Zapi Chopper SEM-X User manual

INSTALLATION AND
USER MANUAL
CHOPPER SEM-X
ELECTRONIC INDUSTRIAL DEVICES
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. [phone] (r.a.) - Fax [phone] - e-mail: [email protected]

Page 1
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

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SIGNED IN APPROVAL
SECIVRES.TPEDYNAPMOCSECIVRES.TPEDYNAPMOC SECIVRES.TPEDYNAPMOC SECIVRES.TPEDYNAPMOCSECIVRES.TPEDYNAPMOCEVITUCEXETNEMEGANAMEVITUCEXETNEMEGANAM EVITUCEXETNEMEGANAM EVITUCEXETNEMEGANAMEVITUCEXETNEMEGANAM
EVITUCEXENOITCESGNIREENIGNE
REGANAMTROPXE
Publication n°: ADRZP0BA
Edition: June 2001

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LEGEND
B SW = Belly Switch
CM = Common Microswitches
CPOT = Wiper Potemtiometer
EMB = Electromechanical Brake
EV = Lowering Valve
FORW SW = Forward Switch
H&S = Hard & Soft
HORN = Horn
HORN SW = Horn Switch
LIFT SW = Lifting Switch
LOW SW = Lowering Switch
MC = Main Contactor
NEMB = Negative Electromechanical Brake
NEV = Negative Lowering Valve
NHORN = Negative Horn
NMC = Negative Main Contactor
NPC = Negative Pump Contactor
NPOT = Negative Potentiometer
PC = Pump Contactor
PEMB = Positive Electromechanical Brake
PEV = Positive Lowering Valve
PHORN = Positive Horn
PMC = Positive Main Contactor
PPC = Positive Pump Contactor
PPOT = Positive Potentiometer
REV SW = Reverse Switch
SR1 = Speed Reduction 1
SR2 = Speed Reduction 2
T SW = Tiller Switch
COLOUR CODES (SINGLE COLOURS)
The following Codes represent the colours of individual wires used by Zapi (unless
specified otherwise).
A - Orange M - Brown
B - White N - Black
BB - Blue R - Pink
C - Sky Blue RR - Red
G - Yellow V - Green
GG - Grey VV - Purple

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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. 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.

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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 ............................................................................. + 40°C
Minimum Ambient temperature ................................................................................ -30°C
Maximum temperature of Chopper ......................................................................... + 90°C
VERSIONS MAXIMUM CURRENT VOLTAGE DROP IN
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 Microswitches
- Microswitches should have a contact resistance lower than 0.1Ω, and a leakage
current lower than 100 µA.
- When full load current is being drawn, the voltage drop across the Key Switch con
tact must be lower than 0.1V.
- If an Electromagnetic Brake is used, the 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.

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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 : 500Ω
Maximum Potentiometer Resistance : 10kΩ
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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2.3 SAFETY & 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 (=<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 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:

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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 contactor 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.
- It is possible to connect SEM-X to MDI intrument.

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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) 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.
2) Standby Diagnosis at rest that checks: VMN Point, Main Contactor Driver, Current
Sensor, Watchdog, Brake, Vfield, NPOT.
3) Diagnosis during operation that checks: Watchdog, VMN Point, Current (field and
armature), Main Contactor, Brake, NPOT.
4) 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 number 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.

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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. 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 10Ωand 100Ω.
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.

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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 0.5mm² section.
For power connections to the motor armature and battery use cable of 10mm² section.
For the Field connections use cable of 4mm² 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.

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3.4 DESCRIPTION OF SEM-X CONNECTORS
PIN REFERENCE DESCRIPTION
A1 NPOT Provides a negative supply to accelerator's potentiometer; the
circuit is designed to provide a control against wire disconnection.
A2 CPOT Accelerator's potentiometer wire input.
A3 PPOT Provides a positive to supply accelerator's potentiometer,
protected against short to +B and -B.
A4 TILLER Tiller (seat) microswitch input, active high (+B).
A5 BELLY Belly switch input, used for quick inversion function, active high
(+B).
A6 FW Forward direction switch input, active high (+B).
A7 REV Reverse direction switch input, active high (+B).
A8 H&S Hard&Soft switch input, active high (+B).
A9 DIGITAL IN. Digital input, free for customization.
A10 ---

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PIN REFERENCE DESCRIPTION
A11 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 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
B7 ---
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.

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3.6 MECHANICAL DRAWING & DIMENSIONS

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4 PROGRAMMING & 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 to
the chopper. The bevel on the connector should be uppermost.
4.2 DESCRIPTION OF CONSOLE & CONNECTION
Digital Consoles used to communicate with SEM-X choppers must be fitted with Eprom
CK ULTRA.

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4.3 DESCRIPTION OF STANDARD CONSOLE MENU

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5 SEM-X: CABLING AND CONFIGURATION
5.1 POWER DIAGRAM

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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: The counter registers travel time only.
- KEY ON: The counter registers when the key switch is Closed.
2 QUICK INVERSION:
- BELLY: Quick inversion is activated while the Belly Button is
pressed.
- TIMED: Quick inversion is activated, while the Belly Button is
pressed, maximum for 3 second.
3 AUX OUTPUT #1:
-ABSENT: A11 output is not used: the controller carry out monitor
function as described at the paragraph 2.5.
-PRESENT: A11 output drives an electromechanical brake. The
controller does not carry out monitor function, but locks
the brake while in rest or alarm status.
4 BATTERY CHECK:
-ON: alarm indication, speed reduction and current reduction
when battery charge =<20%.
-OFF: no alarm indication, no speed and current reduction with
battery discharged.
5 SET ACCEL TYPE:
-OPTION #1: standard 0÷5V potentiometer input.
-OPTION #2: 5÷0V potentiometer input.
6 BACKING FUNCTION:
-ON: input A9 is used as enable backing input.
-OFF: input A9 is a speed reduction; no backing function
available.
7 HANDLE SWITCH:
-PRESENT: A4 is a tiller input: incorrect start if it's closed at key on;
no delay if it is switched off.
-SEAT: A4 is a seat input: no incorrect start if it's closed at key
on; programmable delay if it is switched off.

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Flow Chart showing how to make changes to Configuration Menu using Digital Console.
(Standard Eprom CK ULTRA fitted).
1) Opening Zapi Menu.
2) Press Top Left & Top Right Buttons
simultaneously to enter the Config. Menu.
3) The Display will show :
4) Press ROLL UP (Top Left Button) until
SET OPTIONS appears.
5) The Display will show :
6) Press ENTER to go into this part of the menu.
7) The first “Option” of the menu appears
on the Display.
8) Press either ROLL UP or ROLL DOWN to bring
up the next the Option.
9) 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.