Zapi ZAPIMOS Series 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 characteristic................................................................................... 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 SEM2 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 2 Connectors. ...................................................... 12
3.5 Description of Power Connections ...................................................... 14
3.6 Mechanical Drawing & Dimensions..................................................... 15
4 Programming & Adjustments using Digital Console............................... 16
4.1 Adjustments via Console..................................................................... 16
4.2 Description of Console & Connection.................................................. 16
4.3 Description of Standard Console Menu............................................... 17
5 SEM2 Traction ............................................................................................. 18
5.1 Description of Programmable Functions (Options). ............................ 19
5.2 Description of Parameters that may be Programmed ......................... 21
5.3 Table of Adjustments........................................................................... 22
5.4 SEM 2 Traction Standard Wiring Diagrams ........................................ 23
5.5 Sequence for SEM 2 Traction Settings. .............................................. 24
6 SEM 2 Diagnostics ...................................................................................... 26
6.1 Analysis of Alarms displayed on the Console ..................................... 27
6.2 Tester. Description of the Functions ................................................... 30
6.3 Description of the Console SAVE Function......................................... 32
6.4 Description of Console RESTORE Function. ...................................... 33
6.5 Description of Alarms Menu. ............................................................... 34
6.6 Description of Console PROGRAM VACC function. ........................... 35

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7 Recommended Spare parts for SEM 2 ...................................................... 36
8 Periodic Maintenance to be repeated at times indicated. ....................... 37
= The information contained in the paragraphs marked with this symbol is essential
for the purpose of safety.
SIGNED IN APPROVAL
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publication No. AC1ZP0CA
Edition: Aprile 1998

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LEGEND
BACK.FW = Inching forward direction switch
BACK.REV = Inching reverse direction switch
BTG = Main Contactor Coil
CMM = Common Feed to Microswitches
CPOT = Potentiometer Wiper
FORW = Forward switch
HB = Handbrake switch
KEY = Key switch input
NAUX = Negative supply for auxiliary load
NPOT = Potentiometer Negative supply
PAUX = Positive supply for auxiliary load
PB = Brake pedal switch
PPOT = Potentiometer Positive supply
REV = Reverse switch input
SR1 = Speed Reduction 1 Microswitch
SR2 = Speed Reduction 2 Microswitch
TG = Main Contactor
VMN = Voltage to Negative of Motor
COLOUR CODES (SINGLE COLOURS)
The following Codes represent the colours of individual wires used by Zapi (Unless
specified otherwise).
A - Orange
B - White
BB - Blue
C - Sky Blue
G - Yellow
GG- Grey
M - Brown
N - Black
R - Pink
RR - Red
V - Green
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
behavior 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 2 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 SEM2 family of Choppers are suitable for operating on DC voltages from 24 to
48V inclusive, with maximum armature current up to 350A.
The choppers may be used to control DC Separately Excited Motors with power
ratings up to 5.5kW.

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2 GENERAL CHARACTERISTIC
2.1 TECHNICAL SPECIFICATION
Chopper for Separately Excited DC motors ...................................................2.5 ÷ 5.5kW
Regenerative Braking.
Voltage Range ......................................................................................24 to 48 Volts DC
Maximum Field Current (all the versions.............................................................50 Amps
Armature Switching Frequency ...............................................................................16kHz
Field Switching Frequency ........................................................................................1kHz
Maximum Ambient temperature.............................................................................+ 40°C
Minimum Ambient temperature................................................................................-30°C
Maximum temperature of Chopper ........................................................................+ 85°C
Resistance of field Winding.............................................................................0.3 to 0.6W
VERSION MAXIMUM CURRENT BOOSTER CURRENT VOLTAGE DROP AT
TOTAL CONDUCTION
24V / 500A 500A 580A 0.25V at 200A, 25°C
36V / 500A 500A 580A 0.25V at 200A, 25°C
48V / 350A 350A 400A 0.25V at 100A, 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
tacts must be lower than 0.1V.
- If an Electromagnetic Brake is used, the Handle Microswitch must 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 (A2) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance :500W
Maximum Potentiometer Resistance : 10kW
Faults can occour 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 in
either direction. This function is unique when it is necessary to compensate for asym-
metry 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.
The aquisition procedure is disabled if the potentiometer wiper output does not reach a
minimum of 3 V. If a centre tapped potentiometer is not available, it is possible to use a
standard 3 wire pot set in the middle of its full stroke.

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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 80°C, the maximum current reduces in
proportion to the thermal increase. The temperature can never exceed 85°C.
- 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 Main Contactor will not close if :
- The Power Unit is not functioning
- The Logic is not functioning perfectly.
- Main 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.
- 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.
- 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.
- Presence of a second microprocessor for safety that monitors the CPU that controls
the motor.

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2.6 SEM2 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 SEM2 modules. The filter capaci-
tors contained in the SEM2 module will change the SCR chopper operation 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 SEM2 must be completely disconnected from the bat-
tery. As well as altering the charge current read by the battery charger, the module
can be damaged by higher than normal voltages supplied via the charger.
- The SEM2 module should only be supplied by a traction battery. Do not use the
outputs of convertors 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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3INSTALLATION.
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 Horn, Solenoid Valves, the
coils of any relays, and contactors not supplied by logic or the chopper 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 25 to 35mm²
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 Main 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. If contactors for power steer motors are supplied from the control logic, the sup-
pression will be inside the chopper logic.
For any Contactor using external suppression, ensure that connections are made re-
specting 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 2 CONNECTORS.
PIN REFERENCE DESCRIPTION
A1 PLED Positive of Diagnostic Red Led.
A2 NLED Negative of Diagnostic Red Led.
Output Current is 12mA, for this standard type Led.
B1 KEY B+ Supply into logic Downstream of 10A Fuse & Key Switch.
B2 CMM Positive Supply to Hand Brake and Brush / SR2 Microswitches.
B3 PTG Positive Supply to Main Contactor.
B4 BRUSH / SR2 Input from motor brush switch (normally open), or Input from
second speed reduction switch (normally closed).
B5 HB Input from Hand Brake Switch (normally closed).
B6 FAN / HYDRO Negative Output to Fan or Power Steer Contactor Coil.
B7 NTG Negative Supply to Main Contactor.
B8 - BATT Battery Negative.
C1 PPOT Positive Output to Potentiometer (I max = 25mA).
C2 NPOT Negative Output to Potentiometer.
C3 CPOT Input from Potentiometer Wiper, or output of inductive device.

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PIN REFERENCE DESCRIPTION
E1 CMM Positive Common Feed to Rev, Fwd, SR1, PB, and Seat
Microswitches.
E2 REV Input from Reverse Direction Microswitch. Active High.
E3 FW Input from Forward Direction Microswitch. Active High.
E4 SR1 Input from First Speed Reduction Switch. Active Low.
E5 PB Input from Pedal Brake Switch. Active High.
E6 SEAT Input from Seat Switch. Active High with delay.
E7 MOT. THERM Input from Motor Thermal Switch.
E8 FREE1 Input from any Active High Switch.
E9 - BATT Battery Negative.
F1 - BATT Battery Negative.
F2 - BATT Battery Negative..
G1 PCLRXD Positive Serial Reception.
G2 NCLRXD Negative Serial Reception.
G3 PCLTXD Positive Serial Transmission.
G4 NCLTXD Negative Serial Transmission.
G5 - Batt Negative supply to Digital Console.
G6 + VL Positive supply to Digital Console.
G7 // Free.
G8 // Free.
L1 CMM Common Supply to Fwd & Rev Backing Switches, Motor thermal
switch, Speed Reduction 3 Switch, and 2 spare switches.
L2 BACK FW Input from Forward Backing Switch. Active High.
L3 BACK REV Input from Reverse Backing Switch. Active High.
L4 ENABLE/ SR3 Input from pedal accelerator (Enable) Active High.or Speed Re-
duction 3 Switch Active Low.
L5 FREE Input from Free Microswitch 1. Active High.
L6 FREE2 Input from Free Microswitch 2. Active High.
L7 NAUX Negative Output to Auxilliary.
L8 PAUX Positive Output to Auxiliary.
L9 FREE3 Free Entry 3. Connected to CMM (if J1= 2-3) or to- Batt
(if J1= 1-2) through microswitch.

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NOTES:
1) The BRUSH / SR2 and HB inputs could be connected to Battery Negative (B8). It is
necessary to change the internal link “B” from 1-2 to 2-3. In this case the Normally
Closed microswitches need to be Normally Open, and the Normally Open
microswitches need to be Normally Closed.
2) The REV, FW, SR1, PB, SEAT inputs could be connected to Battery Negative (E9).
It is necessary to change the internal link “A” from 1-2 to 2-3. In this case the Nor-
mally Closed microswitches need to be Normally Open, and the Normally Open
Microswitches need to be normally Closed.
3) The MOTOR THERM, BACK FW, BACK REV, ENABLE/ SR3, FREE inputs could
be connected to Battery Negative (F1 or F2). It is necessary to change the internal
link “C” from 1-2 to 2-3. In this case the Normally Closed microswitches need to be
Normally Open, and the Normally Open Microswitches need to be Normally Closed.
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 “G” connector of the SEM 2
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 SEM2 choppers must be fitted with Eprom
CK ULTRA.

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4.3 DESCRIPTION OF STANDARD CONSOLE MENU

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5 SEM2TRACTION
- Input for 3 Wire Potentiometer.
- 3 Speed Reductions.
- Input for Tiller Switch or Seat Switch (delayed).
- Input for Brake Pedal Microswitch.
- Input for Motor Thermal Switch.
- Management of Backing Speed (Programmable).

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5.1 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.
2 BRUSH SWITCH:
- PRESENT: The Brush Switch provides an input signal from the
motor brushes.
- OPTION #2: The Brush Switch Input may be used as a Second Speed
Reduction.
3 ENABLE SWITCH:
- PRESENT: The Enable Switch provides an input from the pedal
accelerator.
- OPTION #3: The Enable Switch input may be used as a Third Speed
Reduction.
4 AUX FUNCTION:
- OPTION #1: The output on Pin B6 provides a Negative supply to a
fan.
- HYDRO CONT.: The output on Pin B6 provides a Negative supply to the
coil of a steering Contactor.
5 SET BATTERY TYPE: This option allows selection of the Nominal Battery Volt-
age.

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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.
If any changes are made to the Configuration, it is necessary to Open and Re-Close
the Key Switch before the Display will show the new, stored, changes.