Zapi COMBI SEM-1 Operating And Users Manual
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Zapi COMBI SEM-1 Operating And Users Manual

Zapi COMBI SEM-1 Operating And Users Manual

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1
General characteristics ................................................................................. 3
1.1
Technical specifications ........................................................................ 3
1.2
General description ............................................................................... 3
1.3
Main features ........................................................................................ 3
1.4
Safety & protection features .................................................................. 4
1.5
Thermal considerations ......................................................................... 4
1.6
Combi Sem-1 chopper diagnosis .......................................................... 5
1.7
1.8
2
Installation ..................................................................................................... 7
2.1
Connection cables ................................................................................. 7
2.2
Contactors ............................................................................................. 7
2.3
Fuses .................................................................................................... 7
2.4
Combi Sem-1 controller mechanical drawing ........................................ 8
2.5
Serial tiller mechanical drawing ............................................................. 9
3
Connection .................................................................................................. 10
3.1
Combi Sem-1 connection drawing ...................................................... 10
3.2
Serial tiller connection drawing ............................................................ 11
3.3
Description of combi sem-1 connectors .............................................. 12
3.3.1 Connector "A" description .......................................................... 12
3.3.2 Connector "B" description .......................................................... 12
3.3.3 Connector "C" description .......................................................... 13
3.3.4 Connector "D" description .......................................................... 14
3.3.5 Connector "E" description .......................................................... 14
3.3.6 Connector "F" description .......................................................... 16
3.4
Combi Sem-1 power connection ......................................................... 16
4
Regulation .................................................................................................... 17
4.1
Zapi Programming handly console ...................................................... 17
4.2
Description of standard console menu ................................................ 18
4.3
"Parameter Change" menu ................................................................. 19
4.4
"Tester" menu ..................................................................................... 21
4.5
"Adjustment" menu .............................................................................. 21
4.6
"Set Option" menu ............................................................................... 21
5
Alarms .......................................................................................................... 23
6
Recommended spare parts ........................................................................ 27
7
Index
.................................................. 5
............................................ 6
Page
Page 1

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Summary of Contents for Zapi COMBI SEM-1

  • Page 1: Table Of Contents

    Installation ..................... 7 Connection cables ................. 7 Contactors ..................... 7 Fuses ....................7 Combi Sem-1 controller mechanical drawing ........8 Serial tiller mechanical drawing ............. 9 Connection ....................10 Combi Sem-1 connection drawing ............10 Serial tiller connection drawing ............11 Description of combi sem-1 connectors ..........
  • Page 2 The informations included into the marked paragraphs by this symbol are essential for the safety. SIGNATURES TABLE Publications N°: AD3ZP0AA Edition: September 2000 Page 2...

  • Page 3: General Characteristics

    400 A 250 A 1.2 GENERAL DESCRIPTION ZAPI COMBI SEM-1 controller performs all the electric functions that are usually presents in transpallet, stacker, low order picker etc. The controller can perform the following functions: Traction controller for SEM motor; full-bridge on the field, half-bridge on the armatu- Lifting controller for series excited motors.

  • Page 4: Safety & Protection Features

    1.4 SAFETY & PROTECTION FEATURES - Reverse Battery Polarity. Electrical Circuit diagrams must be followed in order to avoid damage to the power unit. A Main contactor, controlled by the logic unit, is necessary to protect the system against reverse battery polarity. - Connection errors All inputs are protected against connections errors.

  • Page 5: Combi Sem-1 Chopper Diagnosis

    1.6 COMBI SEM-1 CHOPPER DIAGNOSIS The microprocessor continually monitors the chopper and carries out diagnostic procedures on the main functions. The diagnosis is made in 4 points: 1) Diagnosis on key switch closing that checks: watch-dog, Current Sensors, VMN point, contactor drivers, presence of a start requirement, and connection with the Serial Tiller ok.

  • Page 6: General Instructions And Precautions

    - The COMBI SEM-1 module should only be connected to a traction battery. Do not use converters outputs or power supplies. For special applications please contact the nearest Zapi Service Centre.

  • Page 7: Installation

    2.3 FUSES - Use a 10A fuse for protection of the auxiliary circuits. - The power fuse is alrady installed on the chopper by Zapi. For special applications or requirements this value can be reduced. Page 7...

  • Page 8: Combi Sem-1 Controller Mechanical Drawing

    2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING Page 8...

  • Page 9: Serial Tiller Mechanical Drawing

    2.5 SERIAL TILLER MECHANICAL DRAWING Page 9...

  • Page 10: Connection

    3 CONNECTION 3.1 COMBI SEM-1 CONNECTION DRAWING Page 10...

  • Page 11: Serial Tiller Connection Drawing

    3.2 SERIAL TILLER CONNECTION DRAWING The folllowing drawing is an example of typical tiller head functions. Page 11...

  • Page 12: Description Of Combi Sem-1 Connectors

    3.3 DESCRIPTION OF COMBI SEM-1 CONNECTORS 3.3.1 Connector "A" description The "A" connector is connected by Zapi. KEY OUT This pin is connected to the pin1 of the F connector; is a key signal. BACKING This pin is connected to the pin2 of the F connector; is a backing signal.

  • Page 13: Connector "C" Description

    B13 PMC Positive of the main contactor. B14 KEY OUT Output of the Key switch signal. B15 NOT USED Free. B16 PEB Positive of the electromechanical brake. B17 PEVP Positive of the proportional electrovalve. B18 PEV2 Positive of the electrovalve 2. B19 PEV1 Positive of the electrovalve 1.

  • Page 14: Connector "D" Description

    3.3.4 Connector "D" description The "D" connector manages the MDI instrument or a Zapi console. NOT USED Free. PCLRXD Positive of the reception from the console or the MDI instrument. -BATT Negative of the console or the MDI instrument. Positive of the console or the MDI instrument.
  • Page 15 INPUT 3 This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10. -BATT Negative free for the customer. INPUT 4 This is a digital input free for customer request. The meaning depends on the software installed (made by Zapi) and the model selected with the input E9 and E10.

  • Page 16: Connector "F" Description

    3.3.6 Connector "F" description The "F" connector is connected by Zapi. KEY OUT This pin is connected to the pin1 of the A connector; is a key signal. BACKING This pin is connected to the pin2 of the A connector; is a backing signal.

  • Page 17: Regulation

    4 REGULATION 4.1 ZAPI PROGRAMMING HANDLY CONSOLE In Combi Sem-1 controller is possible to program several functions through the console. In this way is possible to modify the performances of the truck following the customer needings. The console can remain connected to the controller while running and the parameters can be changed in real time.

  • Page 18: Description Of Standard Console Menu

    4.2 DESCRIPTION OF STANDARD CONSOLE MENU Page 18...

  • Page 19: Parameter Change" Menu

    4.3 "PARAMETER CHANGE" MENU The following parameters are an example of a typical Parameter Change menu; some of this parameters could be changed from customer requests. The parameters with (p) symbol are related to the pump, those with (t) are related to the traction motor.
  • Page 20 17) PUMP ACC DELAY (p) = Pump motor acceleration time:during this time the voltage on the pump motor goes to the desired value. 18) PUMP DEC DELAY (p) = Pump motor deceleration time:during this time the voltage on the pump motor decreases to the desired value.. 19) PUMP CREEP (p) = This parameter sets the minimum voltage applied to the pump motor.

  • Page 21: Tester" Menu

    4.4 "TESTER" MENU The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. 4.5 "ADJUSTMENT" MENU 1) ADJUST BATTERY = Battery voltage reading adjustment according with the real battery voltage.
  • Page 22 AUX FUNCTION #1 the Combi hour-meter is immediately over-written by that of MDI instrument. In this configuration the alarm "AL98" will be displayed on the MDI for 1 minute. If during this minute the user doesn't set ON the "Aux function #1", the MDI hour-meter will be over-written by that of the controller.

  • Page 23: Alarms

    5 ALARMS "ZAPI CONSOLE" "MDI" 1) POWER FAILURE #1 Short-circuit on the ON/OFF valves, or in the main contactor coil, or in the electrobrake coil. 2) EEPROM KO Fault in the area of memory where the parameters are stored. This alarm inhibits machine operation.
  • Page 24 7) VFIELD NOT OK This test is made in standby with the Main Contactor open. In this condition the voltage on both the connections of field must be around ½ VBatt. This alarm is generated if the field voltage is different from this value. Possible causes: a) Frame fault on the motor to chassis.
  • Page 25 13) COIL SHORTED When the key is turned on, the microprocessor tests the overloads protection circuit of the contactor driver. If a problem is detected, this alarm is generated. Possible causes: a) Failure within the contactor coil. b) Incorrect wiring. c) Failure of the protection circuit.
  • Page 26 20) EVP NOT OK At stand: proportional valve opened. Running: the proportional valve doesn’t follow the applied PWM. 21) SERIAL ERROR #1 Wrong message or no message from serial tiller 22) INPUT ERROR #1 No belly switch on the tiller card 23) INPUT ERROR #2 No belly switch on the controller 24) THERMAL PROTECTION...

  • Page 27: Recommended Spare Parts

    6 RECOMMENDED SPARE PARTS PART NUMBER DESCRIPTION C12370 2 pins Molex Minifit connector. C12372 8 pins Molex Minifit connector. C12397 10 pins Molex Minifit connector. C12408 20 pins Molex Minifit connector. C12499 22 pins Molex Minifit connector. C12777 Female receptacle 5556 for Molex Minifit C16530 250A protected fuse C16505...

  • Page 28: Periodic Maintenance To Be Repeated At Times Indicated

    Manual. During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be brought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain.
  • Page 29 Page 29...
  • Page 30 COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it COMBI SEM-1 OPERATING AND USER...

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