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1
Introduction to the Zapimos family ............................................................. 3
2
Specification .................................................................................................. 4
2.1
Technical specifications ........................................................................ 4
2.2
Control Units.......................................................................................... 5
2.2.a Microswitches ............................................................................... 5
2.2.b Potentiometer ............................................................................... 5
2.3
Protection features ................................................................................ 6
2.4
Direction orientation .............................................................................. 7
2.5
Functional features ................................................................................ 7
2.6
Controller's diagnostics ......................................................................... 8
2.7
Thermal precautions ............................................................................. 8
2.8
3
Installation ................................................................................................... 10
3.1
Connection cables ............................................................................... 10
3.2
Contactor ............................................................................................. 10
3.3
Fuses .................................................................................................. 10
3.4
Description of connectors .................................................................... 11
3.5
Description of power connectors ......................................................... 12
3.6
Mechanical drawing ............................................................................ 13
4
Programming and settings using a console ............................................ 14
4.1
Setting by console ............................................................................... 14
4.2
Programming console functions .......................................................... 14
4.3
Programming console ......................................................................... 15
4.4
Map of the console functions............................................................... 16
5
Configuration function ............................................................................... 17
5.1
5.2
Parameter regulation ........................................................................... 21
5.3
Start up: programming instructions ..................................................... 24
5.3.1 Adjustment sequence ................................................................ 24
6
Diagnosis ..................................................................................................... 25
6.1
Alarms displayed on console ............................................................... 25
6.2
Tester: functions descriptions ............................................................. 27
6.3
Save parameters: description ............................................................. 29
6.4
Restore parameters: description ......................................................... 30
6.5
Alarms: menu description .................................................................... 31
6.6
Program vacc: description ................................................................... 32
INDEX
......................................................................... 9
SEM1
Page
Page 1

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Summary of Contents for Zapi SEM1

  • Page 1: Table Of Contents

    5.3.1 Adjustment sequence ..............24 Diagnosis ..................... 25 Alarms displayed on console ............... 25 Tester: functions descriptions ............. 27 Save parameters: description ............. 29 Restore parameters: description ............30 Alarms: menu description ..............31 Program vacc: description ..............32 SEM1 Page 1...
  • Page 2 Suggested spare-parts ................37 = Information included into the marked paragraphs by this symbol is essential for the safety. SIGNATURES TABLE COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE ENGINEERING SECTION EXECUTIVE EXPORT MANAGER Publication N°. ABJZP0AD Edition: September 1997 SEM1 Page 2...
  • Page 3: Introduction To The Zapimos Family

    1 INTRODUCTION TO THE ZAPIMOS FAMILY The ZAPIMOS chopper family is ZAPI’s answer to the needs of users of the ’90s. To ensure that the product stays on the market without running the risk of becoming technologically obsolete, ZAPI has designed the ZAPIMOS family offering the following...
  • Page 4: Specification

    24V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C 36V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C 48V / 180A 180A (1') 220A (5'') 0.39V a 70A, 25°C Block diagram: SEM1 Page 4...
  • Page 5: Control Units

    This function is indispensable when it is necessary to com- pensate for asymmetry in the mechanical components that control the potentiometer, especially regarding the adjustment of the minimum level. The sequence of procedure is described in the programming console manual. SEM1 Page 5...
  • Page 6: Protection Features

    - the power unit is not functioning; - the logic is not perfectly operating; - Main contactor: is to be installed in order to protect against reverse battery polarity; - The chopper is protected against dust and liquid (IP41). SEM1 Page 6...
  • Page 7: Direction Orientation

    - Memory of the last five alarms, with relative hour-meter and temperature displayed on the console. - Console tester for checking the main parameters (see the specific description) - High efficiency of motor and battery due to high frequency commutation. SEM1 Page 7...
  • Page 8: Controller's Diagnostics

    - The power dissipated by the controller is a function of the current and the working cycle. SEM1 Page 8...
  • Page 9: General Warnings

    - During battery charge, disconnect SEM1 from the battery. - Supply the SEM1 only with battery for traction; do not use a power supply. - When the chopper is installed, make tests with the wheels raised from the ground, in order to avoid dangerous situations due to connection errors.
  • Page 10: Installation

    - In order to protect the power unit see the diagram. Values shown are 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 particles in event of a blowout. SEM1 Page 10...
  • Page 11: Description Of Connectors

    (2 sec delay). It is active high (+VB). A12 IR Quick inversion input, it is active HIGH (+VB). A13 CMM Common IR/TIM/MI/MA/RV1/RV2 microswitch (+VB). A14 CH Connected to the power supply through a 6.3A fuse and the key- switch. SEM1 Page 11...
  • Page 12: Description Of Power Connectors

    Negative serial trasmission or negative of the diagnostic LED if the (NLED) console is not connected. Negative console power supply. Positive console power supply. ----- ----- 3.5 DESCRIPTION OF POWER CONNECTORS F1, F2: motor field windings VMN, SH: motor rotor windings +BATT: battery positive -BATT: battery negative SEM1 Page 12...
  • Page 13: Mechanical Drawing

    3.6 MECHANICAL DRAWING SEM1 Page 13...
  • Page 14: Programming And Settings Using A Console

    Alarms - Displays the last 5 Alarms together with the temperature and the hour meter reading when the alarm occurred. Accelerator range programming, records the minimum and maximum output values of the accelerator unit, optimising in this way the full stroke. SEM1 Page 14...
  • Page 15: Programming Console

    4.3 PROGRAMMING CONSOLE The console to be connected the controller SEM1 is to be equipped with the EPROM "CK ULTRA". SEM1 Page 15...
  • Page 16: Map Of The Console Functions

    4.4 MAP OF THE CONSOLE FUNCTIONS SEM1 Page 16...
  • Page 17: Configuration Function

    - OFF: this function is not activated. 8. TRANSPALLET MODE: - ON: in this mode the acceleration and braking ramps are faster (twice). - OFF: standard ramps (switched for golf-car). SEM1 Page 17...
  • Page 18 13) Confirmation of the modification request appears. 14) Press ENTER to confirm the modifications or press OUT to cancel. 15) Headline of the menu SET OPTIONS appears. 16) Press OUT to return back to the opening display. SEM1 Page 18...
  • Page 19: Adjustment: Description And Programming Instructions

    11) The ADJUST BATTERY menu appears. 12) The button SETUP increases the value shown on the display, the button SET DOWN decreases it. Set to the same value as measured on the battery with a multimeter. 13) The new voltage value appears. SEM1 Page 19...
  • Page 20 14) Press OUT to quit the menu. 15) Confirmation of the modification request appears. 16) Press ENTER to confirm the modifications or press OUT to cancel. 17) Headline of the menu appears. 18) Press OUT to return to the main menu. SEM1 Page 20...
  • Page 21: Parameter Regulation

    5.2 PARAMETER REGULATION In addition to the input configuration, parameter modification is made either by ZAPI upon Customer specifications, or directly by the Customer using the programming console. The following parameters can be modified: NAME FUNCTION ACC. DELAY: Determines the acceleration ramp.
  • Page 22 I MAX (version 200A) I MAX (version 300A) ARMA NOM. CURR. (version 180A) ARMA NOM. CURR. (version 200A) ARMA NOM. CURR. (version 300A) WEAK DROPOUT (version 180A) WEAK DROPOUT (version 200A) WEAK DROPOUT (version 300A) FIELD NOM CURR (FNC) SEM1 Page 22...
  • Page 23 12) Press ENTER to confirm the modifications or OUT to cancel. 13) The headline of the menu PARAMETER CHANGE appears. 14) Press ROLL UP or ROLL DOWN for scrolling the other items, or press OUT for coming back to the opening display. SEM1 Page 23...
  • Page 24: Start Up: Programming Instructions

    NOTE: the parameters can not be changed in "real-time" because, when the controllers is running, can not communicate to the console. The parameter must be changed only when the controller is in stand-by status. SEM1 Page 24...
  • Page 25: Diagnosis

    The test is made while in standby. This alarm indicates that the accelerator voltage is 1V greater than the minimum stored value. Possible causes: a. a potentiometer wire is interrupted. b. the potentiometer is not correctly calibrated. c. the potentiometer is defective (interrupted). SEM1 Page 25...
  • Page 26 If the alarm is signalled when the chopper is cold: a. check the wiring of the thermal sensor; b. thermal sensor failure; c. logic board failure. 13. BATTERY LOW The battery is discharged. This alarm is present only if the "battery check" option has been selected. SEM1 Page 26...
  • Page 27: Tester: Functions Descriptions

    OFF / GND = not active, open microswitch. 12) HANDLE / SEAT SWITCH: status of digital input corresponding to the microswitch tiller / seat (MT / MSED: pin A11). ON / +VB = active, closed microswitch. OFF / GND = not active, open microswitch. SEM1 Page 27...
  • Page 28 9) The following signal appears. 10) Press OUT to return to the item list. 11) The selected item appears. 12) Press ROLL UP and ROLL DOWN for scrolling the remaining items, or press OUT to return to the opening display. SEM1 Page 28...
  • Page 29: Save Parameters: Description

    (FREE/BUSY) appears. 10) Press ENTER to confirm the reading operation. 11) On the second line the items of the parameters stored scroll. 12) At the end of the operation it returns to the main menu SAVE PARAM. SEM1 Page 29...
  • Page 30: Restore Parameters: Description

    12) Press ENTER to confirm the loading operation (OUT for cancelling). 13) The list of the parameter items during the loading phase appears. 14) At the end of the operation it returns to the main menu RESTORE PARAM. SEM1 Page 30...
  • Page 31: Alarms: Menu Description

    9) If there are no other alarms, ALARM NULL appears. 10) Press OUT to leave the menu ALARMS. 11) The confirmation request for cancelling all the alarms stored, appears. 12) Press ENTER to confirm the operation (OUT for returning to the main menu). SEM1 Page 31...
  • Page 32: Program Vacc: Description

    11) The new maximum and minimum values for each running direction appear. The arrow indicates the selected direction. 12) Press OUT. 13) The confirmation request for storing new values appears. 14) Press ENTER to confirm or OUT to cancel. SEM1 Page 32...
  • Page 33: Connection Drawing

    Motor cable connection for current feedback Main contactor Motor to negative voltage 7.2 COLOUR CODING The following codes are used to identify the colours of the wires in the wiring drawings. ORANGE YELLOW WHITE BLACK BLUE PINK SKY-BLUE YELLOW GREEN GREY PURPLE SEM1 Page 33...
  • Page 34: Connections

    7.3 CONNECTIONS 7.3.1 Control input / output connections SEM1 Page 34...
  • Page 35: Power Configuration

    7.3.2 Power configuration FUNCTIONAL DRAWING WIRING DIAGRAM SEM1 Page 35...
  • Page 36: Periodic Maintenance To Be Regularly Repeated

    Any problem which is visible or apparent to an ordinary technician who periodically checks the equipment, that may create damage or defect to the device, should be transmitted to ZAPI’s technicians or to the technical commercial net. They will take the responsibility for possible decisions regarding the operational safety of the electric vehicle.
  • Page 37: Suggested Spare-Parts

    Molex connector Fe 8 pin C12761 Pin female (molex) P99060 Diagnostic red led C12403 Molex connector minifit 14 pin female C12771 Pin female for minifit C29548 Contactor SW80 24V C29504 Contactor SW80 36V C29554 Contactor SW80 48V SEM1 Page 37...
  • Page 38 COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259 SEM1 User' s Manual...

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