Table of Contents
Advertisement
Quick Links
1
Main features ................................................................................................. 3
1.1 Field of application .................................................................................... 3
1.2 Control units .............................................................................................. 4
1.2.a Microswitches ............................................................................... 4
1.2.b Potentiometer ............................................................................... 4
1.3 Safety features .......................................................................................... 5
1.4 Operating functions ................................................................................... 6
1.5 Controller diagnosis ................................................................................... 6
1.6 Thermal considerations ............................................................................. 7
2
Installation...................................................................................................... 8
2.1 Choice of connecting cables...................................................................... 8
2.2 Fuses ......................................................................................................... 8
2.3 Description of connectors .......................................................................... 9
2.4 Dimensions .............................................................................................. 10
2.5 Connections ............................................................................................ 11
2.5.a Pallet truck.................................................................................. 11
2.5.b Floor washer............................................................................... 12
3
Console Menu .............................................................................................. 13
3.1 Programming with the console ................................................................ 13
3.2 Console Map ........................................................................................... 14
3.2.a Pallet truck.................................................................................. 14
3.2.b Floor washer............................................................................... 15
3.3 "Tester" Menu .......................................................................................... 16
3.3.a Pallet truck.................................................................................. 16
3.3.b Floor washer............................................................................... 16
3.4 "Parameter Change" Menu ...................................................................... 17
3.4.a Pallet truck.................................................................................. 17
3.4.b Floor washer............................................................................... 17
3.5 "Set Model" Menu .................................................................................... 18
3.6 "Set Option" menu ................................................................................... 18
3.6.a Pallet truck.................................................................................. 18
3.6.b Floor washer............................................................................... 20
3.7 "Adjustment" Menu .................................................................................. 21
3.8 "Hardware Setting" Menu ........................................................................ 22
3.9 "Special Adjust" Menu ............................................................................. 23
3.10 "Clear EEprom" Menu ........................................................................... 23
4
Alarms .......................................................................................................... 24
4.1 Diagnosis ................................................................................................. 24
5
Recommended spare parts for the 4Q ...................................................... 27
6
Regular maintenance at set intervals ........................................................ 28
Index
.................................................... 7
Page 1
Advertisement
Table of Contents
Related Manuals for Zapi 4Q
Summary of Contents for Zapi 4Q
-
Page 1: Table Of Contents
3.8 "Hardware Setting" Menu ................ 22 3.9 "Special Adjust" Menu ................23 3.10 "Clear EEprom" Menu ................23 Alarms ......................24 4.1 Diagnosis ....................24 Recommended spare parts for the 4Q ............27 Regular maintenance at set intervals ............28 Page 1... - Page 2 The informations included into the marked paragraphs by this symbol are essential for the safety. SIGNATURES TABLE COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE ENGINEERING SECTION EXECUTIVE EXPORT MANAGER Publication N°: ADMZP0DA Edition: November 2001 Page 2...
-
Page 3: Main Features
The main contactor (relay) is internal. The 4Q controller can be configured in two different ways: - Pallet truck (Model 1) - Floor washer (Model 2) The parameters, tester and options may vary according to the model chosen with ZAPI console. Page 3... -
Page 4: Control Units
1.2 CONTROL UNITS 1.2.a Microswitches - A contact resistance of less than 0.1Ω and a current leakage of less than 100µA is required. - The key contact must be able to take all the current of the loads without causing a voltage drop of more than 01.V between contacts. -
Page 5: Safety Features
All the inputs are protected against wrong connection. - Thermal protection: If the temperature of the 4Q exceeds 75°C, the maximum current is automatically reduced in proportion to the temperature increase. The temperature cannot exceed 90°C, at this temperature the maximum current is zeroed. If the temperature drops to below –10°C, the maximum current is reduced by 20%. -
Page 6: Operating Functions
1.4 OPERATING FUNCTIONS - Speed control. - Excellent sensitivity at low speeds. - Maximum speed reduction: the maximum speed in both directions can be adjusted using the programming console. - Regenerative braking based on deceleration ramps, release braking, inversion braking. - Speed control in descent: the motor speed is controlled by the accelerator pedal and regenerative braking is activated automatically if the motor speed exceeds the required speed;... -
Page 7: Thermal Considerations
1.7 GENERAL WARNINGS AND PRECAUTIONS - Do not connect the 4Q module to a battery with a different rated voltage to the one indicated on the module’s rating plate. A higher battery voltage can cause irreparable damage the MOSFETs. With a lower battery voltage the module will not work. -
Page 8: Installation
2 INSTALLATION If possible, assemble the chopper with its base on a flat metal surface that has not been painted or cleaned. It is advisable to spread a layer of thermo-conductive grease between the two surfaces to improve the transmission of heat. Although the chopper is protected against external agents, the connector contacts may become oxidised due to the presence of corrosive substances. -
Page 9: Description Of Connectors
2.3 DESCRIPTION OF CONNECTORS pin function description CPOTT Potentiometer unit: connect to the cursor of the accelerator potentiometer. NPOTT Negative pole of accelerator potentiometer. PPOTT Positive pole of accelerator potentiometer. TILLER Tiller/seat switch signal input (or hydro request input if the chop per is configured as a floor washer). -
Page 10: Dimensions
2.4 DIMENSIONS Page 10... -
Page 11: Connections
2.5 CONNECTIONS 2.5.a Pallet truck Page 11... -
Page 12: Floor Washer
2.5.b Floor washer Page 12... -
Page 13: Console Menu
3 CONSOLE MENU 3.1 PROGRAMMING WITH THE CONSOLE The Zapi console can be used to program various 4Q chopper functions. It is therefore possible to adapt the truck performance to suit the client’s requirements. The console can be left connected to the controller when it is in use and the parameters can be modified in real time. -
Page 14: Console Map
3.2 CONSOLE MAP 3.2.a Pallet truck Page 14... -
Page 15: Floor Washer
3.2.b Floor washer Page 15... -
Page 16: Tester" Menu
3.3 "TESTER" MENU 3.3.a Pallet truck BATTERY VOLTAGE battery voltage VMN voltage MOTOR CURRENT motor current TEMPERATURE chopper temperature ACCELERATOR accelerator FORWARD SWITCH forward input BACKWARD SWITCH reverse input TILLER SWITCH tiller switch input CUTBACK SWITCH 1 speed reduction 1 input CUTBACK SWITCH 2 speed reduction 2 input (if configured) BELLY SWITCH... -
Page 17: Parameter Change" Menu
3.4 "PARAMETER CHANGE" MENU 3.4.a Pallet truck ACCELER. DELAY Acceleration time; 9 = maximum time DECELER. DELAY Deceleration time; 9 = maximum time RELEASE BRAKING Release braking time; 9 = max. braking power, minimum time INVERS. BRAKING Inversion braking time; 9 = max. braking power, minimum time CUTBACK SPEED 1 Speed reduction 1... -
Page 18: Set Model" Menu
3.5 "SET MODEL" MENU Model Type Option #1 The 4Q is configured as a transpallet. Option #2 The 4Q is configured as a floor washer. 3.6 "SET OPTION" MENU 3.6.a Pallet truck Hour counter Running The hour counter is active during running only. - Page 19 Handle switch Present Tiller present: incorrect start if pressed at key-on and movement jammed if released during running. A maximum delay time between selecting the running direction and selecting the tiller can be programmed using the “Seat micro delay” parameter. Seat Seat present: no incorrect start is pressed at key-on, delay if released during running (program the delay time using the...
-
Page 20: Floor Washer
Set battery type Sets the battery nominal value 24V battery. 36V battery. 3.6.b Floor washer Hour counter Running The hour counter is active during running only. Key on The hour counter is active at all times. Battery check Battery alarm disengaged. Low battery alarm enabled (plus current limiting device). -
Page 21: Adjustment" Menu
Option #3 If the “Tiller/Seat” input is activated without traction it activates NEV1 for a duration that is programmed by the “Hydro Time” parameter. If the input is activated with traction then the NEV1 output is permanently active. If traction stops, NEV1 remains active for a certain length of time that can be programmed by the “Hydro Time”... -
Page 22: Hardware Setting" Menu
3.8 "HARDWARE SETTING" MENU Set current Adjust the bottom of the scale setting of the current reading visualised on the console. Adjustment #01 Adjust the maximum value of the low battery curve. Adjustment #02 Adjust the minimum value of the low battery curve. Aux function #1 The hour counter of the chopper loads the MDI hour counter. -
Page 23: Special Adjust" Menu
380 hours. 3.9 "SPECIAL ADJUST" MENU Set temperature Fine adjustment of chopper temperature (the chopper temperature is calibrated by Zapi during testing and should not be modified by the client). Maximum Current Adjust the maximum chopper current. A password is required in order to modify this setting and remains active until the key is turned off. -
Page 24: Alarms
4 ALARMS 4.1 DIAGNOSIS 1) POWER FAILURE #1 AL 73 MDI 1 LED FLASH Short circuit on main relay or on auxiliary outputs (NEV1, NEV2). 2) CAPACITOR CHARGE AL 60 MDI 3 LED FLASHES This alarm is signalled if the capacitors have not begun re-charging after a certain amount of time has lapsed. - Page 25 8) CONTACTOR DRIVER AL 75 MDI 6 LED FLASHES Test with the main relay closed, check that the driver is not open. Possible causes: driver open; fault in the feedback circuit of the main relay coil voltage. 9) I=0 EVER AL 49 MDI 5 LED FLASHES Test whilst running.
- Page 26 15) INCORRECT START AL 79 MDI 2 LED FLASHES Forwards/reverse, tiller, quick inversion present at key-on; traction running request given before tiller/seat. 16) THERMAL PROTECTION AL 62 MDI 7 LED FLASHES Temperature alarm activated if the temperature is >+75°C in which case the maximum armature current is reduced linearly until it reaches nil at a threshold temperature of 90°C;...
-
Page 27: Recommended Spare Parts For The 4Q
5 RECOMMENDED SPARE PARTS FOR THE 4Q ITEM CODE DESCRIPTION C12404 16 way Molex Minifit female connector C12777 Molex Minifit female crimp terminal C00077 Console connector plug C18556 Outer gasket for Molex Minifit connector C18557 Inner gasket for Molex Minifit connector... -
Page 28: Regular Maintenance At Set Intervals
ZAPI technicians or to the technical sales network who are responsible for any decisions concerning the safety of the electric vehicle. - Page 29 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 4Q CONTROLLER OPERATING AND USER MANUAL...