Zapi SEM-Zero User manual

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INDEX Page
LEGEND 3
COLOUR CODES (Single Colours) ...................................................................... 3
1 Introduction to the ZAPI-MOS family .......................................................... 4
2 General characteristics................................................................................. 5
2.1 Technical Specification.......................................................................... 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-Zero 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-Zero 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-Zero: cabling and configuration ....................................................... 17
5.1 Power diagram .................................................................................... 17
5.2 Connections ........................................................................................ 18
5.3 Description of Programmable Functions (Options). ............................ 19
5.4 Description of Parameters that may be Programmed ......................... 21
5.5 Table of Adjustments........................................................................... 23
5.4 SEM-Zero Traction Standard Wiring Diagrams................................... 25
5.5 Sequence for SEM-Zero Traction Settings.......................................... 26
6SEM-Zero Diagnostics ................................................................................ 27
6.1 Analysis of Alarms displayed on the Console ..................................... 28
6.2 Tester Description of the Functions .................................................... 31
6.3 Description of the Console SAVE Function......................................... 33
6.4 Description of Console RESTORE Function. ...................................... 34
6.5 Description of Alarms Menu. ............................................................... 35
6.6 Description of Console PROGRAM VACC function. ........................... 36
7 Recommended Spare parts for SEM-Zero .................................................... 37
8 Periodic Maintenance to be repeated at times indicated ............................ 38
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SIGNED IN APPROVAL
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Pubblicazione n°: ACLZP0CA
Edizione: Aprile 1998
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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 INTRODUCTIONTOTHE 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 be-
haviour 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 programme 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 increas-
ing 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-Zero 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 replace-
ment.
- The SEM-Zero family of Choppers are suitable for operating on DC voltages from 24
to 36V inclusive, with maximum armature current up to 200A.
The choppers may be used to control DC Separately Excited Motors with power
ratings up to 2.0kW.
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2 GENERAL CHARACTERISTICS
2.1 TECHNICAL SPECIFICATION
Chopper for Separately Excited DC motors ...................................................0.5 ÷ 2.0kW
Regenerative Braking.
Voltage Range ................................................................................................. 24-36VDC
Maximum Field Current (all the versions) ................................................................. 35 A
Armature Switching Frequency ...............................................................................16kHz
Field Switching Frequency ........................................................................................1kHz
Maximum Ambient temperature.............................................................................+ 40°C
Minimum Ambient temperature................................................................................-30°C
Maximum temperature of Chopper ........................................................................+ 80°C
VERSIONS MAXIMUM CURRENT BOOSTER CURRENT VOLTAGE DROP IN
FULL CONDUCTION
24 / 36V 150A (3') 180A (10'') 0.23V at 50A, 25°C
24 / 36V 200A (2') 230A (10") 0.23V at 50A, 25°C
2.2 CONTROL UNITS
2.2.a Microswitches
- Microswitches should have a contact resistance lower than 0.1W, 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 Handle 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 (B1) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance : 500W
Maximum Potentiometer Resistance : 10kW
Faults can occur if the potentiometer is out of this range.
The Procedure for automatic potentiometer signal aquisition 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 machanical 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
aquisition being made. The Right Hand Graph shows the same relationship after signal
aquisition 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 70°C, the maximum current reduces in
proportion to the thermal increase. The temperature can never exceed 80°C (below
-10°C, the current is reduced to 80%).
- Low Battery Charge :
When the battery charge is low, the maximum current is reduced proportionally to
the battery discharge.
- 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 re-
quires 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, Speed Limit
Braking.
- Speed Control during descent : the motor speed follows the accelerator. The chop-
per 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.
- Programmable Anti Roll Back : When the Key Switch is closed, if the motor is rotat-
ing, 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.
- Output for Hourmeter
- The main contactor is open after 45 seconds of stand-by condition.
- Self Diagnosis with indication of fault shown via flashing Red Led. (In addition to
Console Display).
- 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 tempera-
ture all displayed on the Console.
- Test Function within Console for checking main parameters. See the specific De-
scription.
- High motor and battery efficiency due to High Frequency Switching.
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2.6 SEM-ZERO CHOPPER DIAGNOSIS
The microprocessor continually monitors the chopper and carries out diagnostic proce-
dures 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
sensor, VMN point, Contactor Drivers, the switch sequence for operation is correct,
and the output of the accelerator or tiller is correct.
2) Standby Diagnosis at rest that checks: VMN Point, Contactor Drivers, and Current
Sensor.
3) Diagnosis during operation that checks: Watchdog, VMN Point, Current,
Contactor(s), and VMN when in full conduction.
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.
Diagnosis is provided in 2 ways. The Red Led connected to Connector A will flash a
certain number of times for a given Alarm (See Listings), or the Digital Console may be
used. A permanent Alarm will be displayed on the Console immediately and the RED
LED will flash. An intermittent Alarm will be recorded in the Alarm library, but the RED
LED will only flash at the time of the Alarm.
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 situa-
tions where either ventilation is poor, or heat exchange is difficult, forced air ventila-
tion 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-Zero modules. The filter
capacitors contained in the SEM-Zero module will change the SCR chopper opera-
tion 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-Zero must be completely disconnected from the
battery. As well as altering the charge current read by the battery charger, the mod-
ule can be damaged by higher than normal voltages supplied via the charger.
- The SEM-Zero 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 discon-
nected, and a short circuit is made between Battery Positive and Battery negative
power terminals of the chopper using a Resistor between 10Wand 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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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 corro-
sive 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 cor-
rectly. Ensure that suppression devices are fitted to the coils not protected by the
SEM-Zero 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 16mm² 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 contac-
tor should be fitted with a coil corresponding to the battery voltage. The current ab-
sorbed by the coil must not be greater than 3A.
Suppression for this contactor coil is within the chopper. Do not use external suppres-
sion. 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-ZERO CONNECTORS.
PIN REFERENCE DESCRIPTION
A1 HOURMETER Output hourmeter; it controls a load to -BATT. Maximum output
current 200mA.
A2 KEY B+ Supply into logic downstream of 10A fuse & key switch.
A3 NMC Negative main contactor coil.
A4 NEMB Negative electro-brake.
A5 TILLER Tiller micro-switch.
A6 -BATT -BATT.
A7 PMC Positive main contactor coil and common positive supply for REV,
FORW, B SW, HORN, LIFT, LOW microswitches.
A8 H&S Hard & Soft function input. It should be connected to A7 through
the H&S switch. Active high (+VB).
B1 CPOT Accelerator's potentiometer wiper, or output of inductive device.
B2 NPOT Provides a negative supply to accelerator's potentiometer.
B3 PPOT Provides a positive supply to accelerator's potentiometer.
B4 REV Reverse direction input, it should be connected to A7 by a micro-
switch. Active HIGH (+VB).
B5 B SW Quick inversion input, it should be connected to belly button.
Active HIGH (+VB).
B6 FORW Forward direction input. It should be connected to A7 by a micro-
switch, active HIGH (+VB).
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PIN REFERENCE DESCRIPTION
C1 CM Common positive supply for micro-switch SR1, SR2, (+BATT).
C2 SR1 Input for 1st speed reduction. It should be connected to C1 by
micro-switch, active LOW.
C3 SR2 Input for 2nd speed reduction. . It should be connected to C1 by
micro-switch, active LOW.
D1 REG SIGNAL Regenerative braking status.
Normally high, low while regenerating.
D2 PHORN Positive horn, it should be connected to A7 by the horn
micro-switch.
D3 NHORN Negative horn, it is -BATT.
D4 PPC Positive pump contactor; it should be connected to A7 by lifting
micro-switch LIFT which provides the positive supply to the pump
contactor's coil.
D5 NPC-NEV Negative supply for pump contactor.
D6 PEV Positive electro-valve for lowering.
E1 PCLRXD Positive serial reception.
E2 NCLRXD Negative serial reception.
E3 PCLTXD Positive serial transmission.
E4 NCLTXD Negative serial transmission.
E5 GND Negative console power supply.
E6 +VL Positive console power supply.
E7 --- Free.
E8 --- Free.
3.5 DESCRIPTION OF POWER CONNECTIONS
+BATT = Positive Supply from Battery.
-BATT = 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 “E” connector of the SEM-Zero
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-Zero 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-ZERO: CABLING AND CONFIGURATION
5.1 POWER DIAGRAM
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5.2 CONNECTIONS
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5.3 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.
The A1 output for external hourmeter operates according to internal hourmeter. If the
pump contactor is connected (D4), hourmeter output (A1) is activated during lifting as
well.
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 2 second.
3 AUX OUTPUT #1:
-FREE: A4 output is not used: the controller carry out monitor
function as described at the paragraph 2.5.
-BRAKE: A4 output drives an electromechanical brake. The con-
troller does not carry out monitor function, but locks the
brake while in rest or alarm status.
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Flow Chart showing how to make changes to Configuration Menu using Digital Con-
sole. (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.
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