Zapi COMBI SEM-1 Bedienungsanleitung
Page 1
Index
Page
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 Main Contactor and safety button .................................................. 5
1.8 General instructions and precautions ............................................ 6
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 Periodic maintenance to be repeated at times indicated ........................ 28
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= The informations included into the marked paragraphs by this symbol are
essential for the safety.
SIGNATURES TABLE
SECIVRES.TPEDYNAPMOCEVITUCEXETNEMEGANAM
EVITUCEXENOITCESGNIREENIGNE
REGANAMTROPXE
Publications N°: AD3ZP0AA
Edition: September 2000
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1 GENERAL CHARACTERISTICS
1.1 TECHNICAL SPECIFICATIONS
Motor Types (Traction):.............................................................................. DC SEM
Motor Types (Pump): ............................................................................ DC SERIES
Power ratings (Traction):........................................................................... 1 to 2 kW
Supply Voltage: .........................................................................................24V / 48V
Armature Switching frequency: ..................................................................... 16 kHz
Field Switching frequency: ............................................................................800 Hz
Temperature range: ....................................................................... -30 °C to +40 °C
Maximum controller temperature: ................................................................... 75 °C
Version Maximum Traction current Maximum Pump current
200+250 200 A 250 A
300+300 300 A 300 A
400+250 400 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-
re.
- Lifting controller for series excited motors.
- Drivers for ON/OFF electrovalves and for one proportional valve (electrodistributor)
- Interface for serial tiller head
- MDI interface (Multifunction Digital Instrument) battery discharge indicator,
hourmeter, alarms, programmed maintenance.
1.3 MAIN FEATURES
- High frequency MOSFET controller (high efficency, silent, etc.).
- Speed control with regenerative braking (controls the truck also on the slope)
- Idraulic functions control with different programmable speeds and ramps, It is
possible to use proportional functions.
- Lowering speed control through proportional valve.
- All the parameters are programmable by means of the ZAPI console.
- Complete diagnosis through console or MDI.
- High temperature protection with current reduction.
- Drivers real time diagnosis (electro-brake, general contactor and proportional valve.
- Electrobrake and general contactor are controlled with a PWM.
- Drivers protected against short-circuits.
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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. Contactor drivers are suitable for
loads up to 2 Amps, and are protected against overload.
- Thermal protection
If the controller temperature exceeds 77°C, the maximum current will be reduced
proportionaly to the thermal increase. The temperature can never exceed 90°C.
- Low Battery charge
When the battery charge is low, the maximum current is reduced.
- External Agents
The chopper is protected against dust and spray of liquid to a degree of protection
meeting IP64.
- Protection against accidental Start Up
A precise sequence of operations is necessary before the machine starts. If these
operations are not carried out correctly the machine stops. Driving requests must be
made after closing the Key Switch.
- Protection against uncontrolled movements.
The Main Contactor will not close if:
- The Power Unit is not operating correctly
- The Logic Unit is not operating correctly
- The Serial Tiller is not operating correctly
1.5 THERMAL CONSIDERATIONS
- The heat generated by the power block must be dissipated. For this to be possible,
the compartment must be ventilated and the heat sink materials ample.
- The heat sink material and system should be sized on the performance requirement
of the machine. Abnormal ambient air temperatures should be considered. In
situations where either ventilation is poor, or heat exchange is difficult, forced air
ventilation should be used.
- The thermal energy dissipated by the power block module varies and is dependent
on the current drawn and the duty cycle.
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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.
2) Standby Diagnosis that checks: watch-dog, VMN Point, Contactor Drivers, Current
Sensors.
3) Driving diagnosis that checks: Watchdog, VMN Point, Current, Contactor(s).
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.
1.7 MAIN CONTACTOR AND SAFETY BUTTON
- Battery disconnection should be made according to the Diagram below.
- In order to avoid damage to the controller during the regenerative phase, the supply
to the Key Switch must be cut off at the same time.
Wiring with cut off in series to positive supply.
- An internal protection is activated when the voltage on B12 connector is greater than
30% of battery voltage, or when the key switch is opened before the battery is
opened.
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1.8 GENERAL INSTRUCTIONS AND PRECAUTIONS
- Never combine SCR low frequency choppers with COMBI SEM-1 modules. The filter
capacitors contained in the COMBI SEM-1 module would change the SCR chopper
operation and subject it to excessive workload. If it is necessary to use two or more
control units, the choppers should both 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. A higher battery voltage may cause MOS failure. A lower
voltage may prevent the logic operating.
- During battery recharge, the COMBI SEM-1 must be completely disconnected from
the battery. Beside changing the charging current seen by the battery charger, the
module can be damaged by higher than normal voltages supplied via the charger.
- 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.
- In the first instance, start the machine with the drive wheels raised from the floor to
ensure that any installation error do not compromise safety.
- After operation, even with the Key Switch open, the internal capacitors may remain
charged for some time. For safe operation, we recommend that the battery is
disconnected, and a short circuit is made between Battery Positive and Battery Ne-
gative power terminals of the chopper using a Resistor between 10W and 100W.
Minimum 5 W.
- The susceptibility and electromagnetic emmission levels are seriously influenced by
installation conditions. Take particular care with the length of cables and wires, types
of electrical connections, and braided/screened wires. Zapi declines any
responsibility for incorrect or bad operation that can be attributed to the above
circumstances. Above all, the manufacturer of the machine must ensure that the
requirements of EN 50081-2 are met.
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2 INSTALLATION
Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.
Apply a very 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 corro-
sive elements and substances may cause oxidization of contacts, resulting in bad
operation. Remember this point when deciding the installation position on the vehicle.
Fix the chopper using the special holes located on the baseplate (maximum screwing
torque: 3 Nm for M5 and 4Nm for M8 screws).
Verify that the wiring of the cable terminals and connectors has been carried out
correctly.
2.1 CONNECTION CABLES
For the auxiliary circuits use cables bigger or equal to 0.5mm2section.
For power connections to the motor (pump and traction rotor) and to the battery use
cables of 16÷25 mm2section. The cables from chopper to battery should be run side by
side and be as short as possible.
2.2 CONTACTORS
A Main Contactor, designed for Continuous Operation should be installed. This
contactor should be fitted with a coil corresponding to the battery voltage. The current
absorbed by the coil must not be greater than 2A.
Suppression for this contactor coil is inside the chopper logic. Do not use any
additional external suppression.
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 8
2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING
Page 9
2.5 SERIAL TILLER MECHANICAL DRAWING
Page 10
3 CONNECTION
3.1 COMBI SEM-1 CONNECTION DRAWING
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