ZUCCHETTI L50BEU Installation and operation manual

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I
In ns st ta al ll la at ti io on n C Co ou ur rs se e
L
La aw wn n M Mo ow we er r R Ro ob bo ot t
Introduction & Features.................................................................................................................................. 2
Start-up / Installation ...................................................................................................................................... 3
User interface (LED) ......................................................................................................................................
Connections and Upgrade - Motherboard ...................................................................................................... 7
Troubleshooting............................................................................................................................................ 14
Mechanical assembly operations .................................................................................................................. 18
Revision and Winter revision ....................................................................................................................... 20
01
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2010

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Introduction & Features
Remember that :
Maximum coverage 400 sq.m.
However, it is a good idea to not exaggerate and bear in mind that gardens
that are more comp icated reduce the square meters covered by the robot.
Maximum s ope imit of 27°
The robot can mow this maximum s ope imit.
Remember that the main prob em is the uphi c imb when the robot arrives
at the border and is unab e to go back.

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Start-up / Installation
Getting Started
Recharge the Robot
First, recharge the Robot. It wi come in handy at the end of insta ation for
checking the correct functioning of the awn mower.
Fix the garden
Before starting the Robot, the customer must be instructed on how to fix up
the awn.
The most common prob ems are sma ho es, sma toys, and rocks, basica y
a objects which cannot be detected as an obstac e and which pass under the
body of the robot and may be picked up by the cutting b ade.
Sprink er system
Watch out for the sprink er system; make sure the sprink er heads do not
protrude from the grassy surface. This may damage the cutting b ade.
Marking boundaries
The garden must be checked and adjusted so that the robot has enough
space for recognising when there is no grass. Carefu y fo ow the above
points for the correct and safe use of the robot.
The robot moves in both directions and changes its forward direction on y if
the fo owing events are verified
- No grass.
- Gradua s ope exceeding 27-30°.
- Rapid s ope exceeding 15-20°.
- Knocks to the body detected by the current of the whee motors.
- Too much adsorption of the whee motor.
The figures to the eft show how to mark the boundaries of the awn so that
the robot does not go outside the area to mow.
If there are areas which are dangerous for the robot (e.g. a poo , pond, abyss,
stairs going down, a sudden and steep descent) adjustments must be made to
prevent the robot from being damaged. The first figure shows an incorrect
situation.

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The figure be ow shows a correct insta ation.
Turning off the cutting b ade. The robot turns off the cutting b ade due to
the fo owing reasons
- Ta grass or s ow motor speed.
- A hand e was touched.
- The robot exceeded a 30° s ope
- The inc ination of the robot has changed too quick y.
- If both hand es are touched, the robot wi stop the whee s and cutting
disc.
Power Supp y Unit
Position the power supp y unit according to the fo owing ru es:
- Position it in an area not exposed to water and rain
- Preferab y, indoors
- If p aced outdoors, make sure it is p aced in a we -venti ated box
away from direct sun ight and water.
- It must be positioned in a we -aired area

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User interface (LED)
The keyboard consists of only two keys, an ON/OFF key and a key to start and stop the robot.
The LED always shows the status of the robot. The LEDs relating to the batteries show their charge level
when the robot is running and when it is in Pause.
Two LEDs must be checked when the robot stops. The “ON” LED and the “Pause” LED
During normal operating conditions the LED (ON) must be turned on and steady and the LED (Pause)
shows the reason why the robot has stopped.
The robot can be starter by activating or deactivating the grass detectors and/or the curb drop off detectors

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If the robot breaks down, the LED (ON) will flash indicating the reason for the malfunctioning. As shown
in the table below.
WHEN A ROBOT STOPS, THE FIRST
THING TO UNDERSTAND IS THE
CONDITION OF THE “ON” LED AND
THE “PAUSE” LED
Attention !!! : When the robot is switched
on if all the leds are switched on, it means
that the final test hasn’t been achieved. We
must make the final test as described here
below.

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Connections and Upgrade - Mother oard
Operating LED
Grass sensors
The cable must be
connected to start
from Pin.1
Grass sensors
The cable must
be connected to
start from Pin.1
ON key.
Pin 3-4
Activates the
robot
Start Key
Pin 3-4
Starts the robot
RESET key
(-) Battery (+) Battery
(F1) 20Ah
(F2) 1Ah
Motherboard
Hardware
Version
Recharge
Blade motor
Wheel
motor
Wheel
motor
Body / Handle
sensor
Body /
Handle
sensor
Curb drop off
detectors
Pin 1
-
2
Curb drop off
detectors
Pin 1
-
2

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Connection curb drop off and grass detectors

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Trou leshooting
List of errors
The robot does not turn on.
Reasons
- Interna fuses are burnt
- Prob ems connected to the ON key
- Batteries are comp ete y f at
So utions and checks
- Connect the robot to the recharger for a few minutes
- Check the inside fuses
- Check the charging eve of the battery
- Disconnect the battery, reconnect it and try again. Reset the board.
- Open the robot and assemb e the body in reverse with the ON key
positioned in the Start connector. (For safety purposes, run the test
without the b ade). Obvious y, the contro s wi be inverted but this
operation a ows understanding if the key is broken or if the board
is broken.
Has the prob em not been so ved? (Spare parts to check)
- Motherboard
- Keyboard
- Battery
- Cab ing
The robot turns on but the Start key does
not work and the robot does not start.
Reasons
- Keyboard is defective
- Robot is charging
- Motherboard is broken
So utions and checks
- If connected, disconnect the robot from the recharger
- Disconnect the battery, reconnect it and try again. Reset the board.
- Press the “Start” key is pressed, the sound of a disconnecting or
connecting re ay shou d be heard. If this sound is heard, it is ike y
that the motherboard thinks it is being recharged and therefore the
robot does not start.
- An additiona check for understanding if the prob em re ates to the
motherboard or to the keyboard invo ves opening the robot,
assemb ing the body in reverse with the ON key positioned in the
Start connector. (For safety purposes, run the test without the
b ade). If the robot turns on when the "Start" key is pressed, this
means that the key is working
Has the prob em not been so ved? (Spare parts to check)
- Motherboard
- Keyboard
The robot a ways stays on.
Reasons
- Keyboard is defective
- Robot is charging
- Motherboard is broken
So utions and checks
- If connected, disconnect the robot from the recharger
- Disconnect the battery, reconnect it and try again. Reset the board.
- An additiona check for understanding if the prob em re ates to the
motherboard or to the keyboard, invo ves opening the robot,

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assemb ing the body in reverse with the ON key positioned in the
Start connector. (For safety purposes, run the test without the
b ade). If the robot turns on and off when the “Start” key is
pressed, then this means that the key is working and the fai ure
shou d be in the motherboard.
Has the prob em not been so ved? (Spare parts to check)
- Motherboard
- Keyboard
The robot occasiona y pauses for no
reason ( ow batteries, awn moved, no grass
or error)
Reasons
- Keyboard is defective
- Hand es came into contact with wet objects
So utions and checks
- Try the robot with another body and then with different
Start/Pause keys.
- Run (on y temporari y) the robot with the cab es of the hand es
disconnected from the motherboard. Of course, this test reduces
the safety of the product. It is not a so ution but on y a test.
The robot occasiona y turns off and when
it restarts the batteries are not ow.
Reasons
- Keyboard is defective
- Battery
So utions and checks
- Try the robot with another body and then with different
Start/Pause keys.
- If the prob em depends on the battery, the test is not simp e. The
robot can be started if the b ade is b ocked, but this is not a simp e
test to execute. The safest procedure is to try the robot with a fu y
charged battery.
B ade motor frequent y turns off
This does not necessari y mean that there is something wrong with the
robot.
Norma reasons.
- S ope is greater than 30° or s ope of 20° is reached too quick y.
- Grass is too ta , too much strain on the motor
- A hand e was touched.
- No grass or zone with grass ower than the 6 sensors
Reasons due to defective or worn parts.
- B ade motor encoder
- Motor cutting brushes worn
- Motherboard with fau ty hand e sensitivity.
So utions and checks
- Start the robot norma y. If the modu ation functions correct y, this
shou d mean that the encoder is functioning.
- Open the robot, disconnect the cab ing of the hand es. Retry the
robot without this functiona ity (if the prob em is reso ved contact
ZCS)
- Try the robot without the cutting disc. (If the prob em is reso ved,
the fau t cou d be in the cutting motor or the worn brushes).
Has the prob em not been so ved? (Spare parts to check)
- Motor cutting brushes
- Motor cutting encoder
- Cutting motor
- Motherboard.

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The robot does not turn correct y after
doing a U-turn and makes too many turns,
which affect the norma functioning of the
robot.
NB. The robot cannot contro the direction
and therefore it is norma that it continues
to turn.
Reasons
- Loose be t
- Whee motor with worn brushes
- Whee motor with prob ems
So utions and checks
- Check the tightening of the be t. If oose, tighten the screws of the
motor and of the free b ock by app ying a medium Loctite adhesive
- Check the brushes of the whee motor
- After a owing the robot to operate, open the body and check the
temperature of the whee motors which must be the same. If a
motor is a ot hotter, this means that it is under too much strain.
Has the prob em not been so ved? (Spare parts to check)
- Whee motor
- Mechanica part
- Motherboard
The motherboard has been disassemb ed or
the whee motors have been disassemb ed
and afterwards the robot does not detect
that there is no grass unti the back sensors
exit from the border.
Reasons
- The cab es or connections of the whee motor were inverted
So utions and checks
- Check that the connections on the board and whee motor are
correct. (The red cab e must be facing upwards) as shown in the
figure.
To check the correct functioning it is necessary to turn on the robot and
press the “Start” key. The first movement is executed in the direction
opposite to the recharging knobs. As indicated by the arrow in the figure.
Prob ems with reduced operating times Obvious y, the first eva uation that must be made is based on the ife of the
battery. In case of a new or recent battery, carry out the fo owing checks:

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- On the Battery there must be the abe “Li-Type A” or “Li-Type
B” with a version come out ater than “2009-04-16”
- C ean the b ade and grass residua s
- C ean and check the recharging knobs as we as the impedance of
the recharging knobs as showed in the picture
- Recharge the robot a night ong and check the first operating
cyc e.
- Recharge the robot a night ong. Disconnect the recharging knobs
and measure the vo tage with a tester on the knobs of the whee s.
The vo tage must be approximate y 29.1-29.4Vo t
- Measure the recharging connectors when they are disconnected
from the whee knobs. The vo tage must be approximate y 29.2-
29.4Vo t
The fau t may be in:
- Power Supp y Unit
- Battery
- Recharging cab e
- Motherboard
- Cutting motor
- B ade
Whee motor error. One or two f ashes of
the “ON” LED
The fau t may be in:
- motor
- Worn brushes
- Cab e on the whee motor
- Motherboard
- B ocked be t
- Objects b ocking its movement
B ade motor error. Three f ashes of the
“ON” LED
The fau t may be in:
- Hitting of a rock
- Burnt motor
- Encoder
- Worn brushes (rep ace the brushes)
- Motherboard
- Motor wires broken or disconnected due to vibrations of the
BLADE. As for the motors manufactured before W25/09 we must
check the pin as indicated in the picture

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Mechanical assem ly operations
Assemb y operations
Motherboard connections
Whee motors
Make sure the motherboard is connected correct y. The red cab e of the motor must be
facing upwards.
- Once connected, check the correct functioning by turning on the robot and
pressing the “Start” key. The first movement is executed in the direction opposite
to the recharging knobs. As indicated by the arrow in the figure.

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Cutting motor
Pay attention to the cab es above the motor. An incorrect connection causes an incorrect
rotation of the cutting motor. Respect the co ours of the wires and the p acement as shown
in the figure.

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Revision and Winter Service
Revision for updating the robot
Each time the robot is repaired, it is recommended to:
- Update the robot version using the robot programmer.
- Check the impedance (OHM) of the recharging knobs and the cab e.
It must be ower than 1-2 Ohm. Maybe we must insta a contact
spring (050Z04400A) as indicated in the picture.
- Check the condition of the batteries.
- Check that the screws of the b ade are we secured. And the screws
fastening the motor.
- C ean the recharging knobs with sandpaper.
- C ean and sharpen the b ade.
- Check that the sea gaskets are secure.
Operations during winter storage
- Check/Rep ace the brushes of the b ade motor.
- Check/Rep ace the brushes of the whee motor.
- Test the wear and tear of the battery and recharge it for 24 hours
after the test.
- Check the fastening screws of the whee motor and of the shaft that
id es.
- Check the distribution be t and maybe it must be changed. We must
eva uate the possibi ity to change the comp ete Pu ey Kit and the be t
with the new mode
- Insta , if it is not there, the contact spring (0 0Z04400A) as
indicated in the picture.
- Check the keyboard it mustn’t be detached or raised up. In this case
we must change it in order to prevent water eakages inside the
robots.