Zapi 4Q User manual

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Index
1 Main features ................................................................................................. 3
1.1 Field of application .................................................................................... 3
1.2 Control units .............................................................................................. 4
1.2.a Microswitches ............................................................................... 4
1.2.b Potentiometer ............................................................................... 4
1.3 Safety features .......................................................................................... 5
1.4 Operating functions ................................................................................... 6
1.5 Controller diagnosis ................................................................................... 6
1.6 Thermal considerations ............................................................................. 7
1.7 General warnings and precautions .................................................... 7
2 Installation...................................................................................................... 8
2.1 Choice of connecting cables...................................................................... 8
2.2 Fuses ......................................................................................................... 8
2.3 Description of connectors .......................................................................... 9
2.4 Dimensions .............................................................................................. 10
2.5 Connections ............................................................................................ 11
2.5.a Pallet truck.................................................................................. 11
2.5.b Floor washer............................................................................... 12
3 Console Menu .............................................................................................. 13
3.1 Programming with the console ................................................................ 13
3.2 Console Map ........................................................................................... 14
3.2.a Pallet truck.................................................................................. 14
3.2.b Floor washer............................................................................... 15
3.3 "Tester" Menu .......................................................................................... 16
3.3.a Pallet truck.................................................................................. 16
3.3.b Floor washer............................................................................... 16
3.4 "Parameter Change" Menu ...................................................................... 17
3.4.a Pallet truck.................................................................................. 17
3.4.b Floor washer............................................................................... 17
3.5 "Set Model" Menu .................................................................................... 18
3.6 "Set Option" menu ................................................................................... 18
3.6.a Pallet truck.................................................................................. 18
3.6.b Floor washer............................................................................... 20
3.7 "Adjustment" Menu .................................................................................. 21
3.8 "Hardware Setting" Menu ........................................................................ 22
3.9 "Special Adjust" Menu ............................................................................. 23
3.10 "Clear EEprom" Menu ........................................................................... 23
4 Alarms .......................................................................................................... 24
4.1 Diagnosis ................................................................................................. 24
5 Recommended spare parts for the 4Q ...................................................... 27
6 Regular maintenance at set intervals ........................................................ 28

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SIGNATURES TABLE
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publication N°: ADMZP0DA
Edition: November 2001
= The informations included into the marked paragraphs by this symbol are
essential for the safety.

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1 MAIN FEATURES
The 4Q is the smallest permanent magnet motor controller:
it is designed for use at 24Vor 36V with a maximum armed current of 70A or 90A.
The controller is constructed with a full bridge: no changeover necessary.
1.1 FIELD OF APPLICATION
Power 500W (800W)
Voltages 24V, 36V
Max. current 70A (90A)
Continuos current 30A
The 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.

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1.2 CONTROL UNITS
1.2.a Microswitches
- A contact resistance of less than 0.1Ωand a current leakage of less than 100µA is
required.
- The key 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 a 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 Ω
Maximum resistance: 10KΩ
Automatic minimum and maximum signal acquisition must be carried out (PROGRAM
VACC function) using 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.
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.

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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 current is zeroed. If the temperature drops to
below –10°C, the maximum current is reduced by 20%.
-Battery low:
When the battery runs down (<= 10%) the maximum current is reduced by 50%.
This function can be excluded using the console (“Battery Check” option).
-External agents:
The chopper has IP54 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.

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1.4 OPERATING FUNCTIONS
- Speed control.
- Excellent sensitivity at low speeds.
- Maximum speed reduction: the maximum speed in both directions can be 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
required 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 frequency switching.
- Watchdog circuit to check the µC operations.
- An MDI indicator can be connected to display: software version, hour counter,
alarms, speed reduction and battery charge.
1.5 CONTROLLER DIAGNOSIS
The µC diagnoses the main chopper functions.
Diagnosis consists of 4 main stages and includes the following tests:
1) 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.
2) At rest: test VMN, test main relay, test current sensor, test potentiometer
connection, test watchdog, test accelerator up in absence of start microswitch.
3) Running: test VMN, test main relay, test current sensor, test negative wire of
potentiometer, test watchdog, test electric brake (if configured).
4) 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.

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1.6 THERMAL CONSIDERATIONS
- Since the heat generated by the controller must be dissipated, it is important to install
it in a well ventilated area with adequate cooling surfaces.
- The cooling system must be scaled according to the use required 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
- Do not connect the 4Q 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 battery 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 10Ωand 100Ω.
- 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.

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2 INSTALLATION
If possible, assemble the chopper with its base on a 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
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 0.5mm2for auxiliary circuits.
Use 6mm2cables 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 6A 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.

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2.3 DESCRIPTION OF CONNECTORS
pin function description
A1 CPOTT Potentiometer unit: connect to the cursor of the accelerator
potentiometer.
A2 NPOTT Negative pole of accelerator potentiometer.
A3 PPOTT Positive pole of accelerator potentiometer.
A4 TILLER Tiller/seat switch signal input (or hydro request input if the chop
per is configured as a floor washer).
A5 BELLY Quick inversion switch input.
A6 FORWARD Forward switch input.
A7 BACKWARD Reverse switch input.
A8 RV1 Cutback switch 1 input
A9 RV2 Cutback switch 2 input
A10 NEV1 Negative pole of solenoid valve 1
A11 NEB/NEV2 Negative pole of electric brake or solenoid valve 2.
A12 PEV2 Positive pole of solenoid valve 2.
A13 PEV1 Positive pole of solenoid valve 1.
A14 PEB Positive pole of electric brake.
A15 CM Common switch (voltage output using battery potential).
A16 KEY Key input.
B1 PCLRXD Serial reception positive.
B2 NCLRXD Serial reception negative
B3 PCLTXD Serial transmission positive.
B4 NCLTXD Serial transmission negative.
B5 GND Negative for powering console.
B6 +12 Positive for powering console.
B7 ---
B8 ---

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2.4 DIMENSIONS

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2.5 CONNECTIONS
2.5.a Pallet truck

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2.5.b Floor washer

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3 CONSOLE MENU
3.1 PROGRAMMING WITH THE CONSOLE
The Zapi console can be used to program various 4Q chopper functions. It is therefore
possible to adapt the truck performance to suit the client’s 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 (E2prom) 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 Roll-down press to scroll sub-menus or parameters downwards.
3 Enter 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.
Important
THE CONSOLE SHOULD ONLY BE CONNECTED AND DISCONNECTED WITH THE
PLANT TURNED OFF!

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3.2 CONSOLE MAP
3.2.a Pallet truck

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3.2.b Floor washer

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3.3 "TESTER" MENU
3.3.a Pallet truck
BATTERY VOLTAGE battery voltage
VMN VMN voltage
MOTOR CURRENT motor current
TEMPERATURE chopper temperature
ACCELERATOR accelerator
FORWARD SWITCH forward input
BACKWARD SWITCH reverse input
TILLER SWITCH tiller switch input
CUTBACK SWITCH 1 speed reduction 1 input
CUTBACK SWITCH 2 speed reduction 2 input (if configured)
BELLY SWITCH quick inversion input
BACKING INPUT backing input (if configured)
TOGGLE INPUT toggle input (if configured)
BATTERY CHARGE charge status of battery
3.3.b Floor washer
BATTERY VOLTAGE battery voltage
VMN VMN voltage
MOTOR CURRENT motor current
TEMPERATURE chopper temperature
ACCELERATOR accelerator
FORWARD SWITCH forward input
BACKWARD SWITCH reverse input
HYDRO SPEED REQ. request exclusive hydro (if configured)
CUTBACK SWITCH 1 speed reduction 1 input
CUTBACK SWITCH 2 speed reduction 2 input (if configured)
BELLY SWITCH quick inversion input
BATTERY CHARGE charge status of battery

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3.4 "PARAMETER CHANGE" MENU
3.4.a Pallet truck
ACCELER. DELAY Acceleration time; 9 = maximum time
DECELER. DELAY Deceleration time; 9 = maximum time
RELEASE BRAKING Release braking time; 9 = max. braking power, minimum
time
INVERS. BRAKING Inversion braking time; 9 = max. braking power, minimum
time
CUTBACK SPEED 1 Speed reduction 1
CUTBACK SPEED 2 Speed reduction 2
MAX FORW. SPEED Maximum forward speed
MAX BACK. SPEED Maximum reverse speed
TRACTION IMAX Maximum current (it's a function of the parameter
MAXIMUM CURRENT)
CREEP SPEED Initial step voltage
BACKING TIME Backing time
BACKING SPEED Fixed speed during backing function
SEAT MICRO DELAY 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”).
HYDRO TIME Delayed disengaging of hydro output.
3.4.b Floor washer
ACCELER. DELAY Acceleration time; 9 = maximum time
DECELER. DELAY Deceleration time; 9 = maximum time
RELEASE BRAKING Release braking time; 9 = max. braking power, minimum
time
INVERS. BRAKING Inversion braking time; 9 = max. braking power, minimum
time
CUTBACK SPEED 1 Speed reduction 1
CUTBACK SPEED 2 Speed reduction 2
MAX FORW. SPEED Maximum forward speed
MAX BACK. SPEED Maximum reverse speed
TRACTION IMAX Maximum current (it's a function of the parameter
MAXIMUM CURRENT)
CREEP SPEED Initial step voltage
AUXILIARY TIME Delayed disengaging of auxiliary output NEV2.
HYDRO TIME Delayed disengaging of hydro output (NEV1).

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3.5 "SET MODEL" MENU
Model Type
Option #1 The 4Q is configured as a transpallet.
Option #2 The 4Q is configured as a floor washer.
3.6 "SET OPTION" MENU
3.6.a Pallet truck
Hour counter
Running The hour counter is active during running only.
Key on The hour counter is active at all times.
Battery check
Off Battery alarm disengaged.
On Low battery alarm engaged (plus current limiting device).
Aux output #1 (NEV2 - NEB output)
Free Unused output
Brake Output used to control an electric brake that receives the
positive from the tiller switch (with relative diagnosis).
Option #2 Output used to control an electric brake that does not
receive the positive from the tiller switch (diagnosis
disengaged).
Option #3 Output used to enable the electric brake during release
braking. The brake is controlled as in the option "brake".
Quick inversion
Belly Quick inversion active while the belly button remains
pressed.
Timed Timed quick inversion (fixed duration).
Backing function
This option is effective only if the “Set input #2” is set to “Option #1”
Off The backing function is disengaged; the RV2 input is a
speed reduction.
On The backing function is enabled; the RV2 input is used to
activate the backing function, the direction is chosen
using the gears.

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Handle switch
Present 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 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 The NEV1 output acts as a hydro: it is active during running
and is set at rest with a programmable delay time after
running.
Option #2 The NEV1 output is activated when a thermal alarm is
present (e.s. can be used to activate a fan)
Set input #2
Option #1 The “Aux output #2” and “Backing function” options can be
used.
Option #2 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.
Inversion Mode
Option #1 The quick inversion input is configured as normally open.
Option #2 The quick inversion input is configured as normally closed.
Aux function #2
Option #1 The potentiometer is configured with an electric range of 0V-
5V. Forward and backward micros are present.
Option #2 The potentiometer is configured with an electric range of 0V-
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 5V = backward

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Set battery type
Sets the battery nominal value
24V 24V battery.
36V 36V battery.
3.6.b Floor washer
Hour counter
Running The hour counter is active during running only.
Key on The hour counter is active at all times.
Battery check
Off Battery alarm disengaged.
On Low battery alarm enabled (plus current limiting device).
Quick inversion
Belly Quick inversion is active while the button remains
Timed Timed quick inversion (set duration).
Inversion Mode
Option #1 The quick inversion input is configured as normally open.
Option #2 The quick inversion input is configured as normally
closed.
Automatic function
Off To be defined.
On 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.
Aux function #2
The tiller/seta switch is not used by cleaning machine, so the input can be used for
other purpose.
Option #1 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.
Option #2 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.