Related Manuals for Zapi Chopper SEM-X
Summary of Contents for Zapi Chopper SEM-X
- Page 1 ELECTRONIC INDUSTRIAL DEVICES 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it INSTALLATION AND USER MANUAL CHOPPER SEM-X...
-
Page 2: Table Of Contents
INDEX Page LEGEND ......................3 COLOUR CODES (Single Colours) ..............3 Introduction to the ZAPI-MOS Family ............4 General Characteristics ................5 Technical Specifications ................ 5 Control Units..................5 2.2.a Microswitches ................5 2.2.b Potentiometer ................6 Safety & Protection Features ..............7 Direction Orientation ................ - Page 3 SIGNED IN APPROVAL Publication n°: ADRZP0BA Edition: June 2001 Page 2...
-
Page 4: Legend
Reverse Switch Speed Reduction 1 Speed Reduction 2 T SW Tiller Switch COLOUR CODES (SINGLE COLOURS) The following Codes represent the colours of individual wires used by Zapi (unless specified otherwise). - Orange Brown - White Black BB - Blue... -
Page 5: Introduction To The Zapi-Mos Family
1 INTRODUCTION TO THE 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. -
Page 6: General Characteristics
2 GENERAL CHARACTERISTICS 2.1 TECHNICAL SPECIFICATIONS Chopper for Separately Excited DC motors ..........0.35 ÷ 0.8kW Regenerative Braking Voltage Range ...................... 24VDC Maximum Field Current (all the versions) ..............35 A Armature Switching Frequency ................16kHz Field Switching Frequency ..................16kHz Maximum Ambient temperature ................ -
Page 7: Potentiometer
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 : 500Ω Maximum Potentiometer Resistance : 10kΩ Faults can occur if the potentiometer is out of this range. The Procedure for automatic potentiometer signal acquisition is carried out using the Console. -
Page 8: Safety & Protection Features
2.3 SAFETY & PROTECTION FEATURES - Connection Errors : All Inputs are protected against connection errors. - Thermal Protection : If the chopper temperature exceeds 75°C, the maximum current reduces in proportion to the thermal increase. The temperature can never exceed 90°C (below - 10°C, the current is reduced to 80%). -
Page 9: Operational Features
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, in every condition. - Three different modes of Braking : Release Braking, Inversion Braking, Deceleration Braking. -
Page 10: Sem-X Chopper Diagnosis
2.6 SEM-X 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: the Watch Dog Circuits, the current sensors, VMN point, Main Contactor Driver, if the switch sequence for operation is correct, and if the output of the accelerator or tiller is correct. -
Page 11: General Instructions And Precautions
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. -
Page 12: Installation
3 INSTALLATION 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 corrosive elements and substances may cause oxidization of connector contacts, resulting in bad operation. -
Page 13: Description Of Sem-X Connectors
3.4 DESCRIPTION OF SEM-X CONNECTORS PIN REFERENCE DESCRIPTION NPOT Provides a negative supply to accelerator's potentiometer; the circuit is designed to provide a control against wire disconnection. CPOT Accelerator's potentiometer wire input. PPOT Provides a positive to supply accelerator's potentiometer, protected against short to +B and -B. -
Page 14: Description Of Power Connections
PIN REFERENCE DESCRIPTION A11 NEB electric brake driver output, 1.5A continuous, protected against shortcircuits. A12 NLED Output to drive a led, 100mA max. A13 --- A14 NMC Line contactor driver output, 1.0A continuous, protected against shortcircuit. A15 PMC Line contactor coil positive supply, 1.0A continuous. A16 KEY Controller supply, must be connected to +B through a cable and a 6.3A fuse. -
Page 15: Mechanical Drawing & Dimensions
3.6 MECHANICAL DRAWING & DIMENSIONS Page 14... -
Page 16: Programming & Adjustments Using Digital Console
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 “B” connector of the SEM-X Chopper. Pay attention to the polarity of the Console Connector when connecting to the chopper. -
Page 17: Description Of Standard Console Menu
4.3 DESCRIPTION OF STANDARD CONSOLE MENU Page 16... -
Page 18: Sem-X: Cabling And Configuration
5 SEM-X: CABLING AND CONFIGURATION 5.1 POWER DIAGRAM Page 17... -
Page 19: Description Of Programmable Functions (Options)
5.2 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS) Using the CONFIG MENU of the console, it is possible to select from the following options: SUBMENU “SET OPTIONS”: HOUR COUNTER: - RUNNING: The counter registers travel time only. - KEY ON: The counter registers when the key switch is Closed. QUICK INVERSION: - BELLY: Quick inversion is activated while the Belly Button is... - Page 20 Flow Chart showing how to make changes to Configuration Menu using Digital Console. (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.
-
Page 21: Description Of Parameters That May Be Programmed
5.3 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED In addition to the Configuration, Parameter settings may be made by Zapi using standard default settings, settings to Customer Specifications, or the customer may make changes according to the application, using a Digital Console. - Page 22 14 FIELD NOM. CURR. = Nominal Field Current. This parameter fixes the minimum Field Current when the potentiometer is between 0% and 60% without total conduction of the Armature. Adjustment should be made with reference to the Data on the Motor Label. (The indication of Nominal Field Current). 15 CREEP SPEED = Minimum Speed.
-
Page 23: Table Of Adjustments
5.4 TABLE OF ADJUSTMENTS The following Table shows the different values that the SEM2 Parameters may be adjusted to. A suitable acceleration performance assumes: FIELD CURR. NOM is set to level 5, and MAX SPEED (Fwd or Rev) is set to level 9. PROGRAMMED LEVEL PARAMETERS UNIT... - Page 24 Flow Chart showing how to make Program changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Display. 2) Press ENTER to go into the General Menu. 3) The Display will show : 4) Press ENTER to go into the Parameter Change facility.
-
Page 25: Menu Special Adjust
5.5 MENU SPECIAL ADJUST 1) SET TEMPERATURE Adjusts the temperature of the chopper. 2) MAXIMUM CURRENT Software adjustment of the maximum current level of the chopper. It's a password protected parameter. 3) ADJ FIELD NOM FW Software adjustment of the field nominal current in forward direction. It's a password protected parameter. -
Page 26: Menu Adjustment
5.7 MENU ADJUSMENT 1) ADJUST BATTERY Sets the correct battery voltage level. 2) THROTTLE 0 ZONE Sets the pedal curve type. 3) THROTTLE X POINT Sets the pedal curve type. 4) THROTTLE Y POINT Sets the pedal curve type. Page 25... -
Page 27: Sem-X Traction Standard Wiring Diagrams
5.8 SEM-X TRACTION STANDARD WIRING DIAGRAMS Page 26... -
Page 28: Sequence For Sem-X Traction Settings
5.9 SEQUENCE FOR SEM-X TRACTION SETTINGS When the Key Switch is Closed, if no Alarms or Errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the chopper is not Configured to your requirements, follow the Sequence detailed on Page 20. -
Page 29: Sem-X Diagnostics
6 SEM-X DIAGNOSTICS The following list shows likely problems associated with the flashing RED LED. N° FLASHES MESSAGE NOTES Watch-dog: Logic board and/or software failure. EEPROM KO: Problem with EEPROM or Logic. CHECK UP NEEDED Check up timeout. INCORRECT START: Starting sequence for travel not correct. -
Page 30: Analysis Of Alarms Displayed On The Console
6.1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE WATCH DOG AL 8 MDI The test is executed at the key turn-on, at the stand-by and on running. Possible causes: a) Watch-dog hardware circuit not OK; b) Software not OK. EEPROM KO AL 13 MDI Fault in the area of memory where the adjustment parameters are stored. - Page 31 VFIELD NOT OK AL 15 MDI This test is made at standby with the Line Contactor open. In this condition the voltages on both the connections of field must be to around ½ VBatt. This alarm is generated if the field voltage is different from this value. Possible causes: d) Frame fault on the motor to chassis;...
- Page 32 15 CONTACTOR CLOSED AL 37 MDI This check is made during the initial diagnosis. With the coil of the line contactor de- energized, the capacitors should not be charged, unless there is divert resistor across the power poles. Possible causes: a) The line contactor power poles are welded.
-
Page 33: Tester Description Of The Functions
6.2 TESTER DESCRIPTION OF THE FUNCTIONS 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. The following definition listing shows the relative measurements : 1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key switch. - Page 34 Flow Chart showing how to use the TESTER function of the Digital Console. 1) Opening Zapi Display. 2) Press ENTER to go into the General menu. 3) The Display will show : 4) Press either ROLL UP or ROLL DOWN button until TESTER MENU appear on the display.
-
Page 35: Description Of The Console Save Function
9) Press ENTER to commence SAVE routine. 10) You can see the items that are being stored whilst the SAVE routine is happening. 11) When finished, the Console shows : 12) Press OUT to return to the Opening Zapi Display. Page 34... -
Page 36: Description Of Console Restore Function
13) You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening. 14) When finished the Console displays : 15) Press OUT to return to the Opening Zapi Display . Page 35... -
Page 37: Description Of Alarms Menu
10) When you have finished looking at the Alarms, press OUT to exit the ALARMS menu. 11) The Display will ask CLEAR LOGBOOK ? 12) Press ENTER for yes, or OUT for NO. 13) Press OUT to return to the Opening Zapi Display. Page 36... -
Page 38: Description Of Console Program Vacc Function
11) Select the Reverse Direction and repeat Item 10. 12) When finished , press OUT. 13) The Display will ask : ARE YOU SURE ?. 14) Press ENTER for yes, or OUT for NO. 15) Press OUT again to return to the Opening Zapi Menu. Page 37... -
Page 39: Recommended Spare Parts For Sem-X
7 RECOMMENDED SPARE PARTS FOR SEM-X Part Number Description C16519 Protected 150A Fuse. C16503 Protected 200A Fuse C16520 6.3A 5x20mm Control Circuit Fuse C12404 16 Way Molex Minifit Connector C12777 Insert for Molex Minifit Connectors C29543 SW 80 24V CO Single Pole Contactor Page 38... -
Page 40: Periodic Maintenance To Be Repeated At Times Indicated
The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special requirements should be made after consulting a Zapi Agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual.