Zapi SEM-1C User manual

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INDEX
Page
LEGEND .............................................................................................................. 3
COLOUR CODES (Single Colours) ...................................................................... 3
1 Introduction to the ZAPI-MOS family ........................................................... 4
General characteristics ................................................................................. 5
2.1 Technical S ecification.......................................................................... 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 O erational Features............................................................................. 8
2.6 SEM-1C cho er 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 Descri tion of SEM-1C Connectors. ................................................... 12
3.5 Descri tion 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 Descri tion of Console & Connection.................................................. 15
4.3 Descri tion of Standard Console Menu............................................... 16
5 SEM-1C: cabling and configuration ........................................................... 17
5.1 Power diagram .................................................................................... 17
5.2 Connections ........................................................................................ 18
5.3 Descri tion of Programmable Functions (O tions).............................. 19
5.4 Descri tion of Parameters that may be Programmed ......................... 21
5.5 Table of Adjustments........................................................................... 23
5.6 SEM-1C Traction Standard Wiring Diagrams ...................................... 25
5.7 Sequence for SEM-1C Traction Settings. ........................................... 26
6 SEM-1C Diagnostics.................................................................................... 7
6.1 Analysis of Alarms dis layed on the Console ..................................... 28
6.2 Tester Descri tion of the Functions..................................................... 31
6.3 Descri tion of the Console SAVE Function ......................................... 33
6.4 Descri tion of Console RESTORE Function. ...................................... 34
6.5 Descri tion of Alarms Menu. ............................................................... 35
6.6 Descri tion of Console PROGRAM VACC function. ........................... 36
7 Recommended Spare parts for SEM-1C .................................................... 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
Pubblication n°: AD0ZP0CA
Edition: February 000
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LEGEND
B SW = Belly Switch
CM = Common Microswitches
CPOT = Wi er 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 Pum Contactor
NPOT = Negative Potentiometer
PC = Pum Contactor
PEMB = Positive Electromechanical Brake
PEV = Positive Lowering Valve
PHORN = Positive Horn
PMC = Positive Main Contactor
PPC = Positive Pum Contactor
PPOT = Positive Potentiometer
REV SW = Reverse Switch
SR1 = S eed Reduction 1
SR2 = S eed Reduction 2
T SW = Tiller Switch
COLOUR CODES (SINGLE COLOURS)
The following Codes re resent the colours of individual wires used by Za i (unless
s ecified 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 - Pur le
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1 INTRODUCTION TO THE ZAPI-MOS FAMILY
The ZAPIMOS cho er family re resents ZAPIs answer to the needs of the 90s.
To ensure that roducts 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.
- O en 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 com onents that influence the behav-
iour of the machine, with self diagnosis of the checking circuits themselves.
- Stored Program Machine (SPC), where the hardware is com letely se arate from
the functions to be configured. The rogramme is arametric and can easily be modi-
fied by the end user.
- Various cho er configurations can be selected by the user, without the need for
hardware modifications.
- Future technological u dates 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. Za i can offer a range of individually designed
Console Software with various features and rices.
- SEM-1C meets the requirements of (IP54). This rovides excellent rotection
against s ray (water, acid.), and against the ingress of dust or small foreign articles.
Access to the control logic is very sim le, and allows sim le substitution or re lace-
ment.
- The SEM-1C family of Cho ers are suitable for o erating on DC voltages from 24
to 48V inclusive, with maximum armature current u to 300A.
The cho ers may be used to control DC Se arately Excited Motors with ower
ratings from 1.0KW to 3.5 KW.
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GENERAL CHARACTERISTICS
.1 TECHNICAL SPECIFICATION
Cho er for Se arately Excited DC motors ................................................... 1.0÷ 3.5kW
Regenerative Braking.
Voltage Range ............................................................................................ 24-36-48VDC
Maximum Field Current (all the versions) .................................................................. 35 A
Armature Switching Frequency ...............................................................................16kHz
Field Switching Frequency ........................................................................................1kHz
Maximum Ambient tem erature ............................................................................. + 40°C
Minimum Ambient tem erature ................................................................................-30°C
Maximum tem erature of Cho er......................................................................... + 80°C
FIeld resistance .......................................................................................... 0.3 ÷ 0.6 Ohm
VERSIONS MAXIMUM CURRENT BOOSTER CURRENT VOLTAGE DROP IN
FULL CONDUCTION
24V-36V 200A (3') 220A (10'') 0.23V a 100A, 25°C
24V-36V 300A (2') 330A (10") 0.23V a 100A, 25°C
48V 180A (3') 200A (10") 0.18V a 50A, 25°C
. CONTROL UNITS
. .a Microswitches
- Microswitches should have a contact resistance lower than 0.1Ω, and a leakage
current lower than 100 µA.
- When full load current is being drawn, the voltage dro 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 o erate
the Brake Coil.
- The Microswitches send a voltage signal to the micro rocessor when an o erating
request (running) is made.
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. .b Potentiometer
The Potentiometer should be wired in the 3 - Wire Configuration.
CPOT (B1) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance : 500Ω
Maximum Potentiometer Resistance : 10kΩ
Faults can occur if the otentiometer is out of this range.
The Procedure for automatic otentiometer 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 nec-
essary to com ensate for asymmetry with the machanical elements associated with the
otentiometer, es ecially relating to the minimum level.
The two gra hs show the out ut voltage from a non-calibrated otentiometer with
res ect to the mechanical zero of the control lever. MI and MA indicate the oint
where the direction switches close. 0 re resents the mechanical zero of the rotation.
The Left Hand gra h shows the relationshi of the motor voltage without signal
aquisition being made. The Right Hand Gra h shows the same relationshi after signal
aquisition of the otentiometer.
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.3 SAFETY & PROTECTION FEATURES
- Connection Errors :
All In uts are rotected against connection errors.
- Thermal Protection :
If the cho er tem erature exceeds 70°C, the maximum current reduces in
ro ortion to the thermal increase. The tem erature 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 ro ortionally to
the battery discharge.
- Protection against accidental Start up :
A recise sequence of o erations are necessary before the machine will start.
O eration cannot commence if these o erations 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 erfectly.
- Main / Line Contactor :
Should be fitted to give rotection to the cho er against reverse battery olarity,
and safety.
- External Agents :
The cho er is rotected against dust and the s ray of liquid to a degree of
rotection meeting IP54.
.4 DIRECTION ORIENTATION
Machines fitted with Tillers, Belly Switches, and Pulse Control Systems roviding ra id
reversal should conform to the requirements of Directive rEN 1175. This Directive re-
quires that Direction Orientation should match the following drawing:
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.5 OPERATIONAL FEATURES
- S eed Control .
- O timum sensitivity at low s eeds.
- S eed Reductions in both the directions. Levels can be set using Console.
- Regenerative Braking based on deceleration ram s, in every condition.
- Three different modes of Braking : Release Braking, Inversion Braking, S eed Limit
Braking.
- S eed Control during descent : the motor s eed follows the accelerator. The cho -
er automatically brakes if the motor s eed overcomes the accelerator set oint.
This rovides o timum erformance on a gradient.
- Starts on a Ram 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 cho er controls the s eed and automatically brakes and kee s the motor at
a very low s eed during descent on a gradient. This is a very useful safety feature
and is not driver de endent.
- Out ut for Hourmeter
- The main contactor is o en after 45 seconds of stand-by condition.
- Self Diagnosis with indication of fault shown via flashing Red Led. (In addition to
Console Dis lay).
- Modification of the arameters via Digital Console. See the s ecific descri tion.
- Internal Hour Meter that is dis layed on the Console.
- Memory of the last 5 Alarms, with relative Hour meter count and cho er tem era-
ture all dis layed on the Console.
- Test Function within Console for checking main arameters. See the s ecific De-
scri tion.
- High motor and battery efficiency due to High Frequency Switching.
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.6 SEM-1C CHOPPER DIAGNOSIS
The micro rocessor continually monitors the cho er and carries out diagnostic roce-
dures on the main functions.
The diagnosis is made in 4 oints:
1) Diagnosis on Key Switch closing that checks: the Watch Dog Circuits, the current
sensor, VMN oint, Contactor Drivers, the switch sequence for o eration is correct,
and the out ut of the accelerator or tiller is correct.
) Standby Diagnosis at rest that checks: VMN Point, Contactor Drivers, and Current
Sensor.
3) Diagnosis during o eration that checks: Watchdog, VMN Point, Current,
Contactor(s), and VMN when in full conduction.
4) Continuos Diagnosis that checks: Cho er tem erature, Battery Voltage.
Diagnosis is rovided 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 ermanent Alarm will be dis layed 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.
.7 THERMAL CONSIDERATIONS
- The heat generated by the ower block must be dissi ated. For this to be ossible,
the com artment must be ventilated and the heat sink materials am le.
- The heat sink material and system should be sized on the erformance requirement
of the machine. Abnormal ambient air tem eratures should be considered. In situa-
tions where either ventilation is oor, or heat exchange is difficult, forced air ventila-
tion should be used.
- The thermal energy dissi ated by the ower block module varies and is de endent
on the current drawn and the duty cycle.
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.8 GENERAL INSTRUCTIONS AND PRECAUTIONS
- Never combine SCR low frequency cho ers with SEM-1C modules. The filter ca-
acitors contained in the SEM-1C module will change the SCR cho er o eration
and subject it to excessive workload. If it is necessary to use two or more control
units (eg. Lift + traction), the cho ers must be of the High Frequency Za i family.
- Do not connect the cho er to a battery with a different nominal voltage to the value
indicated on the cho er. A higher battery voltage may cause MOS failure, and a
lower voltage may revent the logic o erating.
- During battery recharge, the SEM-1C must be com letely 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 su lied via the charger.
- The SEM-1C module should only be su lied by a traction battery. Do not use the
out uts of converters or ower su lies. For s ecial a lications lease contact the
nearest Za i 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 com romise safety.
- After o eration, even with the Key Switch o en, the internal ca acitors may remain
charged for some time. For safe o eration, we recommend that the battery is discon-
nected, and a short circuit is made between Battery Positive and Battery negative
ower terminals of the cho er using a Resistor between 10Ω and 100Ω.
Minimum 5 W.
- The susce tibility and electromagnetic emmission levels are seriously influenced by
installation conditions. Take articular care with the length of cables and wires, ty es
of electrical connections, and braided/screened wires.
Za i declines any res onsibility for incorrect or bad o eration 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 cho er base late onto a flat metallic surface that is clean and un ainted.
A ly a thin layer of thermo-conductive grease between the two surfaces to ermit
better heat dissi ation.
Des ite the rotection rovided against external agents, the continuous attack of corro-
sive elements and substances may cause oxidization of connector contacts, resulting in
bad o eration. Remember this oint when deciding the installation osition on the vehi-
cle.
Fix the cho er using the s ecial holes located on the base late.
Verify that the wiring of the cable terminals and connectors has been carried out cor-
rectly. Ensure that su ression devices are fitted to the coils not rotected by the
SEM-1C itself.
3.1 CONNECTION CABLES
For the auxiliary circuits use cables better or equal to 0.5mm² section.
For ower connections to the motor armature and battery use cable of 16mm² section.
For the Field connections use cable of 4mm² section.
For the o timum cho er erformance, the cables to the battery should be run side by
side and be as short as ossible.
3. CONTACTORS
A Line Contactor, designed for Continuous O eration should be installed. This contac-
tor should be fitted with a coil corres onding to the battery voltage. The current ab-
sorbed by the coil must not be greater than 3A.
Su ression for this contactor coil is within the cho er. Do not use external su res-
sion. For any Contactor using external su ression, ensure that connections are made
res ecting correct olarity.
3.3 FUSES
- Use a 6.3A Fuse for rotection of the auxiliary circuits.
- For rotection of the ower unit, refer to diagrams.. The Fuse value shown is the
maximum allowable. For s ecial a lications or requirements these values can be
reduced.
- For Safety reasons, we recommend the use of rotected fuses in order to revent the
s read of fused articles should the fuse blow.
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3.4 DESCRIPTION OF SEM-1C CONNECTORS.
PIN REFERENCE DESCRIPTION
A1 HOURMETER Out ut hourmeter; it controls a load to -BATT. Maximum out ut
current 200mA.
A2 KEY B+ Su ly 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 ositive su ly for REV,
FORW, B SW, HORN, LIFT, LOW microswitches.
A8 H&S Hard & Soft function in ut. It should be connected to A7 through
the H&S switch. Active high (+VB).
B1 CPOT Accelerator's otentiometer wi er, or out ut of inductive device.
B2 NPOT Provides a negative su ly to accelerator's otentiometer.
B3 PPOT Provides a ositive su ly to accelerator's otentiometer.
B4 REV Reverse direction in ut, it should be connected to A7 by a micro-
switch. Active HIGH (+VB).
B5 B SW Quick inversion in ut, it should be connected to belly button.
Active HIGH (+VB).
B6 FORW Forward direction in ut. It should be connected to A7 by a micro-
switch, active HIGH (+VB).
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PIN REFERENCE DESCRIPTION
C1 CM Common ositive su ly for micro-switch SR1, SR2, (+BATT).
C2 SR1 In ut for 1st s eed reduction. It should be connected to C1 by
micro-switch, active LOW.
C3 SR2 In ut for 2nd s eed 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 um contactor; it should be connected to A7 by lifting
micro-switch LIFT which rovides the ositive su ly to the um
contactor's coil.
D5 NPC-NEV Negative su ly for um contactor.
D6 PEV Positive electro-valve for lowering.
E1 PCLRXD Positive serial rece tion.
E2 NCLRXD Negative serial rece tion.
E3 PCLTXD Positive serial transmission.
E4 NCLTXD Negative serial transmission.
E5 GND Negative console ower su ly.
E6 +VL Positive console ower su ly.
E7 --- Free.
E8 --- Free.
3.5 DESCRIPTION OF POWER CONNECTIONS
+BATT = Positive Su ly from Battery.
-BATT = Negative Su ly from Battery.
VMN = Negative Su ly (via cho er) to Motor.
F1, F = 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 cho ers configuration are made using
the Digital Console. The Console is connected to the E connector of the SEM-1C
Cho er.
Pay attention to the polarity of the Console Connector when connecting to
the chopper. The bevel on the connector should be uppermost.
4. DESCRIPTION OF CONSOLE & CONNECTION
Digital Consoles used to communicate with SEM-1C cho ers must be fitted with
E rom CK ULTRA.
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4.3 DESCRIPTION OF STANDARD CONSOLE MENU
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5 SEM-1C: CABLING AND CONFIGURATION
5.1 POWER DIAGRAM
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5. CONNECTIONS
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5.3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS).
Using the CONFIG MENU of the console, it is ossible to select from the following
o tions:
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 out ut for external hourmeter o erates according to internal hourmeter. If the
um contactor is connected (D4), hourmeter out ut (A1) is activated during lifting as
well.
2 QUICK INVERSION
- BELLY: Quick inversion is activated while the Belly Button is
ressed.
- TIMED: Quick inversion is activated, while the Belly Button is
ressed, maximum for 2 second.
3 AUX OUTPUT #1:
-FREE: A4 out ut is not used: the controller carry out monitor
function as described at the aragra h 2.5.
-BRAKE: A4 out ut drives an electromechanical brake. The con-
troller does not carry out monitor function, but locks the
brake while in rest or alarm status.
4 BATTERY CHECK
-ON Is controlled the battery charge. Whe the battery is
discarged is dis layed "BATTERY LOW"
-OFF Is controlled the battery charge,but not dis layed the
alarms.
5 SEAT SWITCH
-HANDLE a tiller switch is resent
-SEAT a seat switch is resent
6 BACKING INPUT
-ON The backing function is activated
-OFF The backing function is deactivated
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Flow Chart showing how to make changes to Configuration Menu using Digital Console.
(Standard E rom CK ULTRA fitted).
1) O ening Za i Menu.
2) Press To Left & To Right Buttons
simultaneously to enter the Config.Menu.
3) The Dis lay will show :
4) Press ROLL UP (To Left Button) until
SET OPTIONS a ears.
5) The Dis lay will show :
6) Press ENTER to go into this art of the menu.
7) The first O tion of the menu a ears
on the Dis lay.
8) Press either ROLL UP or ROLL DOWN to bring
u the next the O tion.
9) A new O tion a ears on the Dis lay.
10) When the desired O tion is dis layed, ress
PARAM (To Right) or SET (Bottom Right)
button to change the configuration
11) The new Configuration for the selected
O tion a ears on the Dis lay.
12) Press OUT to exit the Menu.
13) Press ENTER to acce t the changes,
or Press OUT if you do not acce t the
changes and wish to make further
modifications to the articular O tion.
14) The Dis lay now shows:
15) Press OUT again. Dis lay now shows
the O ening Za i Menu.
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