Zapi COMBI SEM-1 User manual

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Index
Page
1 General characteristics................................................................................. 3
1.1 Technical specifications ........................................................................ 3
1.2 General description ............................................................................... 3
1.3 Main features ........................................................................................ 3
1.4 Safety & protection features.................................................................. 4
1.5 Thermal considerations......................................................................... 4
1.6 Combi Sem-1 chopper diagnosis .......................................................... 5
1.7 Main Contactor and safety button .................................................. 5
1.8 General instructions and precautions ............................................ 6
2 Installation ..................................................................................................... 7
2.1 Connection cables................................................................................. 7
2.2 Contactors............................................................................................. 7
2.3 Fuses .................................................................................................... 7
2.4 Combi Sem-1 controller mechanical drawing........................................ 8
2.5 Serial tiller mechanical drawing............................................................. 9
3 Connection .................................................................................................. 10
3.1 Combi Sem-1 connection drawing ...................................................... 10
3.2 Serial tiller connection drawing............................................................ 11
3.3 Description of combi sem-1 connectors .............................................. 12
3.3.1 Connector "A" description .......................................................... 12
3.3.2 Connector "B" description .......................................................... 12
3.3.3 Connector "C" description .......................................................... 13
3.3.4 Connector "D" description .......................................................... 14
3.3.5 Connector "E" description .......................................................... 14
3.3.6 Connector "F" description .......................................................... 16
3.4 Combi Sem-1 power connection ......................................................... 16
4 Regulation.................................................................................................... 17
4.1 Zapi Programming handly console...................................................... 17
4.2 Description of standard console menu................................................ 18
4.3 "Parameter Change" menu ................................................................. 19
4.4 "Tester" menu ..................................................................................... 21
4.5 "Adjustment" menu.............................................................................. 21
4.6 "Set Option" menu............................................................................... 21
5 Alarms .......................................................................................................... 23
6 Recommended spare parts ........................................................................ 27
7 Periodic maintenance to be repeated at times indicated ........................ 28

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= The informations included into the marked paragraphs by this symbol are
essential for the safety.
SIGNATURES TABLE
SECIVRES.TPEDYNAPMOCEVITUCEXETNEMEGANAM
EVITUCEXENOITCESGNIREENIGNE
REGANAMTROPXE
Publications N°: AD3ZP0AA
Edition: September 2000

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1 GENERAL CHARACTERISTICS
1.1 TECHNICAL SPECIFICATIONS
Motor Types (Traction):.............................................................................. DC SEM
Motor Types (Pump): ............................................................................ DC SERIES
Power ratings (Traction):........................................................................... 1 to 2 kW
Supply Voltage: .........................................................................................24V / 48V
Armature Switching frequency: ..................................................................... 16 kHz
Field Switching frequency: ............................................................................800 Hz
Temperature range: ....................................................................... -30 °C to +40 °C
Maximum controller temperature: ................................................................... 75 °C
Version Maximum Traction current Maximum Pump current
200+250 200 A 250 A
300+300 300 A 300 A
400+250 400 A 250 A
1.2 GENERAL DESCRIPTION
ZAPI COMBI SEM-1 controller performs all the electric functions that are usually
presents in transpallet, stacker, low order picker etc.
The controller can perform the following functions:
- Traction controller for SEM motor; full-bridge on the field, half-bridge on the armatu-
re.
- Lifting controller for series excited motors.
- Drivers for ON/OFF electrovalves and for one proportional valve (electrodistributor)
- Interface for serial tiller head
- MDI interface (Multifunction Digital Instrument) battery discharge indicator,
hourmeter, alarms, programmed maintenance.
1.3 MAIN FEATURES
- High frequency MOSFET controller (high efficency, silent, etc.).
- Speed control with regenerative braking (controls the truck also on the slope)
- Idraulic functions control with different programmable speeds and ramps, It is
possible to use proportional functions.
- Lowering speed control through proportional valve.
- All the parameters are programmable by means of the ZAPI console.
- Complete diagnosis through console or MDI.
- High temperature protection with current reduction.
- Drivers real time diagnosis (electro-brake, general contactor and proportional valve.
- Electrobrake and general contactor are controlled with a PWM.
- Drivers protected against short-circuits.

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1.4 SAFETY & PROTECTION FEATURES
- Reverse Battery Polarity.
Electrical Circuit diagrams must be followed in order to avoid damage to the power
unit. A Main contactor, controlled by the logic unit, is necessary to protect the system
against reverse battery polarity.
- Connection errors
All inputs are protected against connections errors. Contactor drivers are suitable for
loads up to 2 Amps, and are protected against overload.
- Thermal protection
If the controller temperature exceeds 77°C, the maximum current will be reduced
proportionaly to the thermal increase. The temperature can never exceed 90°C.
- Low Battery charge
When the battery charge is low, the maximum current is reduced.
- External Agents
The chopper is protected against dust and spray of liquid to a degree of protection
meeting IP64.
- Protection against accidental Start Up
A precise sequence of operations is necessary before the machine starts. If these
operations are not carried out correctly the machine stops. Driving requests must be
made after closing the Key Switch.
- Protection against uncontrolled movements.
The Main Contactor will not close if:
- The Power Unit is not operating correctly
- The Logic Unit is not operating correctly
- The Serial Tiller is not operating correctly
1.5 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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1.6 COMBI SEM-1 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: watch-dog, Current Sensors, VMN
point, contactor drivers, presence of a start requirement, and connection with the
Serial Tiller ok.
2) Standby Diagnosis that checks: watch-dog, VMN Point, Contactor Drivers, Current
Sensors.
3) Driving diagnosis that checks: Watchdog, VMN Point, Current, Contactor(s).
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.
1.7 MAIN CONTACTOR AND SAFETY BUTTON
- Battery disconnection should be made according to the Diagram below.
- In order to avoid damage to the controller during the regenerative phase, the supply
to the Key Switch must be cut off at the same time.
Wiring with cut off in series to positive supply.
- An internal protection is activated when the voltage on B12 connector is greater than
30% of battery voltage, or when the key switch is opened before the battery is
opened.

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1.8 GENERAL INSTRUCTIONS AND PRECAUTIONS
- Never combine SCR low frequency choppers with COMBI SEM-1 modules. The filter
capacitors contained in the COMBI SEM-1 module would change the SCR chopper
operation and subject it to excessive workload. If it is necessary to use two or more
control units, the choppers should both 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. A lower
voltage may prevent the logic operating.
- During battery recharge, the COMBI SEM-1 must be completely disconnected from
the battery. Beside changing the charging current seen by the battery charger, the
module can be damaged by higher than normal voltages supplied via the charger.
- The COMBI SEM-1 module should only be connected to a traction battery. Do not
use converters outputs or power supplies. For special applications please contact the
nearest Zapi Service Centre.
- In the first instance, start the machine with the drive wheels raised from the floor to
ensure that any installation error 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 Ne-
gative power terminals of the chopper using a Resistor between 10W and 100W.
Minimum 5 W.
- The susceptibility and electromagnetic emmission 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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2 INSTALLATION
Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.
Apply a very 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 corro-
sive elements and substances may cause oxidization of 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 (maximum screwing
torque: 3 Nm for M5 and 4Nm for M8 screws).
Verify that the wiring of the cable terminals and connectors has been carried out
correctly.
2.1 CONNECTION CABLES
For the auxiliary circuits use cables bigger or equal to 0.5mm2section.
For power connections to the motor (pump and traction rotor) and to the battery use
cables of 16÷25 mm2section. The cables from chopper to battery should be run side by
side and be as short as possible.
2.2 CONTACTORS
A Main 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 2A.
Suppression for this contactor coil is inside the chopper logic. Do not use any
additional external suppression.
2.3 FUSES
- Use a 10A fuse for protection of the auxiliary circuits.
- The power fuse is alrady installed on the chopper by Zapi. For special applications or
requirements this value can be reduced.

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2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING

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2.5 SERIAL TILLER MECHANICAL DRAWING

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3 CONNECTION
3.1 COMBI SEM-1 CONNECTION DRAWING

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3.2 SERIAL TILLER CONNECTION DRAWING
The folllowing drawing is an example of typical tiller head functions.

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3.3 DESCRIPTION OF COMBI SEM-1 CONNECTORS
3.3.1 Connector "A" description
The "A" connector is connected by Zapi.
A1 KEY OUT This pin is connected to the pin1 of the F connector; is a key signal.
A2 BACKING This pin is connected to the pin2 of the F connector; is a backing
signal.
3.3.2 Connector "B" description
The "B" connector managed the main contactor, the brake and the electrovalves coils.
B1 + BATT Positive after the main contactor; is the electrovalves positive.
B2 NMC Negative of the main contactor
B3 -BATT Negative free for the customer.
B4 -BATT Negative free for the customer.
B5 NEB Negative of the electromechanical brake.
B6 NEVP Negative of the proportional electrovalve.
B7 NEV2-NHO Negative of the electrovalve 2; (option: negative of the horn).
B8 NEV1 Negative of the electrovalve 1.
B9 NEV4 Negative of the electrovalve 4.
B10 NEV3 Negative of the electrovalve 3.
B11 NEV5 Negative of the electrovalve 5.
B12 KEY IN Input of the Key switch signal.

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B13 PMC Positive of the main contactor.
B14 KEY OUT Output of the Key switch signal.
B15 NOT USED Free.
B16 PEB Positive of the electromechanical brake.
B17 PEVP Positive of the proportional electrovalve.
B18 PEV2 Positive of the electrovalve 2.
B19 PEV1 Positive of the electrovalve 1.
B20 PEV4 Positive of the electrovalve 4.
B21 PEV3 Positive of the electrovalve 3.
B22 PEV5 Positive of the electrovalve 5.
Note:
Proportional valve can be programmed by console as proportional or ON/OFF: if
proportional the valve has an acceleration and deceleration ramp and its current is
controlled by the lifting potentiometer.
If ON/OFF the valve is completely opened/closed without ramps.
The positive supply to the main contactor is provided from the key (pin 12) trough a
diode against polarity inversion. The positive supply for the electrobrake is available in
the pin 16 only if the tiller switch is closed.
The positive for the brake and all the other ON/OFF valves comes from the main
contactor, so these loads do not affect the key input but only the auxiliary fuse.
3.3.3 Connector "C" description
The "C" connector manages the serial link of the tiller card.
C1 -BATT Negative free for the customer.
C2 BELLY Quick inversion microswitch input. This signal is directly connected
with the Combi for safety reason.
C3 SNAIL + T Snail microswitch input. It is necessary that the tiller microswitch is
cabled in the serial tiller card; in this case it is possible to run the
truck also with the handle released at a slow speed.
C4 TILLER Tiller microswitch input. In this case the tiller is directly connected
with the Combi.
C5 DRFT Data from the serial tiller
C6 -BATT Negative for the serial tiller card.
C7 KEY OUT Positive for the serial tiller card (is a key switch signal).
C8 KEY OUT Positive for the tiller microswitch (is a key switch signal).
Note:
The tiller microswitch can be cabled in the serial tiller (see ‘serial tiller’ drawing) or
directly in the controller (PIN 4 and 8 for the key in the serial tiller).

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3.3.4 Connector "D" description
The "D" connector manages the MDI instrument or a Zapi console.
D1 NOT USED Free.
D2 PCLRXD Positive of the reception from the console or the MDI instrument.
D3 -BATT Negative of the console or the MDI instrument.
D4 +12 Positive of the console or the MDI instrument.
D5 NOT USED Free.
D6 NOT USED Free.
D7 NCLTXD Negative of the transmission to the console or the MDI instrument.
D8 PCLTXD Positive of the transmission to the console or the MDI instrument.
D9 NCLRXD Negative of the reception from the console or the MDI instrument.
D10 NOT USED Free.
Note:
The console must be connected to "D" at the place of MDI by means of an adaptor
(follow the table for the right connections).
3.3.5 Connector "E" description
The "E" connector manages the inputs from the chassis of the truck.
E1 INPUT 1 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E2 -BATT Negative free for the customer.
E3 CM Positive for the "Input 2"; is a key switch signal interrupted by a diode
for safety reason.

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E4 INPUT 3 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E5 -BATT Negative free for the customer.
E6 INPUT 4 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E7 CM Positive for the "Input 5"; is a key switch signal interrupted by a diode
for safety reason.
E8 CM Positive for the "Input 6"; is a key switch signal interrupted by a diode
for safety reason.
E9 SELECT 1 This is a digital input for model configuration.
E10 SELECT 2 This is a digital input for model configuration.
E11 CM Positive for the "Input 1"; is a key switch signal interrupted by a diode
for safety reason.
E12 -BATT Negative free for the customer.
E13 INPUT 2 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E14 CM Positive for the "Input 3"; is a key switch signal interrupted by a diode
for safety reason.
E15 -BATT Negative free for the customer.
E16 CM Positive for the "Input 4"; is a key switch signal interrupted by a diode
for safety reason.
E17 INPUT 5 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E18 INPUT 6 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E19 -BATT Negative of the "Select 1" input.
E20 -BATT Negative of the "Select 2" input.
Note:
For the inputs is acceptable a PNP sensor with a 24V output. The maximum load for
single inputs is less than 5mA.

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3.3.6 Connector "F" description
The "F" connector is connected by Zapi.
F1 KEY OUT This pin is connected to the pin1 of the A connector; is a key signal.
F2 BACKING This pin is connected to the pin2 of the A connector; is a backing
signal.
3.4 COMBI SEM-1 POWER CONNECTION
+BATT before FUSE Positive of the battery after the main contactor
+BATT after FUSE Positive of the battery after the main cont. and after the fuse.
-BATT Negative of the battery.
F1, F2 Field connections for traction motor.
VMNT Traction motor current sensor input.
VMNP Pump motor input (without the current sensor).

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4 REGULATION
4.1 ZAPI PROGRAMMING HANDLY CONSOLE
In Combi Sem-1 controller is possible to program several functions through the console.
In this way is possible to modify the performances of the truck following the customer
needings.
The console can remain connected to the controller while running and the parameters
can be changed in real time. In this case it is important to go in stand by condition
before switch off the controller in order to give the possibility to store the new values in
the Eeprom.
This section describes the ZAPI console functions.
Six buttons provide the capability of changing or reading the parameter of the Combi:
1 Roll-Up push to scroll up the submenu and to select a parameter;
2 Roll-Down push to scroll down the submenu and to select a parameter;
3 Enter push to have access to the selected submenu or to confirm a
changement;
4 Out push to exit the selected menu or to refuse a changement;
5 Set-Up push to increase a parameter;
6 Set-Down push to decrease a parameter;
Note: After a modify, memoriz the new value pushing the "4" (Out) button and the "3"
(Enter) button. Double pushing of the "4" (Out) button doesn't save the value.
Numbers inside the triangles in the following map correspond to the same number on
the console keyboard buttons shown in the figure below. The orientation of the triangle
indicates the way to the next function.
Important
CONNECT AND DISCONNECT THE CONSOLE ONLY WITH THE CONTROLLER
SWITCHED OFF.

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4.2 DESCRIPTION OF STANDARD CONSOLE MENU

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4.3 "PARAMETER CHANGE" MENU
The following parameters are an example of a typical Parameter Change menu; some
of this parameters could be changed from customer requests.
The parameters with (p) symbol are related to the pump, those with (t) are related to
the traction motor.
1) ACCELERATION DELAY (t) = Sets the acceleration ramp.
2) FLD ACCELERATION (t) = Field acceleration ramp: is the time needed to lower the
field till to the weakened value, is a function of "Acceler. delay".
3) DECELERATION DELAY (t) = Sets the deceleration ramp according to the
accelerator potentiometer position.
4) RELEASE BRAKING (t) = Sets the deceleration ramp when the driving request is
released.
5) INVERS BRAKING (t) = Sets the deceleration ramp when is inverted the driving
direction.
6) CUTBACK SPEED 1 (t) = Speed reduction 1.
7) CUTBACK SPEED 2 (t) = Speed reduction 2.
8) MAX. SPEED FORW. (t) = Maximum Forward speed, obtained by weakening the
field current after reaching 100% conduction on the armature. With the parameter
set at level 0, the armature is in full conduction but the field current does not
decrease below the nominal value (low speed).
9) MAX SPEED BACK (t) = Maximum Reverse speed, obtained by weakening the
field current after reaching 100% conduction on the armature. With the parameter
set at level 0, the armature is in full conduction but the field current does not
decrease below the nominal value (low speed).
10) TRACTION I MAX (t) = Sets the maximum current of the Chopper (Armature).
11) ARMA NOM. CURR (t) = Nominal armature current. This parameter fixes a limit for
the armature current above which the field current is at least the nominal value
(FIELD NOM. CURR.), regardless of accelerator position.
12) WEAK DROPOUT (t)= This parameter fixes a limit on the armature current above
which the field current is increased linearly up to the nominal field current
(proportionally to the armature current).
13) FIELD CURR. MAX. (t) = Maximum field current. This parameter fixes the
maximum field current when the armature reaches the maximum value.
14) FIELD NOM. CURR. (t)= Nominal field current. This parameter fixes the minimum
field current when the accelerator is between 0% and 60% without full conduction
on the armature. Adjustment should be made with reference to the data on the
motor label. (The indication of Nominal Field Current).
15) CREEP SPEED (t)= Minimum speed. This parameter sets the minimum start
voltage applied to the motor.
16) SOFT WORKING (t) = Sets the entity of the acceleration and deceleration curves
with the Snail (H&S) function selected.

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17) PUMP ACC DELAY (p) = Pump motor acceleration time:during this time the
voltage on the pump motor goes to the desired value.
18) PUMP DEC DELAY (p) = Pump motor deceleration time:during this time the voltage
on the pump motor decreases to the desired value..
19) PUMP CREEP (p) = This parameter sets the minimum voltage applied to the pump
motor.
20) 1ST SPEED COARSE (p) = Main lift maximum speed.
21) FORK LIFT SPEED (p) = Forks lift maximum speed.
22) FORK DOWN SPEED (p) = Forks down maximum speed.
23) R - SHIFT SPEED (p) = Right shift maximum speed.
24) L - SHIFT SPEED (p) = Left shift maximum speed.
25) MIN EVP COARSE (p) = Sets the minimum voltage applied to the EVP. This is a
big regulation.
26) MAX EVP COARSE (p) = Sets the maximum voltage applied to the EVP. This is a
big regulation.
27) MIN EVP FINE (p) = Sets the minimum voltage applied to the EVP. This is a fine
regulation.
28) MAX EVP FINE (p) = Sets the maximum voltage applied to the EVP. This is a fine
regulation.
29) EVP ACC. DELAY (p) = Sets the acceleration time of the EVP.
30) EVP DEC. DELAY (p) = Sets the deceleration time of the EVP.
31) BACKING SPEED (t) = Sets the maximum backing (inching) speed.
32) BACKING TIME (t) = Sets the duration of the backing function.