Zapi COMBI SEM-1 User manual

Page 1SEM1
INDEX
Page
1 Introduction to the Zapimos family ............................................................. 3
2 Specification .................................................................................................. 4
2.1 Technical specifications ........................................................................ 4
2.2 Control Units.......................................................................................... 5
2.2.a Microswitches............................................................................... 5
2.2.b Potentiometer............................................................................... 5
2.3 Protection features ................................................................................ 6
2.4 Direction orientation .............................................................................. 7
2.5 Functional features................................................................................ 7
2.6 Controller's diagnostics ......................................................................... 8
2.7 Thermal precautions ............................................................................. 8
2.8 General warnings ......................................................................... 9
3 Installation ................................................................................................... 10
3.1 Connection cables............................................................................... 10
3.2 Contactor............................................................................................. 10
3.3 Fuses .................................................................................................. 10
3.4 Description of connectors.................................................................... 11
3.5 Description of power connectors......................................................... 12
3.6 Mechanical drawing ............................................................................ 13
4 Programming and settings using a console ............................................ 14
4.1 Setting by console............................................................................... 14
4.2 Programming console functions.......................................................... 14
4.3 Programming console ......................................................................... 15
4.4 Map of the console functions............................................................... 16
5 Configuration function ............................................................................... 17
5.1 Adjustment: description and programming instructions ...................... 19
5.2 Parameter regulation........................................................................... 21
5.3 Start up: programming instructions ..................................................... 24
5.3.1 Adjustment sequence................................................................ 24
6 Diagnosis ..................................................................................................... 25
6.1 Alarms displayed on console............................................................... 25
6.2 Tester: functions descriptions ............................................................. 27
6.3 Save parameters: description ............................................................. 29
6.4 Restore parameters: description ......................................................... 30
6.5 Alarms: menu description.................................................................... 31
6.6 Program vacc: description................................................................... 32

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Page
7 Connection drawing.................................................................................... 33
7.1 Diagram part list .................................................................................. 33
7.2 Colour coding ...................................................................................... 33
7.3 Connections ........................................................................................ 34
7.3.1 Control input / output connections............................................. 34
7.3.2 Power configuration................................................................... 35
8 Periodic maintenance to be regularly repeated ....................................... 36
9 Suggested spare-parts ............................................................................... 37
= Information included into the marked paragraphs by this symbol is essential for
the safety.
SIGNATURES TABLE
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publication N°. ABJZP0AD
Edition: September 1997

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1 INTRODUCTIONTOTHE ZAPIMOS FAMILY
The ZAPIMOS chopper family is ZAPI’s answer to the needs of users of the ’90s.
To ensure that the product stays on the market without running the risk of becoming
technologically obsolete, ZAPI has designed the ZAPIMOS family offering the following
features:
- Advanced technology and economical costs
- Maximum safety
- Maximum flexibility
- Open to future technological innovations
- Optimum level of protection.
This implies:
- High frequency Mos technology
- Real-time control over the internal and external parts that can influence the
behaviour of the machine, with self-diagnosis of the checking circuits themselves.
- Stored programme machine (SPC) where the hardware is completely separate from
the functions to be configured. The programme is parametric and can also be
modified by the end user.
- Various chopper functional configurations can be selected by the user, without the
need for hardware modifications.
- Any future technological updates are made clear to the user.
The communication protocol will continue to evolve, thus offering increasing
possibilities of interaction.For this reason, the ZAPIMOS family offers a standard
dialogue mode with external systems, for easy interfacing with commercially
available machines. ZAPI offers a range of programming consoles with various
features and prices.
Within the ZAPIMOS family, the SEM1 choppers are the models suitable for operating
at voltages from 16V to 48V with separately excited motors.
Power ratings will be between 0.5kW to 3.5kW.
This chopper is particularly suited for medium power machines, such as transpallets,
golf cars etc. Its goal is to join optimized performances and low cost.

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2 SPECIFICATIONS
2.1 TECHNICAL SPECIFICATIONS
Separately excited DC motor chopper.
Regenerative braking function.
Operating voltages: ........................................................................... 16-24-36-48V.
Operating frequency:....................................................................................... 8kHz.
Max external temperature: .............................................................................. 40°C.
Min external temperature: ............................................................................... -30°C
Max chopper temperature:.............................................................................. 85°C.
VERSION MAXIMUM CURRENT BOOSTER CURRENT VOLTAGE DROP ON
FULL CONDUCTION
16V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C
24V / 200A 200A (2' 00'') 250A (5'') 0.39V a 70A, 25°C
24V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C
36V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C
48V / 180A 180A (1') 220A (5'') 0.39V a 70A, 25°C
Block diagram:

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2.2 CONTROL UNITS
2.2.a. Microswitches.
- The microswitches must have a contact resistance lower than 0.1Wand a leakage
current lower than 100µA.
- When full load connected, the voltage between the key switch contacts must be
lower than 0.1V.
- The handle microswitch must operate the electromechanical brake coil (if the
electromechanical brake is used).
- The microswitches send a voltage signal when a function request (for ex.: running
request) is made.
2.2.b. Potentiometer
Potentiometer should be in the 3-wire configuration.
CPOT (A2) signal ranges from 0 to 10V.
Pot. value should be in the 0.5 - 10 KWrange. Faults can occour if it is outside this
range.
The procedure for automatic potentiometer signal acquisition is carried out from the
console. This makes it possible to adjust the minimum and maximum useful signal in
the respective directions. This function is indispensable when it is necessary to com-
pensate for asymmetry in the mechanical components that control the potentiometer,
especially regarding the adjustment of the minimum level.
The sequence of procedure is described in the programming console manual.

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The two graphs show the output voltage from an uncalibrated potentiometer with respect
to the mechanical "zero" of the knob of one handle (MI and MA indicate the point at which
the speed microswitches close, 0 is the mechanical zero of the handle rotation).
The first graph shows the correspondence of the motor voltage without having made
the acquisition, while the second graph shows the same correspondence after signal
acquisition by the potentiometer.
The acquisition procedure is invalidated by the machine if the signals do not reach at
least 3V. It is possible to use a normal 3-wire pot., instead of one with central zero, set
on the mean value of its full stroke.
2.3 PROTECTION FEATURES
-Connection errors:
all the inputs are protected against connection errors.
-Thermal protection:
if the temperature exceeds 75°C, the maximum current is reduced in proportion to
the thermal increase. The temperature never exceeds 85°C.
-Low battery charge:
when the battery charge is low, the maximum current is reduced proportionally to the
battery discharge.
-Protection against accidental startup:
a precise sequence of operations is necessary for starting the machine; if these
operations are not carried out correctly, the machine will not start; the request for
running must be activated after the key.
-Protection against uncontrolled movements:
the contactor will not close if:
- the power unit is not functioning;
- the logic is not perfectly operating;
-Main contactor:
is to be installed in order to protect against reverse battery polarity;
-The chopper is protected against dust and liquid (IP41).

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2.4 DIRECTION ORIENTATION
Machines with tiller and belly-switch follow the prEN 1175 directive. This directive es-
tablishes that the direction microswitches (MA and MI) connections must match the
following drawing.
2.5 FUNCTIONAL FEATURES
- Speed control.
- Optimum sensitivity to low speeds.
- Quick inversion: it is activated if the belly-switch is closed when travelling in the
forward direction.
- Regenerative braking based upon adjustable deceleration ramps.
- Three different kinds of braking: release braking, inversion braking, speed limit braking.
- Speed control on a 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.
- Start on a ramp without roll back even without the electric brake.
- Programmable anti roll-back: with the key on, the chopper controls the motor speed;
if the motor is moving, the chopper automatically brakes and keeps the motor at a
very low speed during the descent (this function is very useful for the safety even
without the driver).
- The chopper controls also an electromechanical brake.
- Self diagnosis with indication of the fault through a flashing led.
- Parameters modification via console ( see the specific description).
- Internal hour-meter. The value can be displayed on the console.
- Memory of the last five alarms, with relative hour-meter and temperature displayed
on the console.
- Console tester for checking the main parameters (see the specific description)
- High efficiency of motor and battery due to high frequency commutation.

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2.6 CONTROLLER’S DIAGNOSTICS
The microprocessor carries out the diagnostics of the main operating functions of the
controller.
The diagnostics is organised in four main stages:
1) Check at the start-up (key on) includes: watch-dog test, current sensor test, VMN
test, driver of the line contactor’s coil test, test of the running request, test high
accelerator input.
2) Check while stand-by includes: watch-dog test, current sensor test, VMN test, driver
of the line contactor’s coil test.
3) Check while running includes: watch-dog test, current sensor test, VMN test, driver
of the line contactor’s coil test, VMN full conduction test.
4) Continuous check: temperature test, battery state of charge test.
The diagnostics message can be read through the number of periodic flashes of the
alarm LED fitted or simply connected to the B connector.
By means of the programming console is possible to display the alarm message rela-
tive to the current and already occurred alarms.
2.7 THERMAL PRECAUTIONS
- The heat generated by the controller must be dissipated. The housing of the
controller and the cooling surfaces must be wide enough to allow the necessary
dissipation.
- The cooling system must be sized depending on the performances requested. In
some cases of poor ventilation, where the heat exchange is difficult because of the
materials, a forced ventilation is advisable.
- The power dissipated by the controller is a function of the current and the working
cycle.

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2.8 GENERAL WARNINGS
- Never connect SCR low frequency chopper with SEM1 because the SEM1 filter
capacitors alter the SCR choppers' work. If it is necessary to use two or more control
units (traction + lift. for ex.), they must belong to the ZAPIMOS family.
- Do not connect the chopper to a battery with a nominal value different from the value
indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it
is lower, the control unit does not "power up".
- During battery charge, disconnect SEM1 from the battery.
- Supply the SEM1 only with battery for traction; do not use a power supply.
- When the chopper is installed, make tests with the wheels raised from the ground, in
order to avoid dangerous situations due to connection errors.
- After the chopper is switched off (key off), the filter capacitor remains charged for
some minutes; if you need to work on the chopper, discharge them using a
10W÷ 100Wresistance connected from the +Batt to the -Batt.
- Electromagnetic susceptibility and emission are strongly influenced by the
installation. Special attention must be given to the lengths and the paths of the
electric connections and the shields.
This situation is beyond ZAPI's control. Therefore ZAPI declines any responsibility for
noncompliance if correct testing is not made (the irradiated emission directive is
EN50081-2).

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3 INSTALLATION
Install the chopper with the base-plate on a flat metallic surface that is clean and
unpainted. Apply a light layer of thermo-conductive grease between the two surfaces in
order to allow better heat dissipation.
Ensure that the wiring of the cable terminals and connectors is carried out correctly.
Fit transient suppression devices to the horn, solenoid valves, and contactors not con-
nected to the chopper such as those for activating the pump motor or steering motor.
3.1 CONNECTION CABLES
For the auxiliary circuits, use cables of 0.5mm² section.
For power connections to the motor and to the battery, use cables having section
of 16 mm².
For the field winding connections use cable with a 4mm² section.
In order improve the chopper performance, the battery cables must be as short as
possible and near each other.
3.2 CONTACTOR
The general contactor is installed on the chopper. Use a contactor the same voltage as
the battery. The current coil must be lower than 3A. The coil transient suppression is
integrated the chopper
3.3 FUSES
- In order to protect the auxiliary circuits, use a 6.3A fuse.
- In order to protect the power unit see the diagram. Values shown are 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 particles in event of a blowout.

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3.4 DESCRIPTION OF CONNECTORS
PIN NAME DESCRIPTION
A1 NEF Negative output of the electromechanical brake's coil (max. 3A).
A2 CPOT Potentiometer wiper (range: 0V (min) to 10V (max)).
A3 NPOT Negative potentiometer.
A4 PPOT Potentiometer positive: 12V output. Keep load >500W.
A5 PTG Positive of the main contactor's coil (max. 3A).
A6 NTG Negative of the main contactor's coil (max. 3A).
A7 RV2 Input for 2nd speed reduction request. If left free or connected to
battery negative the reduction function operates. If connected to A13,
the reduction is inhibited.
A8 RV1 Input for 1st speed reduction request. If left free or connected to
battery negative the reduction function operates. If connected to A13,
the reduction is inhibited. This speed reduction is linked to an adjust-
able braking (curve braking).
A9 MA Forward direction microswitch. It should be connected to the forward
microswitch, active HIGH (+VB).
A10 MI Backward direction microswitch. It should be connected to the back-
ward microswitch, active HIGH (+VB).
A11 TIM/SEAT It should be connected to the tiller microswitch or to the seat
microswitches (2 sec delay). It is active high (+VB).
A12 IR Quick inversion input, it is active HIGH (+VB).
A13 CMM Common IR/TIM/MI/MA/RV1/RV2 microswitch (+VB).
A14 CH Connected to the power supply through a 6.3A fuse and the key-
switch.

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B1 PCLRXD Positive serial reception.
B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial trasmission or positive of the diagnostic LED if the
(PLED) console is not connected.
B4 NCLTXD Negative serial trasmission or negative of the diagnostic LED if the
(NLED) console is not connected.
B5 GND Negative console power supply.
B6 +14 Positive console power supply.
B7 -----
B8 -----
3.5 DESCRIPTION OF POWER CONNECTORS
F1, F2: motor field windings
VMN, SH: motor rotor windings
+BATT: battery positive
-BATT: battery negative

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3.6 MECHANICAL DRAWING

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4 PROGRAMMING AND SETTINGS USING A CONSOLE
4.1 SETTING BY CONSOLE
Adjustments of the parameters and the configurations are to be carried out by the pro-
grammable Console. The Console is connected to the relative connector B.
The connection is to be carried out with the key sw. open or the battery disconnected.
Pay attention to the connector polarity of the console when it is connected
to the controller.
4.2 PROGRAMMING CONSOLE FUNCTIONS
- Configuration Function.
- Parameter Settings.
- Tester - When the chopper is running, this function is not available.
In Standby Mode the following can be tested:
- Battery Voltage
- Internal Temperature of the Chopper
- Accelerator Potentiometer Wiper
- Forward Switch
- Reverse Switch
- Handle/Seat Switch
- Cut Back Switches 1 & 2
- Quick Inversion.
- Save Function - Saves Program Configuration.
- Restore Function - Restores Program Configuration.
- Alarms - Displays the last 5 Alarms together with the temperature and the hour
meter reading when the alarm occurred.
- Accelerator range programming, records the minimum and maximum output values
of the accelerator unit, optimising in this way the full stroke.

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4.3 PROGRAMMING CONSOLE
The console to be connected the controller SEM1 is to be equipped with the EPROM
"CK ULTRA".

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4.4 MAP OF THE CONSOLE FUNCTIONS

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5 CONFIGURATION FUNCTION
Using the CONFIG MENU of the programming console, the user can configure the
following functions:
SUBMENU "SET OPTIONS":
1. HOUR COUNTER:
- RUNNING: the hour counter is active only when running.
- KEYON: the hour counter is active when the key is ON.
2. BATTERY CHECK:
- ON: the battery charge is continuosly monitored .
- OFF: the battery test is not carried out.
3. QUICK INVERSION:
- FREE: the IR is active in standby, it has no timeout and finishes
only when the operator switches all the input signals off;
- HANDLE: the IR finishes after a timeout; the chopper starts again
only when the operator switches all the input signals off.
4. CURVE BRAKING:
- ON: when the RV1 is held ACTIVE during running, the new
speed is reached by braking with an intensity established
by the CURVE BRAKING parameter (see 4.2).
- OFF: the new speed is reached with a deceleration whose
intensity is established by the SPEED LIMIT BRAKING
parameter (see 5.2).
5. SAFETY SWITCH:
- NONE: the safety switch is not present.
- HANDLE: a tiller is present.
- SEAT: a seat switch is present.
6. DIR. SELECTOR:
- NONE: double pedal (one for forward direction, the other one for
backward direction).
- PRESENT: running selector + single pedal.
7. ANTI ROLL-BACK:
- ON: when left on a ramp without a running request the ma-
chine does not roll-down.
- OFF: this function is not activated.
8. TRANSPALLET MODE:
- ON: in this mode the acceleration and braking ramps are faster
(twice).
- OFF: standard ramps (switched for golf-car).

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Programming "options", using the console:
1) Opening Display
2) Press ROLL UP + SET UP to simultaneously
enter the menu SET.
3) Headline of the menu SET MODEL.
4) Press ROLL UP to select the menu SET OPTIONS.
5) Headline of the menu SET OPTIONS.
6) Press ENTER to enter the menu.
7) The first item of the menu appears.
8) Press ROLL UP or ROLL DOWN to
scroll the different items.
9) A new item appears.
10)Press SET UP or SET DOWN to modify the configuration.
11)The new configuration appears.
12)Press OUT to come out of the menu.
13)Confirmation of the modification request appears.
14)Press ENTER to confirm the modifications
or press OUT to cancel.
15)Headline of the menu SET OPTIONS appears.
16)Press OUT to return back to the opening display.

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5.1 ADJUSTMENT: DESCRIPTION AND PROGRAMMING INSTRUCTIONS
This functions allows fine tuning of the internal measurement of the battery voltage.
The tuning permits to compensate the possible voltage drops along the wires in order to
get the voltage value displayed on the console equal to the true voltage value of the
battery.
ADJUSTMENT operations with the console:
1) Opening display.
2) Press ROLL UP + SETUP to enter
the menu CONFIG.
3) Headline of the menu
SET MODEL (function not available) appears.
4) Press ROLL UP to select the menu ADJUSTMENT.
5) Headline of the menu ADJUSTMENT appears.
6) Press ENTER to enter the menu.
7) The first item of the menu: SET BATTERY TYPE.
8) Press the SET PARAM buttons to select the suitable
nominal battery voltage.
9) The new value appears.
10) Press ROLL UP for a new menu.
11) The ADJUST BATTERY menu appears.
12) The button SETUP increases the value shown on the
display, the button SET DOWN decreases it.
Set to the same value as measured on the battery
with a multimeter.
13) The new voltage value appears.

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14)Press OUT to quit the menu.
15)Confirmation of the modification request appears.
16)Press ENTER to confirm the modifications
or press OUT to cancel.
17)Headline of the menu appears.
18)Press OUT to return to the main menu.