INDEX

Legend .............................................................................................................. 3
1 Introduction to the ZAPIMOS family ............................................................. 4
2 General characteristic ................................................................................... 5
2.1 COMBISEM2 technical specifications ..................................................... 5
2.2 COMBISEM3 technical specifications ..................................................... 5
2.3 Command units ...................................................................................... 6
2.3a Microswitches................................................................................. 6
2.3b Potentiometer................................................................................. 6
2.3c Lifting potentiometer ....................................................................... 7
2.4 Operational features .............................................................................. 8
2.5 Safety & protection features .................................................................... 9
2.6 Thermal considerations ........................................................................ 10
2.7 COMBISEM chopper diagnosis ............................................................ 10
2.8 Main contactor and safety button .................................................... 11

2.9 General instructions and precautions ............................................. 12

3 Installation .................................................................................................... 13
3.1 Connection cables ................................................................................ 13
3.2 Contactors ........................................................................................... 13
3.3 Fuses ................................................................................................... 13
3.4 COMBISEM connectors description ..................................................... 14
3.5 COMBISEM power connection ............................................................. 15
3.6 COMBISEM2/3 controller mechanical drawing ...................................... 16
4 Programming and adjustments using digital console .............................. 17
4.1 Adjustments via console ....................................................................... 17
4.2 Description of console & connection ...................................................... 17
4.3 Description of standard console menu ................................................... 18
5 CombiSem: Connection and configuration ................................................ 19
5.1 Power diagram ..................................................................................... 19
5.2 Control Circuit Wiring ........................................................................... 20
5.3 Description of programmable functions (options) ................................... 21
5.4 Adjustments: Set Pump Potentiometer Minimum & Maximum ............... 23
5.5 Adjustments: Set Nominal Battery Voltage ........................................... 24
5.6 Adjustments: Calibrate Battery Voltage ................................................ 25
5.7 Description of progammable Parameters
(Parameter change menu) .................................................................... 26
5.8 Adjustments table................................................................................. 28
5.9 COMBISEM wiring diagram .................................................................. 30
5.10 Sequence for COMBISEM settings ....................................................... 31

Page 1
6 COMBISEM diagnostic ................................................................................ 33
6.1 Alarms associated with the flashing red led ............................................. 33
6.2 Analisys of alarms displayed on the console ........................................... 34
6.3 Tester: description of the function .......................................................... 37
6.4 Description of the console Save function ................................................ 40
6.5 Description of console Restore function ................................................. 41
6.6 Description of Alarms Menu .................................................................. 42
6.7 Description of Program VACC function .................................................. 43
7 Recommended spare parts for COMBISEM .............................................. 44
8 Periodic maintenance to be repeated at times indicated ......................... 45

   
    
 




  

 

  


Pubblication n°: AD1ZP0DA

Edition: January 1999
Page 2
 LEGEND

ACC POTENTIOMETER = Accelerator Potentiometer

CM = Common feed to Microswitch
CPOTS = Pump Potentiometer Wiper
CPOTT = Traction Potentiometer Wiper
EB = Electric Brake
ENABLE = Accelerator Microswitch
FORW = Forward direction
HB = Handbrake switch
KEY = Input from Key Switch
LC = Line Contactor
LCC = Line Contactor Coil
LIFT = Pump Microswitch
LIFT POT = Pump potentiometer
NLC = Negative to Line contactor
NPOTS = Pump Potentiometer Negative supply
NPOTT = Traction Potentiometer Negative supply
PB = Brake Pedal Switch
PLC = Positive to Line Contactor
PPOTS = Pump Potentiometer Positive supply
PPOTT = Traction Potentiometer Positive supply
REV = reverse direction
SEAT = Seat switch input
SR = Speed reduction
THP = Pump motor temperature switch
THT = Traction motor temperature switch
VMN = Voltage to negative side of motor
1ST SPEED = First lifting speed

Page 3
 1 . INTRODUCTION TO THE ZAPI-MOS FAMILY

The ZAPIMOS chopper family represent 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 offer the following features:

- Advanced technology.
- Economical costs.
- Maximum safety.
- Maximum flexibility.
- Open to future technical innovations.
- Optimum levesl of protection.

The design has been derived from:

- High Frequency Mos Technology .

- Real time control over the internal and external components that influence the behavior of
the machine, with self diagnosis of the checking circuits themselves.
- Stored Program Machine (SPC), where the hardware is completely separate fromthe
functions to be configured. The programme is parametric and can easily be modified by
the end user.
- Various chopper configurations can be selected by the user, without the need for hardware
modifications.
- Future technological updates are made easy for the user.
- The communication protocol will continue to evolve, thereby offering increased
possibilities of interaction and expansion. For this reason, the Zapimos family offers
a standard dialogue mode with external systems. This allows interfacing with
commercially available systems. Zapi can offer a range of individually designed Console
Software options with various features and prices.
- Dual-SEM meets the requirements of (IP51). This provides excellent protection against
spray (water, acid.), and against the ingress of dust or small foreign particles. Access to
the control logic is very simple, and allows simple substitution or replacement.
- The Dual-SEM family of Choppers are suitable for operating on DC voltages from 24V to
96V inclusive, with maximum Armature currents up to 600A. The choppers may be used to
control two DC Separately Excited Motors with power ratings from 1.5kW up to 15kW.

Page 4
 2 . GENERAL CHARACTERISTICS

2.1 COMBISEM2 TECHNICAL SPECIFICATIONS

Motor Types: ........................................... DC SEM Traction + DC Series Excited Pump

Power ratings: Traction ........................................................................... 1.5 to 5.0 kW
Pump ........................................................................................... 13kW
Supply Voltage : ................................................................................... 24V, 36V, 48V
Maximum Field Current (all versions): ................................................................. 50A
Armature Switching frequency: ....................................................................... 16 kHz
Field Switching frequency: ................................................................................. 1 kHz
Pump Motor Switching frequency: ................................................................... 16 kHz
Temperature range: ........................................................................... -30 °C to+40 °C
Maximum controller temperature: ...................................................................... 92 °C

Voltage drop at
Max armature Voltage drop
Versions total condution Max pump current
current (traction) (pump)
(traction)
24V 250mV a 200A, 300mV a 150A,
500A 350A
500A 25°C 25°C
36V 250mV a 200A, 300mV a 150A,
500A 350A
500A 25°C 25°C
48V 220mV a 100A, 250mV a 150A,
350A 350A
350A 25°C 25°C

2.2 COMBISEM3 TECHNICAL SPECIFICATIONS

Motor Types: ......................................... DC SEM Traction + DC Series Excited Pump

Power ratings: Traction ............................................................................ up to 12 kW
Pump ............................................................................... up to 25 kW
Supply Voltage ........................................................................... 48V, 72V, 80V, 96V.
Maximum Field Current (all versions): .................................................................. 50A
Armature Switching frequency: ....................................................................... 16 kHz
Field Switching frequency: ................................................................................. 1 kHz
Pump Motor Switching frequency: .................................................................... 16 kHz
Temperature range: .......................................................................... -30 °C to +40 °C
Maximum Controller temperature: ..................................................................... 92 °C

Voltage drop at
Max armature Voltage drop
Versions total conduction Max pump current
current (traction) (pump)
(traction)
48V 230mV a 200A, 260mV a 200A,
600A 500A
600A 25°C 25°C
72,80,96V 520mV a 200A, 780mV a 200A,
500A 500A
400A 25°C 25°C

Page 5
 2.3 COMMAND UNITS

2.3a Microswitches
Send a voltage signal when a running request or the function requested is activated.

2.3b Potentiometer
The Potentiometer should be wired in the 3 - Wire Configuration.
CPOT (A14) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance : 500 Ohms
Maximum Potentiometer Resistance : 10 K Ohms
Faults can occour if the Potentiometer Resistance is out of this range.
Motor voltage according to central potentiometer.

The figure below shows the relationship between the Voltage on Pin A14 and the Motor
Armature Voltage.

From 60% to 100% of pedal stroke, the Speed is increased by Weakening the field current.

Page 6
The Procedure for automatic potentiometer signal aquisition is carried out using the Console.
This enables adjustment of the minimum and maximum useful signal level in either direction.
This function is unique when it is necessary to compensate for any asymmetry with the
mechanical elements associated with the potentiometer, especially relating to the minimum
level.

fig. 1a fig. 1b
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
aquisition being made. The Right Hand Graph shows the same relationship after signal
aquisition of the potentiometer.
The aquisition procedure is disabled if the potentiometer wiper output does not
reach a minimum of 3 V. If a centre tapped potentiometer is not available, it is
possible to use a standard 3 wire pot set in the middle of its full stroke.

2.3c Lifting potentiometer

The potentiometer should be wired in 3- wire configuration.
CPOTS (B7) signal ranges from 0 to 10V.
Potentiometer Resistance must be between 500 Ohms and 10KOhms. Faults can occour if
the potentiometer resistance is out of this range.

Pump Motor Voltage according to the potentiometer wiper.

Page 7
The procedure for automatic potentiometer signal aquisition is carried out using the Console.
This enables adjustment of the minimum and maximum useful signal level (cap. 5.4).

fig. 2a fig. 2b

2.4 OPERATIONAL FEATURES

- Speed Control.
- Optimum sensitivity at low speeds.
- Speed Reduction in both directions. Levels can be set using Console.
- Regenerative Braking based on deceleration ramps.
- Three different modes of Braking : Release Braking, Inversion Braking, Speed Limit
Braking.
- Speed Control during descent : the motor speed follows the accelerator. The chop-
per automatically brakes if the motor speed overcomes the accelerator set point.
This provides optimum performance on a gradient.
- Starts on a Ramp without roll back, even without an electric brake.
- Programmable Anti Roll Back : When the Key Switch is closed, if the motor is
rotating, the chopper controls the speed and automatically brakes. This keeps the motor at
a very low speed during descent on a gradient. This is a very useful safety feature and is not
driver dependent.
- The highest speed can be selected for the Pump Motor.
- Electromagnetic Brake Control (optional).
Page 8
- Output for hydraulic steering with adjustable delay.
- Self Diagnosis with fault indication via flashing Red Led. (In addition to Console Display).
- Modification of Parameters via Digital Console. See the specific description.
- Internal Hour Meter count displayed on the Console.
- Memory of the last 5 Alarms, with relative Hour meter count and chopper temperature, all
displayed on the Console.
- Test Function within Console for checking main parameters. See the specific Description.
- Contactor Coil Suppression is made internally.
- High motor and battery efficiency due to High Frequency Switching.
- A second microprocessor is fitted for Safety. This processor monitors the CPU that
controls the motor.

2.5 SAFETY & PROTECTION FEATURES

- Reverse Battery Polarity.

Electrical Circuit diagrams must be comlied with in order to avoid damage to the power unit.
A Line / 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 reduces in
proportion to the thermal increase. The temperature can never exceed 92°C.
- Low Battery charge
When the battery charge is low, the maximum current is reduced proportionally to
the battery discharge.
- External Agents
The chopper is protected against dust and spray of liquid to a degree of protection
meeting IP51.
- Protection against accidental Start Up
A precise sequence of operations are necessary before the machine will start. Operation
cannot commence if these operations are not carried out correctly. Requests for drive
must be made after closing the Key Switch.
- Protection against uncontrolled movements.
The Main Contactor will not close if:
- The Power Unit is not functioning correctly
- The Logic Unit is not operating correctly
- The output voltage of the accelerator is notl below the minimum voltage value stored,
with 1Volt added.
- The Accelerator Microswitch is in the closed position.

Page 9
 2.6 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.

2.7 COMBISEM 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 security Processor, the current sensors,
the VMN point, the contactor drivers, the presence of a start requirement, the presence of
a lifting requirement,and that the output of the accelerator or tiller potentiometer is
correct.
2) Standby Diagnosis at rest that checks: VMN Point, Contactor Drivers, and the Current
Sensors.
3) Diagnosis during operation that checks: Watchdog, VMN Point, Current, Contactor(s),
and VMN when in full conduction.
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage. Diagnosis is
provided in 2 ways. The Red Led connected to Connector A will flash a certain number of
times for a given Alarm (See Listings), or the Digital Console may be used. A permanent
Alarm will be displayed on the Console immediately and the RED LED will flash. An
intermittent Alarm will be recorded in the Alarm library, but the RED LED will only flash at
the time of the Alarm.

Page 10
 2.8 MAIN CONTACTOR AND SAFETY BUTTON

- Disconnection of the battery 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 A1 connector is greater than 30% of
battery voltage, or when the key switch is opened before the battery is opened.

Page 11
 2.9 GENERAL INSTRUCTIONS AND PRECAUTIONS

- Never combine SCR low frequency choppers with COMBISEM modules. The filter
capacitors contained in the COMBISEM module will 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 COMBISEM 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 COMBISEM module should only be connected to a traction battery. Do not use
the outputs of converters 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 errors 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 Negative
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.

Page 12
 3 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 contactor 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. Verify that the wiring of the cable
terminals and connectors has been carried out correctly. Ensure that suppression devices
are fitted to the Horn, Solenoid Valves, the coils of any relays, and contactors not supplied by
logic or the chopper itself.

3.1 CONNECTION CABLES

For the auxiliary circuits use cables bigger or equal to 0.5mm2 section.
For power connections to the motor (pump and traction rotor) and to the battery use
cables of 25 to 35 mm2 section for COMBISEM2; 50mm2 section for COMBISEM3. The
cables from chopper to battery should be run side by side and be as short as possible.

3.2 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. If contactors for power steer motors are supplied
from the control logic, the suppression will be inside the chopper logic.
For any Contactor(s) that require external suppression, ensure that connections are
made respecting correct polarity.

3.3 FUSES

- Use a 10A fuse for protection of the auxiliary circuits.

- For protection of power unit, refer to diagrams. The fuse value shown is the
maximum allowable. For special applications or requirements this value can be
reduced.
- For safety reasons, we recommend the use of enclosed fuses in order to prevent the
spread of fused particles should the fuse blow.

Page 13
 3.4 DESCRIPTION OF COMBISEM CONNECTORS

pin function description

A1 KEY Input from KEY: must be connected to the key.
A2 CM Common running microswitches (positive battery output voltage).
A3 REV Reverse Direction microswitch Input.
A4 FORW Forward Direction microswitch Input.
A5 SEAT Seat input.
A6 ENABLE Input for accelerator pedal microswitch.
A7 HB Input for hand brake microswitch.
A8 PLC Positive Supply to Line Contactor.
A9 NLC Negative Supply to Line Contactor.
A10 PB Brake microswitch input.
A11 SR Speed reduction input.
A12 PPOTT Positive supply to accelerator (+12V).
A13 NPOTT Negative supply to accelerator.
A14 CPOTT Centre of potentiometer. (Wiper)
A15 EB Negative supply to Electro Magnetic Brake.

B1 1ST First speed input (active if closed on +Batt)

B2 2ND Second speed input (active if closed on +Batt)
B3 3RD Third speed input (active if closed on +Batt)
B4 LIFT Lifting microswitch input
B5 4TH Fourth speed input (active if closed on +Batt)
B6 PPOTS Positive supply to pump potentiometer (output at 10V)
B7 CPOTS Wiper of Pump potentiometer. Signal range between 0V (minimum
speed) and 10V (maximum speed)
B8 NPOTS Negative supply to pump potentiometer (-Batt)
B9 THT Traction motor temperature input (normaly closed sensor)
B10 THP Pump motor temperature input (normaly closed sensor)
Page 14
C1 PCLRXD Positive Serial RX.
C2 NCLRXD Negative Serial RX.
C3 PCLTXD Positive Serial TX.
C4 NCLTXD Negative Serial TX.
C5 GND Negative Console supply.
C6 +12V Positive Console supply.
C7 — -C8

3.5 COMBISEM POWER CONNECTION

+BATT Battery positive supply

-BATT Battery negative supply
VMN Power driver traction motor
F1, F2 Field connections for traction motor
+SH Pump motor current sensor output
-SH Pump motor current sensor input

Page 15
 3.6 COMBISEM 2/3 CONTROLLER MECHANICAL DRAWING

Page 16
4 . PROGRAMMING AND 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 “C” connector of the COMBISEM
Chopper.
Pay attention to the polarity of the Console Connector when connecting to
the chopper. The bevel on the connector should be uppermost.

4.2 DESCRIPTION OF CONSOLE & CONNECTION

Digital consoles used to comunicate with Dual SEM controllers must be fitted with
EPROM CK ULTRA, minimum “Release Number 3.02”.
Page 17
 4.3 DESCRIPTION OF STANDARD CONSOLE MENU

Page 18
5 COMBISEM: CONNECTION AND CONFIGURATION

5.1 POWER DIAGRAM

Page 19
 5.2 CONTROL CIRCUIT WIRING

Page 20
 5.3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS)

The options can be set on the “SET OPTIONS” Menu.

Function Option Meaning

1) HOUR COUNTER running Hour meter enabled when running.
key on Hour meter enabled when the key is on.
2) BATTERY CHECK on Battery voltage check activated on stand
by. When the charge is lower than 60%, the
maximum current is reduced by 50% and the
diagnostic LED flashes continuously.
off Battery discharge is not checked.
3) ENABLE SWITCH on Microswitch accelerator pedal is present.
off Microswitch accelerator pedal is not
present.
4) AUX OUTPUT #1 hydro contactor A15 output drives a contactor for hydraulic
power steering.
brake A15 output drives an electromagneticl brake.
Output voltage is reduced to 70% of battery
voltage.
Flow chart showing how to make changes to Option Menu.

Page 21
1) Opening Zapi Menu

2) Press Top Left & Right Buttons together to enter

SET Menu.

3) The Display will show: SET MODEL

4) Press ROLL UP or ROLL DOWN BUTTONS until

SET MODEL Menu appears.

5) SET OPTIONS appears on the display.

6) Press ENTER to go into the SET MODEL Menu.

7) The display will shows the first OPTION.

8) Press ROLL UP or ROLL DOWN BUTTONS until

desired OPTION appears

9) Desired OPTION appears.

10) Press SET UP or SET DOWN BUTTONS in order to

modify the changes.

11) New OPTION appears.

12) Press OUT to exit the Menu.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press OUT

if you do not accept the changes.

15) SET OPTIONS Menu appears.

16) Press OUT again. Display now show the

Opening Zapi Menu.

Page 22
 5.4 ADJUSTMENTS: TO SET PUMP POTENTIOMETER MIN.& MAX. LEVELS.

Using this function it is possible store the ends of pump potentiometer (maximum and
minimum ends).

How to execute SET PUMP ACC MIN with the console.

1) Opening Zapi Menu

2) Press Top Left & Right Buttons together to enter

CONFIG Menu.

3) The Display will show: SET MODEL

4) Press ROLL UP or ROLL DOWN BUTTONS

until ADJUSTMENTS Menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will shows SET PUMP ACC MIN and the
minimum stored value.

8) Press ENTER to begin the search of the minimum

value. Turn the steering wheel until minimum value
appears.

9) Press OUT.

10) Press ENTER to confirm.

11) Repeat the same from 5 to 10 points for the maximum

value SET PUMP ACC MAX.

12) Repeat the same from 5 to 10 points for straight wheels

SET STEER 0-POS.

Page 23
 5.5 ADJUSTMENTS: SET BATTERY TYPE

Using this function it is possible store the nominal value of the battery

How to execute SET BATTERY TYPE with the Console.

1) Opening Zapi Menu

2) Press Top Left & Right Buttons together to enter

CONFIG Menu.

3) The Display will show: SET MODEL

4) Press ROLL UP BUTTON until ADJUSTMENTS

Menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will shows SET STEER MIN.

8) Press ROLL UP or ROLL DOWN BUTTONS until

SET BATTERY TYPE appears.

9) The display will show: SET BATTERY TYPE.

10) Press SET UP to choose nominal value of the battery.

11) New battery value appears.

12) Press OUT.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press

OUT if you do not accept the changes.

15) Press OUT. Display now shows the Opening Zapi Menu.

Page 24
 5.6 ADJUSTMENTS: ADJUST BATTERY

Using this function it is possible to calibrate the internal voltmeter to a fine level. It is necessary
to input the battery voltage value after measurement using an external calibrated digital
voltmeter.

Procedure showing how to carry out ADJUSTMENT BATTERY operation by console.

1) Opening Zapi Menu

2) Press Top Left & Right Buttons to enter

CONFIG Menu.

3) The Display will show: SET MODEL

4) Press ROLL UP BUTTON until ADJUSTMENT

Menu appears.

5) ADJUSTMENTS appears on the display.

6) Press ENTER to go into the ADJUSTMENTS Menu.

7) The display will shows SET PUMP ACC MIN.

8) Press ROLL UP or ROLL DOWN BUTTONS until

desired OPTION appears

9) ADJUST BATTERY appears.

10) Press SET UP or SET DOWN BUTTONS in order to

increase or decrease respectively. Set the value read
by an external calibrated digital voltmeter.

11) Battery value appears on the display.

12) Press OUT to exit the Menu.

13) Confirmation request appears.

14) Press ENTER to accept the changes, or press

OUT if you do not accept the changes.

15) ADJUSTMENTS Menu appears.

16) Press OUT. Display now show the Opening Zapi Menu.

Page 25
5.7 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED (PARAMETER
CHANGE MENU)
In addition to the Configuration, Parameter settings may be made by Zapi using stan-dard
default settings, settings to Customer Specifications, or the customer may make changes
according to the application, using a Digital Console. During the setting up procedure on the
machine, the Console can remain connected to the chopper during travel. The Parameters
can be modified in real time, during operation. Pay attention to the polarity of the Console
Connector. Refer to Page 20 of this Manual for connection details.
CONNECTION OF THE CONSOLE TO THE CONTROLLER MUST BE MADE WITH
THE KEY SWITCH TURNED OFF.
The following Parameters can be modified :

1) ACCELERATION DELAY (t) = Determines the acceleration ramp.

2) DECELERATION DELAY (t) = Determines the deceleration ramp according to the
accelerator pedal position.
3) RELEASE BRAKING (t) = Determines the deceleration ramp when the travel
request is released.
4) PEDAL BRAKING (t) = Determines the deceleration ramp when the brake pedal is
operated during travel.
5) INVERS BRAKING (t) = Determines the deceleration ramp the Direction Switch is
inverted during travel.
6) CUT BACK SPEED (t) = Speed Reduction.
7) MAX. SPEED FORW. (t) = Maximum Forward Speed, obtained by weakening the
Field Current after it has reached 100% conduction of the Armature. With the
Parameter set at level 0, the armature is in total conduction but the field current
does not decrease below the Nominal value (low speed).
8) MAX SPEED BACK (t) = Maximum Reverse Speed, obtained by weakening the
Field Current after it has reached 100% conduction of the Armature. With the
Parameter set at level 0, the armature is in total conduction but the field current
does not decrease below the Nominal value (low speed).
9) TRACTION IMAX (t) = Maximum Current of the Chopper (A).
10) ARMA NOM. CURR (t) = Nominal Armature Current. This parameter fixes a limit for
the armature current above which the Field Current is at least the Nominal Value
(FIELD NOM. CURR.), regardless of accelerator position.
11) WEAK DROPOUT (t)= This Parameter fixes a limit on the Armature Current above
which the Field Current is increased linearly up to the Nominal Field Current (in
proportion to the armature current).
12) FIELD NOM. CURR. (t)= Nominal Field Current. This parameter fixes the minimum
Field Current when the accelerator 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).
13) CREEP SPEED (t)= Minimum Speed. This Parameter sets the minimum voltage
applied to the motor at the start of travel.
14) SEAT MICRO DELAY = Delay time after Seat Microswitch has opened.

Page 26
15) PUMP I MAX (p) = Maximum pump controller current.
16) PUMP ACC DELAY (p) = Pump motor acceleration time:during this time the
voltage on the pump motor goes to the desired value.
17) PUMP DEC DELAY (p) = Pump motor deceleration time:during this time the voltage
on the pump motor goes to zero.
18) PUMP CREEP (p) = This Parameter sets the minimum voltage applied to the motor
at the start of travel with lifting require pending.
19) 1ST SPEED COARSE (p) = Pump 1st speed, coarse.
20) 1ST SPEED FINE (p) = Pump 1st speed, fine.
21) 1ST SPEED COMP. (p) = Pump 1st speed compensation.
22) 2ND SPEED COARSE (p) = Pump 2nd speed, coarse.
23) 2ND SPEED FINE (p) = Pump 2nd speed, fine.
24) 2ND SPEED COMP. (p) = Pump 2nd speed compensation.
25) 3RD SPEED COARSE (p) = Pump 3rd speed, coarse.
26) 3RD SPEED FINE (p) = Pump 3rd speed, fine.
27) 3RD SPEED COMP. (p) = Pump 3rd speed compensation.
28) 4TH SPEED COARSE (p) = Pump 4th speed, coarse.
29) 4TH SPEED FINE (p) = Pump 4th speed, fine.
30) 4TH SPEED COMP. (p) = Pump 4th speed compensation
31) HYD. SPEED COARSE (p) = Hydrodrive speed, coarse.
32) HYD. SPEED FINE (p) = Hydrodrive speed, fine.
33) HYD. SPEED COMP. (p) = Hydrodrive speed compensation.
34) HYDRO TIME (p) = Hydrodrive off delay.
35) SPEED LIMIT (p) = Maximum pump speed.
36) COMPENSATION (p) = Pump speed compensation while using lifting
potentiometer.

Page 27
 5.8 ADJUSTMENTS TABLE

 






          


  
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(*) = When reduction speed is activated, this value is increased of 100%.

(**) = If the braking parameter increases, the braking time decreases. This adjustment
provides gradual and smooth braking. The braking time depends on the type of motor
and the operating conditions (laden, unladen, on plane, on gradient).
(***) = TRACTION IMAX is the maximum current of the traction controller. Pump IMAX is
the maximum current of the pump motor controller.
(****)= Maximum compensation for the motor at current equal to IMAX.

Page 28
Flow Chart showing h ow to make Programme changes u sing 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 : PARAMETER CHANGE.

4) Press ENTER to go into the Parameter Change facility.

5) The Display will show the first Parameter.

6) Press either ROLL UP and ROLL DOWN to display

the next parameter.

7) The names of the Parameters appear on the Display.

8) When the desired Parameter appears, the Display
will show a Level Number that will be between 0 and 9.
press either PARAM (Top Right) or SET (Bottom Right)
buttons to change the Level value.
9) The Display will show the New Level.

10) When you are satisfied with the results of the changes
you have made, Press OUT.

11) The Display asks “ ARE YOU SURE ?

12) Press ENTER to accept the changes, or Press OUT

if you do not wish to accept the changes and wish
to make further modifications to the parameters.
13) The Display will show : PARAMETER CHANGE

14) Press either ROLL UP and ROLL DOWN to display

other parameters or press OUT.

Page 29
 5.9 COMBISEM WIRING DIAGRAM

Page 30
 5.10 SEQUENCE FOR COMBISEM 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.

General Settings
If the chopper is not Configured to your requirements, follow the Sequence, otherwise
go to point 3.
1) Option selection (cap. 5.3).
2) Battery setting and adjustment (cap. 5.5, 5.6).
3) Confirm correct installation of all wires. Use the Console’s TESTER function to
assist.(cap. 6.3)
Traction Settings
1) Perform the accelerator signal acquisition procedure using the Console “PRO-
GRAM VACC”. Procedure is detailed on Chapter 6.7.
2) Set the “TRACTION I MAX” Current, taking into account any Boost requirements.
Use Table on Chapter 5.8.
3) Set the Acceleration Delay requirements for the machine. Test the parameters in
both directions.
4) Set the CREEP level starting from level 0. The machine should just move when the
accelerator microswitch is closed. Increase the Level accordingly.
5) Set the Speed Reductions as required. Make adjustments to “CUT BACK SP” Che-
ck the performance with the accelerator pedal totally depressed. If the machine is a
forklift, check the performance with and without load.
6) RELEASE BRAKING. Operate the machine at full speed. Release the accelerator
pedal. Adjust the level to your requirements. If the machine is a forklift, check the
performance with and without load.
7) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst traveling
INVERT the Direction Switch. Set a soft Level of Inversion Braking. When
satisfactory, operate the machine at Full Speed and repeat. If the machine is a
Forklift, repeat the tests and make adjustments with and without load. The unladen
full speed condition should be the most representative condition.
8) PEDAL BRAKING (If used). Operate the machine at full Speed. Press the Pedal
Brake. Set braking level to your requirements.
9) Set “MAX SPEED FORW” and “MAX SPEED BACK” (Reverse).
10) Set the NOM FIELD CURR. (Nominal Field Current) of the drive motor making
reference to information given on the motor nameplate.
11) Set “WEAK DROPOUT” and “ARMA NOM CURR” (Field Weakening Drop Out
Level) according to the requirements of the application.

Page 31
Pump Settings.
1) Perform the lifting potentiometer maximum and minimum signal acquisition (cap.
5.4)
2) Set the “PUMP I MAX” Current, selecting the desired value. Use Table on Chapter 5.8.
3) Set the speeds with no load and compensation level adjusted to “0”, then apply the load
and adjust compensation until the desired speed is reached. Because speed and
compensation adjustments are independent, the levels should be adjusted until optimal
values are reached.
4) Set HYDRO SPEED with no steering power and compensation with steering power.
5) Set acceleration, deceleration and creep according to requirements.

Page 32
 6 COMBISEM DIAGNOSTIC

6.1 ALARMS ASSOCIATED WITH THE FLASHING RED LED

The type /code of Alarm is shown in parenthesis. A more detailed description is given in
chapter 6.2.

1 flash = Problem with logic (SYSTEM CHECK KO, EEPROM KO).

2 flashes = Running request at key-on (INCORRECT START).
3 flashes = Error on voltages tests (CAPACITOR CHARGE, VMN NOT OK,
VFIELD NOT OK, PUMP VACC NOT OK).
4 flashes = Error in the accelerator (VACC NOT OK, PEDAL WIRE KO, PUMP
VACC NOT OK).
5 flashes = Error on current sensors (STBY I HIGH, PUMP STBY I HIGH, I=0
EVER, PUMP I=0 EVER, HIGH FIELD CURRENT, NO FIELD
CURRENT).
6 flashes = Problem with Contactor driver in logic (DRIVER SHORTED, COIL
SHORTED, CONTACTOR DRIVER, CONTACTOR CLOSED,
LOGIC FAILURE #1).
7 flashes = Controller temperature high in traction controller (TH PROTECTION)
or in pump controller (PUMP TEMPERATURE); traction motor tem-
perature high (MOTOR TEMPERATURE), pump motor temperature
high (PUMP MOTOR TEMPERATURE).
8 flashes = Problem with brake driver (BRAKE DRIVER KO) or handbrake applied
(HANDBRAKE).
Led flashing Continually = Discharged battery (LOW BATTERY).
Led Permanently ON = Double running request (FORW + BACK).

Page 33
 6.2 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE

1) SYSTEM CHECK KO
During the initial diagnosis, the Main Microprocessor t ests and verifies the operation of
the Safety µP. If it is not correct this Alarm is generated. Possible causes:
a) Failure of the Safety Microprocessor.
b) The Safety Microprocessor has established a condition of danger and has disabled
operation of the Main Contactor.
2) EEPROM KO
Fault in the area of memory where the adjustment parameters are stored. This
Alarm inhibits machine operation. If the fault continues when the Key Switch is re-
cycled, replace the logic. If the fault disappears, the previously stored Parameters
will have been replaced by the default parameters.
3) INCORRECT START
Alarm generated by an incorrect Starting Sequence. Possible causes:
a) The ENABLE microswitch has welded or failed.
b) Error in the starting sequence from the operator.
c) Error in the wiring.
d) Lifting operation awaiting whenthe key is turned on.
4) CAPACITOR CHARGE
This check is made during the initial diagnosis. This Alarm is generated if the
Capacitors are not charged within 500 mSec after the Key Switch is closed. Probable
cause is failure within the power block.
5) VMN NOT OK
This test is performed at rest, with the Main Contactor Closed, and also during operation.
At rest if VMN is lower than battery voltage this Alarm is generated. During operation this
Alarm is generated if VMN does not follow the duty-cycle of the chopper. Possible causes:
a) Incorrect Motor connection.
b) Frame fault of motor to chassis.
c) defect in the power unit.
6) VFIELD NOT OK
This test is made at standby with the Main Contactor open. In this condition the
voltage 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:
a) Frame fault on the motor to chassis.
b) Incorrect connection of the field winding to the chopper.
c) Failure of the chopper in the section relative to the field.

Page 34
7) PUMP VMN NOT OK
This test is performed in the pump controller when the key is turned on and at rest. If VMN
is lower than battery voltage this Alarm is generated.
Possible causes:
a) Frame fault of pump motor to chassis.
b) Defect in the pump controller power unit.
c) Fault in the voltage feed back circuit of the pump motor
8) VACC NOT OK
This Alarm is generated if the accelerator output voltage differs more than 2V from
the acquired minimum during the PROGRAM VACC. Possible causes:
a) the track of the potentiometer has become open.
b) the potentiometer is not wired correctly.
c) the potentiometer itself is defective.
d) the values set in PROGRAM VACC routine have not remained or made correctly.
9) PEDAL WIRE KO
This Alarm is generated if potentiometer or wiring fault is detected (NPOTT or
PPOTT are open circuit).
10) PUMP VACC NOT OK
This alarm is generated if, when the key is turned on or at rest, the lifting
accelerator voltage is different more than 2V from the minimum aquired in the menu
“ADJUSTMENTS”.
11) STBY I HIGH, PUMP STBY I HIGH
This test is made during the initial diagnosis and at standby. The test verifies that
the currents are zero. This Alarm disables the machine. Possible causes:
a) defective current sensor.
b) Feed back circuit failure or logic failure or power unit failure.
12) I=0 EVER, PUMP I=0 EVER
This check is made during travel. If the current is not higher than a preset minimum
value, this Alarm is generated and the machine disabled. Possible causes: see
STBY I HIGH.
13) NO FIELD CURRENT
Problem detected with the field winding current. Possible causes:
a) Failure of the field current sensor.
b) Field cables not connected or incorrectly connected.
c) Failure of the Field Power Unit.
d) The alarm may be generated also if the security microswitch does not close the field
circuit.
14) HIGH FIELD CURRENT
Problem detected with the Field Current Sensor. Possible causes:
a) Failure of the Field Current Sensor.
b) Failure of the Field Power Unit.

Page 35
15) DRIVER SHORTED
The test is carried out with Main Contactor open. The logic unit verifies that the coil of the
Main Contactor is not shorted. Possible causes:
a) Driver shorted.
b) Problems in the feed back circuit of the Main Contactor coil.
c) Wiring error.
d) Fault in the protection circuit.
16) COIL SHORTED
When the key is turned on, the microprocessor tests the overloads protection circuit
of the contactor driver. If a problem is detected, this alarm is generated. Possible causes:
a) Failure within the contactor coil.
b) Incorrect wiring.
c) Failure of the protection circuit.
17) CONTACTOR DRIVER
This Alarm is generated if there is a problem with the Main Contactor. Possible causes:
a) The Contactor Coil Driver is open-circuit.
c) Defect in the Main Contactor coil voltage feed back circuit.
18) CONTACTOR CLOSED
This check is made before than Main Contactor closes. It checks that the driver is not
open. Possible causes:
a) the contactor's power poles are not welded.
b) This alarm could be generated if the line contactor has opened, but there is a problem
within the field circuit.
20) THERMAL PROTECTION, PUMP TEMPERATURE
If the temperature of the chopper rises above 77°C, this alarm is generated. If this alarm is
displayed when the chopper's temperature is the same as ambient or above zero
degrees:
a) check the connection of the temperature sensor.
b) the temperature sensor may be defective.
c) the logic may be defective.
21) MOTOR TEMPERATURE, PUMP MOTOR TEMPERATURE
This alarm is generated if the temperature of one or both the motors have become higher
than the threshold set by the motor sensor. If this alarm appears with a cold motor:
a) check the connection to the temperature sensor.
b) check that there is no problem with the temperature sensor.
c) Fault in in the input circuit of the logic.

Page 36
22) BRAKE DRIVER KO
This alarm is shown when a problem in the electro-brake is found. Possible causes:
b) Failure of the driver.
c) Problems in the feed back circuit of the electro-brake coils.
23) HANDBRAKE
If the handbrake is applied and there is a start request, the motor torque is delivered for 2
sec. The alarm isthen generated. If the alarm is present without the handbrake applied
the fault may be:
a) Failure of the handbrake microswitch.
b) Logic failure.
24) FORW + BACK
This check is made continually. The Alarm is generated when forward and reverse
directions are requested simultaneously. Possible causes:
a) Incorrect Wiring.
b) Welding or Failure of a direction switch.
c) Incorrect operation from the operator.
25) BATTERY LOW
This Alarm is generated when the battery becomes 90% discharged from the
nominal value. If there is the alarm and the battery is not discharged, check the battery
value in the “TESTER” menu of the console; if it is incorrect, re-adjust via the “CONFIG
MENU/ADJUSTMETS”

6.3 DESCRIPTION OF TESTER THE FUNCTION

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 listing shows the measurements that may be
made :

1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key
switch.
2) TR MOTOR VOLTAGE: level of traction motor voltage measured between VMN
and “+Batt”.
3) PU MOTOR VOLTAGE: level of pump motor voltage measured between -SH and
“+Batt”.
4) TRAC. CURRENT: the current flowing in the traction motor armature.
5) PUMP CURRENT: the current flowing in the pump motor armature.
6) V FIELD: Voltage referred to F1 connector of traction Motor.
7) FIELD CURRENT: the field current expressed as a ratio of nominal field current.
8) TR CHOP. TEMP: the temperature measured on the aluminum heat sink holding
the MOSFET devices for Traction Motor.
9) CHOP. R TEMP: the temperature measured on the aluminum heat sink holding the
MOSFET devices for Pump Motor.

Page 37
10) ACCELERATOR: the voltage of the accelerator potentiometer’s wiper (CPOTT). The
voltage level is shown on the Left Hand Side of the Console Display and the value in
percentage is shown on the Right Hand Side.
11) LIFTING CONTROL: the voltage of the lifting potentiometer’s wiper (CPOTS). The
voltage level is shown on the Left Hand Side of the Console Display and the value
in percentage is shown on the Right Hand Side.
12) ENABLE SWITCH: the level of Enable Switch digital input.
ON / +VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
13) SEAT SWITCH: the level of the Seat Microswitch digital entry.
ON / +VB = active entry of closed seat switch.
OFF / GND = non active entry of open seat switch.
14) FORWARD SWITCH: the level of the Forward direction digital entry MA.
ON / +VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
15) BACKWARD SWITCH: the level of the Reverse direction digital entry MI.
ON / +VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
16) BRAKE SWITCH: the level of the Pedal Brake Microswitch.
ON / +VB = active entry of Brake pedal Microswitch.
OFF / GND = non active entry of microswitch.
17) HAND BRAKE: the level of the Handbrake Microswitch.
ON / +VB = active entry of Handbrake Switch.
OFF/ GND = non active entry of microswitch.
18) CUTBACK SWITCH: the level of the Speed Reduction Microswitch.
ON / GND = active entry of speed reduction microswitch.
OFF / +VB = non active entry of microswitch.
19) 1st SPEED SWITCH: the level of the first Speed Microswitch.
ON / +VB = active entry, microswitch closed.
OFF / GND = non active entry, microswitch open.
20) 2nd SPEED SWITCH: the level of the second Speed Microswitch.
ON / +VB = active entry, microswitch closed.
OFF / GND = non active entry, microswitch open.
21) 3rd SPEED SWITCH: the level of the third Speed Microswitch.
ON / +VB = active entry, microswitch closed.
OFF / GND = non active entry, microswitch open.
22) 4th SPEED SWITCH: the level of the fourth Speed Microswitch.
ON / +VB = active entry, microswitch closed.
OFF / GND = non active entry, microswitch open.
23) LIFTING SWITCH: the level of the lifting Microswitch.
ON / +VB = active entry, microswitch closed.
OFF / GND = non active entry, microswitch open.
24) BATTERY CHARGE: the percentage Charge level of the battery.

Page 38
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 ROLL UP or ROLL DOWN button until

TESTER menu appear on the display.

5) The Display shows :

6) Press ENTER to go into the TESTER function.

7) The first variable to be tested is shown on the Display.

8) Press either ROLL UP or ROLL DOWN buttons.

9) Next variable for measurement appears

10) When you have finished, Press OUT.

11) The Display shows :

12) Press OUT again and return to Opening Zapi Display.

Remember it is not possible to make any changes
using TESTER. All you can do is measure as if
you were using a pre-connected multimeter.

Page 39
 6.4 DESCRIPTION OF THE CONSOLE SAVE FUNCTION

The SAVE PARAM. function allows the operator to transmit the Parameter values and
Configuration data of the chopper into the Console memory. It is possible to load 64
different programmes. The information saved in the Console memory can then be
reloaded into another chopper using the RESTORE function. The data that is available
via the SAVE function is as follows:
- All Parameter Values (PARAMETER CHANGE).
- Options (SET. OPTIONS).
- The Level of the Battery (ADJUST BATTERY).

Flow Chart showing how to use the SAVE 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 ROLL UP or ROLL DOWN button until

SAVE PARAM. appears on the display

5) The Display will show :

6) Press ENTER to go into the SAVE function.

7) If this facility has been used before, the type

of chopper data stored appears on the top
Main with a 2 digit reference.
8) Keep pressing either ROLL UP or ROLL DOWN keys
until the second Main indicates a FREE storage facility.

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 :

13) Press OUT to return to the Opening Zapi Display.

Page 40
 6.5 DESCRIPTION OF CONSOLE RESTORE FUNCTION

The RESTORE PARAM function allows transfer of the Console’s stored data into the
memory of the chopper. This is achieved in a fast and easy way using the method
previously used with the SAVE PARAM. function. The data that is available via the
RESTORE PARAM. function is as follows :
- All Parameter Values (PARAMETER CHANGE).
- Options (SET OPTIONS)
- The level of the Battery (ADJUST BATTERY)
ATTENTION: When the RESTORE operation is made, all data in the chopper memory
will be writtten over and replaced with the data being restored.

Flow Chart showing how to use the RESTORE 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 ROLL UP or ROLL DOWN button until

RESTORE PARAM. appears on the display.

5) The Display will show :

6) Press ENTER to go into the RESTORE PARAM. function.

7) The Display shows the type of Model stored,

with a Code Number.

8) Keep pressing either ROLL UP and ROLL DOWN buttons

until the desired model appears on the Display.

9) Press ENTER to commence the Restore operation.

10) The Display will ask “ARE YOU SURE”.

Press ENTER for YES, or OUT for No.

11) You can see the items that are being stored in
the chopper memory whilst the RESTORE
routine is happening.
12) When finished the Console displays :

13) Press OUT to return to the Opening Zapi Display .

Page 41
 6.6 DESCRIPTION OF ALARMS MENU

The microprocessor in the chopper remembers the last five Alarms that have occurred.
Items remembered relative to each Alarm are : the code of the alarm, the number of
times the particular Alarm occurred, the Hour Meter count, and the chopper temperature.
This function permits deeper diagnosis of problems as the recent history can now be
accessed.

Flow Chart showing how to use the ALARMS function via the Digital Console.

1) Opening Zapi Display.

2) Press ENTER to go into the General menu.

3) The Display will show :

4) Press ROLL UP or ROLL DOWN button until

PARAMETER CHANGE appears on the display.

5) The Display will show:

6) Press ENTER to go into the ALARMS function.

7) The Display will show the most recent Alarm.

8) Each press of the ROLL UP button brings up following

Alarms. Pressing ROLL DOWN returns to the most recent.

9) If an Alarm has not occurred, the Display will show:

ALARM NULL.

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 42
 6.7 DESCRIPTION OF PROGRAM VACC FUNCTION

This function looks for and remembers the minimum and maximum potentiometer wiper
voltage over the full mechanical range of the pedal. It enables compensation for non
symmetry of the mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM VACC
function.

Flow Chart showing how to use the PROGRAM VACC 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 ROLL UP or ROLL DOWN button until

PROGRAM VACC appears on the display.

5) The Display will show :

6) Press ENTER to go into the PROGRAM VACC routine.

7) The Display will show the minimum and maximum

values of potentiometer wiper output.
Both directions can be shown.

8) Press ENTER to clear these values.

Display will show 0.0.
9) Select Forward Direction, close any interlock
switches that may be in the system.

10) Slowly depress the accelerator pedal (or tiller butterfly) to

its maximum value. The new minimum and maximum
voltages will be displayed on the Console plus an
arrow indicating the direction.

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 43
 7 RECOMMENDED SPARE PARTS FOR COMBISEM

PART
NUMBER DESCRIPTION

E07008 5kW, Single turn Potentiometer.

C12231 15 pins Mate in Lock connector.
C12227 12 pins Mate in Lock connector.
C12767 Female Insert (for Mate in Lock)
C16505 355A protected fuse
C16506 425A protected fuse
C16507 500A protected fuse
C29564 SW 200 24V contactor
C29608 SW 200 48V contactor
C29604 SW 200 80V contactor

Page 44
 8 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED

Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical
Contacts should be checked every; _______________________________ 3 MONTHS

Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that
there is no electrical resistance between the contacts by measuring the volt drop
between the terminals. Switches should operate with a firm click sound. Microswitches
should be checked every; _______________________________________ 3 MONTHS

Check the Battery cables, cables to the chopper, and cables to the motor. Ensure the
insulation is sound and the connections are tight. Cables should be checked every;
___________________________________________________________ 3 MONTHS

Check the mechanical operation of the pedal or tiller . Are the return springs ok. Do the
potentiometers wind up to their full or programmed level. Check every; ___ 3 MONTHS

Check the mechanical operation of the Contactor(s). Moving contacts should be free to
move without restriction. Check every; _____________________________ 3 MONTHS

Checks should be carried out by qualified personnel only and any replacement parts used
should be original. Beware of NON ORIGINAL PARTS. 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. During periodic checks, if a technician
finds any situation that could cause damage or compromise safety, the matter should
be bought to the attention of a Zapi Agent immediately. The Agent will then take the
decision regarding operational safety of the machine. Remember that Battery Powered
Machines feel no pain.

NEVER USE A VEHICLE WITH A FAULTY

ELECTRONIC CONTROLLER

Page 45
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALY
Tel. +39 522 960050 (r.a.) - Fax +39 522 960259 - e-mail: infozapi@tin.it

INSTALLATION AND USER MANUAL

FOR COMBISEM ZAPI