................................................................................ 5
2.1 Technical Specifications ........................................................................ 5
2.2 Control Units.......................................................................................... 5
2.2.a Microswitches ............................................................................... 5
2.2.b Potentiometer ............................................................................... 6
2.3 Safety & Protection Features ................................................................ 7
2.4 Direction Orientation .............................................................................. 7
2.5 Operational Features ............................................................................. 8
2.6 SEM-X Chopper Diagnosis ................................................................... 9
2.7 Thermal Considerations ........................................................................ 9
2.8 General Instructions and Precautions ................................................. 10
3 Installation.................................................................................................... 11
3.1 Connection Cables .............................................................................. 11
3.2 Contactors ........................................................................................... 11
3.3 Fuses................................................................................................... 11
3.4 Description of SEM-X Connectors ....................................................... 12
3.5 Description of Power Connections ...................................................... 13
3.6 Mechanical Drawing & Dimensions ..................................................... 14
4 Programming & Adjustments using Digital Console ............................... 15
4.1 Adjustments via Console ..................................................................... 15
4.2 Description of Console & Connection .................................................. 15
4.3 Description of Standard Console Menu ............................................... 16
5 SEM-X: Cabling and Configuration ............................................................ 17
5.1 Power Diagram .................................................................................... 17
5.2 Description of Programmable Functions (Options).............................. 18
5.3 Description of Parameters that may be Programmed ......................... 20
5.4 Table of Adjustments ........................................................................... 22
5.5 Menu Special Adjust............................................................................ 24
5.6 Menu Hardware Setting ....................................................................... 24
5.8 Menu Adjustment ................................................................................ 25
5.8 SEM-X Traction Standard Wiring Diagrams ........................................ 26
5.9 Sequence for SEM-X Traction Settings ............................................... 27
6 SEM-X Diagnostics ...................................................................................... 28
6.1 Analysis of Alarms Displayed on the Console ..................................... 29
6.2 Tester Description of the Functions ..................................................... 32
6.3 Description of the Console SAVE Function ......................................... 34
6.4 Description of Console RESTORE Function. ...................................... 35
6.5 Description of Alarms Menu ................................................................ 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
Publication n: ADRZP0BA
Edition: June 2001
Page 2
MANAGEMENT EXECUTIVE
LEGEND
B SW
CM
CPOT
EMB
EV
FORW SW
H&S
HORN
HORN SW
LIFT SW
LOW SW
MC
NEMB
NEV
NHORN
NMC
NPC
NPOT
PC
PEMB
PEV
PHORN
PMC
PPC
PPOT
REV SW
SR1
SR2
T SW
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Belly Switch
Common Microswitches
Wiper Potemtiometer
Electromechanical Brake
Lowering Valve
Forward Switch
Hard & 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 represent the colours of individual wires used by Zapi (unless
specified otherwise).
A
- Orange
Brown
- White
Black
BB - Blue
Pink
RR -
Red
G - Yellow
Green
GG - Grey
VV
Purple
- Sky Blue
Page 3
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2 GENERAL CHARACTERISTICS
2.1 TECHNICAL SPECIFICATIONS
Chopper for Separately Excited DC motors ................................................. 0.35 0.8kW
Regenerative Braking
Voltage Range ...................................................................................................... 24VDC
Maximum Field Current (all the versions) .................................................................. 35 A
Armature Switching Frequency ............................................................................... 16kHz
Field Switching Frequency ...................................................................................... 16kHz
Maximum Ambient temperature ............................................................................. + 40C
Minimum Ambient temperature ................................................................................ -30C
Maximum temperature of Chopper ......................................................................... + 90C
VERSIONS
MAXIMUM CURRENT
VOLTAGE DROP IN
FULL CONDUCTION
24V
90A (3')
24V
110A (2')
Page 5
2.2.b Potentiometer
The Potentiometer should be wired in the 3 - Wire Configuration.
CPOT (A2) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance :
500
Maximum Potentiometer Resistance :
10k
Faults can occur if the potentiometer is out of this range.
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.
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.
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3 INSTALLATION
Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.
Apply a thin layer of thermo-conductive grease between the two surfaces to permit
better heat dissipation.
Despite the protection provided against external agents, the continuous attack of
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-X 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 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
NPOT
A2
CPOT
A3
PPOT
A4
TILLER
A5
BELLY
Belly switch input, used for quick inversion function, active high
(+B).
A6
FW
A7
REV
A8
H&S
A9
DIGITAL IN.
A10 ---
Page 12
A12 NLED
A15 PMC
A16 KEY
PIN REFERENCE
B1
---
B2
NCLRXD
B3
PCLTXD
B4
NCLTXD
B5
GND
B6
+12
B7
---
B8
---
-B
VMN
F1, F2
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Digital Consoles used to communicate with SEM-X choppers must be fitted with Eprom
CK ULTRA.
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HOUR COUNTER:
- RUNNING:
- KEY ON:
QUICK INVERSION:
- BELLY:
- TIMED:
-PRESENT:
BATTERY CHECK:
-ON:
-OFF:
-OPTION #2:
BACKING FUNCTION:
-ON:
-OFF:
HANDLE SWITCH:
-PRESENT:
-SEAT:
Page 18
Flow Chart showing how to make changes to Configuration Menu using Digital Console.
(Standard Eprom CK ULTRA fitted).
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Page 20
14 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).
15 CREEP SPEED = Minimum Speed. This Parameter sets the minimum voltage
applied to the motor at the start of travel.
16 FIELD CURR MAX = Maximum field current. The chopper reaches this field current
when the armature current is at the maximum value.
17 BACKING TIME = Maximum backing function time.
18 BACKING SPEED = Fixed speed when the backing function is active.
19 SEAT MICRO DELAY = This parameter sets the time for which the seat switch
opening is ignored.
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PARAMETERS
PROGRAMMED LEVEL
UNIT
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
RELEASE BRAKING
INVERS BRAKING
CUTBACK SPEED 1
%ACC
20
25
31
37
43
49
55
61
67
100
CUTBACK SPEED 2
%ACC
20
25
31
37
43
49
55
61
67
100
%FCN
100
92
84
77
70
63
56
48
42
38
** %FCN
%FCN
100
92
84
77
70
63
56
48
42
38
** %FCN
TRACTION I MAX
%IMax
72
76
79
81
84
86
90
94
96
100
%IMax
29
31
34
36
39
41
44
46
49
51
%ACN
30
35
40
45
50
55
60
65
70
75
6.7
7.2
7.4
7.6
7.8
8.0
8.2
8.4
8.6
8.8
CREEP SPEED
%VBatt
1.2
1.6
2.3
2.7
3.5
3.9
4.7
5.1
5.9
6.3
BACKING SPEED
%ACC
20
23
27
31
35
39
43
47
51
55
BACKING TIME
sec.
0.2
0.5
0.8
1.1
1.5
1.8
2.2
2.6
3.0
12.8 13.2 13.6 14.1 14.5 14.9 15.3 15.7 16.1 16.6
*=
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).
**=
Page 22
Flow Chart showing how to make Program changes using Digital Console fitted with
Eprom CK ULTRA.
1) Opening Zapi Display.
2) Press ENTER to go into the General Menu.
3) The Display will show :
4) Press ENTER to go into the Parameter Change facility.
5) The Display will show the first Parameter.
6) Press either ROLL UP or ROLL DOWN to display
the next parameter.
7) The names of the Parameters appear on the Display.
8) When the desired Parameter appears, the Display will
show a Level Number that will be between 0 and 9.
press either PARAM (Top Right) or SET (Bottom Right)
buttons to change the Level value.
9) The Display will show the New Level.
10) When you are satisfied with the results of the changes
you have made, 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 :
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6 SEM-X DIAGNOSTICS
The following list shows likely problems associated with the flashing RED LED.
N FLASHES MESSAGE
1
Watch-dog:
NOTES
Logic board and/or software failure.
EEPROM KO:
CHECK UP NEEDED
Check up timeout.
INCORRECT START:
FORW + BACK:
CAPACITOR CHARGE
VMN NOT OK
VFIELD NOT OK
VACC NOT OK
Potentiometer Wiper.
PEDAL WIRE KO
NO FIELD CURR.
STBY I HIGH
I= 0 EVER
CONTACTOR DRIVER
DRIVER SHORTED
CONTACTOR CLOSED
TH. PROTECTION
POWER FAILURE #1
Shortcircuit on EB or MC coil.
EB DRIVER SHORT
Shortcircuit on EB driver.
EB DRIVER KO
32
BATTERY LOW
Page 28
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.
2
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 recycled, replace the logic. If the fault disappears, the previously stored Parameters
will have been replaced by the default parameters.
3
CHECK UP NEEDED
AL 99 MDI
The "check up type" parameter is active and the time from last check up is > 300
hours.
4
INCORRECT START
AL 79 MDI
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.
6
CAPACITOR CHARGE
AL 60 MDI
This check is made during the initial diagnosis. This 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.
7
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 doesnt 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
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 VBatt. This alarm is
generated if the field voltage is different from this value. Possible causes:
d) Frame fault on the motor to chassis;
e) 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
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 I = 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 I 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.
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15 CONTACTOR CLOSED
AL 37 MDI
This check is made during the initial diagnosis. With the coil of the line contactor deenergized, the capacitors should not be charged, unless there is divert resistor
across the power poles. Possible causes:
a) The line contactor power poles are welded.
b) This alarm could be generated even if the line contactor has opened, but there is
a problem with either the field circuit, or a problem detected by the safety
microprocessor.
16 TH. PROTECTION
AL 62 MDI
If the temperature of the chopper rises higher than 75C, this alarm is generated.
The chopper current is reduced in proportion to the increase in temperature. At
90C the chopper totally stops. If the temperature of the chopper is <- 10C, 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 =<10C:
a) Check the connection of the temperature sensor.
b) The temperature sensor may be defective.
c) The logic may be defective.
17 POWER FAILURE #1
AL 73 MDI
AL 2 MDI
AL 91 MDI
The EB driver is shorted. Check the negative of the brake: it may be in short circuit
with -B.
20 BATTERY LOW
AL 66 MDI
This Alarm is generated when the battery becomes 50% discharged from the
nominal value.
Page 31
Flow Chart showing how to use the TESTER function of the Digital Console.
1) Opening Zapi Display.
2) Press ENTER to go into the General menu.
3) The Display will show :
4) Press either ROLL UP or ROLL DOWN button until
TESTER MENU appear on the display.
5) The Display shows :
6) Press ENTER to go into the TESTER function.
7) The first variable to be tested is shown on the Display.
8) Press either ROLL UP or ROLL DOWN buttons until your
desired variable for measurement appears on the Display.
9) Next variable is shown.
10) When you have finished, Press OUT.
11) The Display shows :
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.
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Part Number
Description
C16519
C16503
C16520
C12404
C12777
C29543
SW 80 24V CO
Single Pole Contactor
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