Yale ZAPI MPW045-E Maintenance Manual
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Yale ZAPI MPW045-E Maintenance Manual

Yale ZAPI MPW045-E Maintenance Manual

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Maintenance
ZAPI™ CONTROLLERS
MPW045-E [B802];
MPW050-E [C802]
PART NO. 524188546
2200 YRM 1067

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Summary of Contents for Yale ZAPI MPW045-E

  • Page 1 Maintenance ZAPI™ CONTROLLERS MPW045-E [B802]; MPW050-E [C802] PART NO. 524188546 2200 YRM 1067...
  • Page 2 • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

  • Page 3: Table Of Contents

    Alarms................................. Programming Tilt and Sideshift on the ZAPI Controller (Laptop) ..............Repair .................................. Remove ................................Brass Stud Replacement ..........................Remove............................... Install ................................Install................................Repair................................This section is for the following models: MPW045-E [B802]; MPW050-E [C802] ©2010 Yale Materials Handling Corp.

  • Page 5: General

    2200 YRM 1067 Description General This section describes the ZAPI™ transistor motor con- troller. Procedures are outlined for controller safety, ad- justments, troubleshooting, and repairs. See Figure 1. Figure 1. Controller MPW045/050-E Description ZAPI™ TRANSISTOR MOTOR with specialized ZAPI™ software. The controller soft- ware features a Test Menu for monitoring controller in- CONTROLLER puts and outputs, a Diagnostic Menu for viewing fault...

  • Page 6: Principles Of Operation

    Controller Safety 2200 YRM 1067 PRINCIPLES OF OPERATION NOTE: The dash indicator will display the code: EP 107 (or a higher number) for 1 to 2 seconds every time The ZAPI™ transistor motor controller uses a sophisti- the key switch is turned to the ON position. The ZAPI cated microprocessor to control the logic and operation handset similarly displays V1.07 (or higher).

  • Page 7: Controller Adjustments

    3. ZAPI™ Handset - A diagnostic handset is available ods: through your Yale dealer. The handset makes it 1. LED - An LED may be installed in trucks that do possible to diagnose faults and modify controller not use a display.

  • Page 8: Programming

    Programming 2200 YRM 1067 Programming CUSTOM PERFORMANCE MODE In some instances, it may be preferable to disable the Drive Modes and use a custom setting. This controller has adjustable parameters that may be modified to suit specific customer needs. There are two methods used to adjust these parameters: the ZAPI™...

  • Page 9: Tester Menu

    2200 YRM 1067 Programming Table 1. Parameters Parameter Description Value and Affect ACCELERATION DELAY Adjusts truck acceleration. 0 = short or rapid acceleration 9 = long or slow acceleration DECELERATION DELAY Adjusts truck deceleration according to 0 = short or rapid deceleration throttle position.

  • Page 10: Set Option Menu

    The orientation of Yale dealer. Connect the handset to plug B. The hand- the triangle indicates the way to the next function. See set can remain connected to the controller while run- Figure 3.
  • Page 11 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 12 Programming 2200 YRM 1067...
  • Page 13 2200 YRM 1067 Programming Figure 4. ZAPI™ Handset Instructions...

  • Page 14: Troubleshooting

    Troubleshooting 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC LCD display Red LED Red LED Fault Indicator Located at base of motor Error codes stored under Main Menu Alarms controller. (Trucks equipped with (Trucks without dash Message displayed on Handset or PC optional dash display) display) CORRESPONDING SCHEMATIC SHOWING...
  • Page 15 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC - 12V No LEDs or LCDs LED OFF Handset does not operate illuminated CONDITION Dash display, controller LED, and truck inoperative. TRUCK RESPONSE Travel and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 16 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC - 24V No LEDs or LCDs LED OFF Handset does not operate illuminated CONDITION Dash display, controller LED, and truck inoperative. TRUCK RESPONSE Travel and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 17 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC No LEDs or LCDs LED OFF No error codes present illuminated CONDITION Dash display and/or controller LED inoperative. TRUCK RESPONSE Travel and hydraulic functions normal. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 18 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC No Alarm LED OFF - No Flashes INCORRECT START CONDITION Improper startup sequence by operator. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Throttle or hydraulic function selected at key ON. Steer handle in run position at key ON.
  • Page 19 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL01 1 Flash VACC NOT OK CONDITION Connection/communication error between tiller card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle calibration is out of range. Install handset.
  • Page 20 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC AL01 1 Flash PUMP VACC NOT OK CONDITION Connection/communication error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • A lift/lower switch is damaged or defective. Install handset.
  • Page 21 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL01 1 Flash FORW + BACK CONDITION Connection/communication error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Control card throttle device may be damaged or Cam Magnetic Holder may not be properly aligned with Alignment Window.
  • Page 22 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC AL01 1 Flash SERIAL ERROR #1 CONDITION Connection/communication error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Loose or damaged electrical connection between con- trol card and controller.
  • Page 23 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL01 1 Flash INPUT ERROR #1 CONDITION Connection/communication error between control card and traction controller. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Traction reversing switch is not connected. Install handset.
  • Page 24 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC AL01 1 Flash BATTERY CHARGING CONDITION Controller waits in standby mode while a battery charger is connected. TRUCK RESPONSE Traction and hoist functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 25 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC - 24V AL02 2 Flashes CONTACTOR CLOSED CONDITION Main contactor circuit is damaged. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Main contactor tips are welded closed. Disconnect power leads at contactor.
  • Page 26 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC 5 Flashes EB DRIVER KO CONDITION Electric brake does not release or remains released at all times. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 27 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC 6 Flashes VFIELD NOT OK CONDITION Voltage measured at field connections is not correct. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged. Verify connection of field wires to motor and con- troller.
  • Page 28 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC 6 Flashes HIGH FIELD CURR, BW HIGH FLD CURR, FW HIGH FLD CURR CONDITION High field current values measured by controller. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 29 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC 6 Flashes STBY I HIGH CONDITION Controller detects motor current during standby mode. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Damaged controller. Replace controller. LOGIC Occurs if controller detects motor currents during standby mode.
  • Page 30 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC 8 Flashes POWER FAILURE #1 CONDITION Short circuit in device connected to controller. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Overcurrent detected in driven component. Check main harness for damaged or shorted con- nections to main contactor, brake, and electric valve coils.
  • Page 31 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL10 LED ON (No Flashing) CAPACITOR CHARGE CONDITION Main controller capacitors did not charge within 500 ms of key ON. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 32 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC - 12V AL10 LED ON (No Flashing) VMN NOT OK CONDITION Measured voltage at traction motor inputs does not match battery voltage. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 33 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC - 24V AL10 LED ON (No Flashing) VMN NOT OK CONDITION Measured voltage at traction motor inputs does not match battery voltage. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 34 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC AL10 LED ON (No Flashing) VFIELD NOT OK CONDITION Voltage measured at field connections is not correct. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 35 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL10 LED ON (No Flashing) Driver Shorted CONDITION Voltage measured at field connections is not correct. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Cable connection to motor field is loose or damaged. Verify connection of field wires to motor and con- troller.
  • Page 36 Troubleshooting 2200 YRM 1067 Dash Display Controller LED Handset or PC AL94 NONE CONDITION Controller is installing hourmeter memory from MDI display if controller has been replaced. TRUCK RESPONSE Traction and hydraulic functions disabled for 1 minute. POSSIBLE CAUSES AND TEST PROCEDURES •...
  • Page 37 2200 YRM 1067 Troubleshooting Dash Display Controller LED Handset or PC AL99 Continuous Flash BATTERY KO CONDITION Improper battery connection or defective battery. TRUCK RESPONSE Traction and hydraulic functions disabled. POSSIBLE CAUSES AND TEST PROCEDURES • Incorrect battery selected. Verify correct battery voltage for truck. •...

  • Page 38: Control Card Functional Test

    Control Card Functional Test 2200 YRM 1067 Control Card Functional Test Refer to Figure 5 for the following procedures. 6. If handset test are not passed, open tiller head and verify connection at control card: 1. Follow all safety precautions as listed at the begin- ning of this section prior to performing any electrical a.
  • Page 39 2200 YRM 1067 Control Card Functional Test Ensure 7 segment LED displays the auto-learning procedure listed in the proper control handle card setting: Electrical System 2200 YRM 1007 • The proper setting for these models is section. number 3. 7. If speed is other than desired, refer to Programming If not, proceed to reconfigure in this section.

  • Page 40: Zapi™ Pc Interface

    ZAPI™ PC Interface 2200 YRM 1067 ZAPI™ PC Interface CONNECTING PC TO ZAPI™ 4. Connect the interface cable to the controller and the PC. See Figure 8 and Figure 9. CONTROLLER NOTE: Values used on the following figures are for ex- ample only.
  • Page 41 2200 YRM 1067 ZAPI™ PC Interface 6. You should now see a screen as shown in Fig- ure 11. Figure 11. ZAPI™ Software Screen 7. Click on the START button first and then turn the key switch to ON. See Figure 12. Figure 12.
  • Page 42 ZAPI™ PC Interface 2200 YRM 1067 8. If the connection was successful, you should now see the screen shown in Figure 13. If you get an error message, go back to Step 7 and try again. Explanation of Screen Connected To: MPB NA V1.01 This tells the current software revision.

  • Page 43: File Menu

    2200 YRM 1067 ZAPI™ PC Interface FILE MENU Open File When you select this function, you will be able to open a previously saved file that contains parameter settings for the controller. See Figure 14. Figure 14. File - Open...

  • Page 44: Tx From File

    ZAPI™ PC Interface 2200 YRM 1067 Note that the previously saved file has the .csv exten- the Save File section of this manual for proper file sav- sion, and observe how the file name was used. See ing techniques. See Figure 15. Figure 15.
  • Page 45 2200 YRM 1067 ZAPI™ PC Interface Notice the CONNECTION STATUS while the file is downloaded into the controller. See Figure 17. Figure 17. Connection Status...

  • Page 46: Save File

    ZAPI™ PC Interface 2200 YRM 1067 Save File The ZAPI™ PC software can save configurations for up to 500 controllers. When saving a configuration to the PC, the following steps should be followed to help track which file goes with each controller. See Figure 18. Figure 18.
  • Page 47 2200 YRM 1067 ZAPI™ PC Interface 1. Try to use the actual truck serial number and put the word "settings" after it. (This is to keep the con- troller settings file separate from the tester function Save file.) See Figure 19. Figure 19.

  • Page 48: Print Settings

    ZAPI™ PC Interface 2200 YRM 1067 Print Settings This selection allows you to print out your current pa- rameter settings in the controller. See Figure 21. Figure 21. File - Print...

  • Page 49: Exit

    2200 YRM 1067 ZAPI™ PC Interface Exit This selection will exit the ZAPI™ PC console software. See Figure 22. Figure 22. File - Exit...

  • Page 50: Connection Menu

    ZAPI™ PC Interface 2200 YRM 1067 CONNECTION MENU 2. Stop - Stops the connection between the controller and PC (operates the same as the main Stop button There are two selections under this menu: on the right-hand side of the display screen). 1.

  • Page 51: Parameter

    2200 YRM 1067 ZAPI™ PC Interface Parameter 1. Receive menu - This will only download the current selected tab. When you first activate this selection, the screen will 2. Receive - This will download all parameters and look as indicated in Figure 24. In order to see the pa- configurations to the PC so you can adjust them.
  • Page 52 ZAPI™ PC Interface 2200 YRM 1067 Now that the parameters have downloaded, you should see a screen as indicated in Figure 26. Figure 26. Drive Mode Please note that the current drive mode the lift truck You will also notice that there are six tabs along the top was in will be displayed.
  • Page 53 2200 YRM 1067 ZAPI™ PC Interface There are six parameters that can be adjusted to affect the performance of the lift truck. See Figure 27. Figure 27. Adjustable Parameters 1. ACCELER. DELAY - Amount of ramp-up to full 4. INVERSE BRAKING - Amount of braking when the speed.
  • Page 54 ZAPI™ PC Interface 2200 YRM 1067 Notice that the ACCELER. DELAY function has been react to the setting. Once the lift truck is performing as adjusted. The parameter settings are "live," which wanted, the Store button is pressed to save the settings means as they are being adjusted.

  • Page 55: Memory Menu

    2200 YRM 1067 ZAPI™ PC Interface Memory Menu If you wish to start all over with your adjustments prior to pressing the Store button, then you can select the Memory menu to see the screen in Figure 29. Figure 29. Memory Menu This menu has three selections: 3.

  • Page 56: Set Options

    ZAPI™ PC Interface 2200 YRM 1067 Set Options This selection will allow Mode 4 to be activated, so that the performance parameters can be adjusted for a cus- tom configuration. See Figure 30. Figure 30. Set Options...
  • Page 57 2200 YRM 1067 ZAPI™ PC Interface Highlight Drive Modes and then click on the scroll bar to the right and select OFF. See Figure 31. Figure 31. Turn Off Drive Modes Do the following steps once this has been done: 4.

  • Page 58: Tester

    ZAPI™ PC Interface 2200 YRM 1067 Tester This selection allows the technician to monitor up to four items at a time to help troubleshoot problems. See Fig- ure 32. Figure 32. Tester The Tester function also features a data-logging capa- bility to further assist the technician and the factory with problems.
  • Page 59 2200 YRM 1067 ZAPI™ PC Interface The PC software can test the following (four selections 12. Lowering Switch - refers to switch on right side of at a time). See Figure 33. tiller head. 1. Battery Voltage - voltage across the battery. 13.

  • Page 60: Data Logger

    ZAPI™ PC Interface 2200 YRM 1067 Data Logger Figure 34. Data Logger In addition to "live testing" of the controller, the ZAPI™ The Advanced button allows the user to initiate a series PC software also includes a data-logging capability. of samples to be taken for the 4 items you have selected See Figure 34.
  • Page 61 2200 YRM 1067 ZAPI™ PC Interface Figure 36. Logging Process As the data logger is running, the screen will look like Once the data logger is done, you can save the log what is shown in Figure 36. During the logging process, using the Save Rec.
  • Page 62 ZAPI™ PC Interface 2200 YRM 1067 Once the log file has been saved, the user can either 0;0;0.00 0;80;0.0; analyze the data him/herself or e-mail the file to the fac- 10;0;0.00 0;80;0.0; tory for analysis. 20;0;0.00 0;80;0.0; The raw data file looks like this (see Figure 38): 30;0;0.00 0;80;0.0;...

  • Page 63: Alarm Logbook

    2200 YRM 1067 ZAPI™ PC Interface Alarm Logbook The ZAPI™ controller can record up to five unique alarms and store them in a logbook that the PC can access. See Figure 39. Figure 39. Alarm Logbook...

  • Page 64: Alarms

    ZAPI™ PC Interface 2200 YRM 1067 The display screen (Figure 40) will display any current "live" alarms. Note the display ACTUAL ALARM that indicates a current "live" alarm condition. Figure 40. Actual Alarm The PC software will provide the alarm name and the 7.

  • Page 65: Programming Tilt And Sideshift On The Zapi Controller (Laptop)

    2200 YRM 1067 ZAPI™ PC Interface PROGRAMMING TILT AND SIDESHIFT ON 4. On the drop down menu, click on "Function," "EEP- ROM Function." THE ZAPI CONTROLLER (LAPTOP) a. Delete the value in the address box and enter 1. Connect the laptop to the ZAPI Controller: F000.

  • Page 66: Repair

    Repair 2200 YRM 1067 Repair REMOVE Install 1. Park lift truck in a safe, level area. The stud must be installed in the correct orientation with regard to the relief groove. 2. Block drive wheel to prevent lift truck from moving. 1.
  • Page 68 Yale Materials Handling Corp. 1400 Sullivan Dr., Greenville, NC 27834-2011 2200 YRM 1067 8/10 (11/07)(8/05)(7/03) Printed in U.S.A.

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Zapi mpw050-eB802C802

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