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INDEX
Page
1 INTRODUCTION. ............................................................................................ 2
2 SPECIFICATIONS .......................................................................................... 3
2.1 Technical Specifications ........................................................................ 3
2.2 Control Units.......................................................................................... 4
2.2a Microswitches ............................................................................... 4
2.2b Potentiometers ............................................................................. 4
2.3 Functional Features............................................................................... 5
2.4 Direction Orientation .............................................................................. 6
2.5 Protection Features ............................................................................... 6
2.6 General Warnings ......................................................................... 7
2.7 Susceptibility & Electromagnetic Emission .................................... 7
3 INSTALLATION .............................................................................................. 8
3.1 Connection Cables ................................................................................ 8
3.2 Contactors ............................................................................................. 8
3.3 Fuses..................................................................................................... 8
3.4 Description of Connectors ..................................................................... 9
3.5 Description of Power Connections. ..................................................... 10
3.6 Mechanical Drawing ............................................................................ 11
4 REGULATIONS. ........................................................................................... 12
4.1 Configuration Function ........................................................................ 12
4.2 Parameter Regulation ......................................................................... 13
4.3 Programming Console Functions. ....................................................... 15
5 DIAGNOSTICS .............................................................................................. 16
5.1 Alarms Displayed on the Console. ................................................. 16-18
6 CONNECTION DRAWINGS.......................................................................... 19
6.1 Abbreviations....................................................................................... 19
6.2 Colour Coding ..................................................................................... 19
6.3 Connections ........................................................................................ 20
6.3.1 Control Input/Output Connections. ............................................ 20
6.3.2 Power Circuit. ............................................................................ 21
6.3.3 Alternative Power Circuit ........................................................... 22
7 PERIODIC MAINTENANCE .......................................................................... 23
8 RECOMMENDED SPARE PARTS ............................................................... 24

= Information included in marked paragraphs by this symbol are essential

for safety.
SIGNATURES TABLES

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

ENGINEERING SECTION
EXECUTIVE

EXPORT MANAGER

Pubblication N°: ABQZP0CA

Edition: April 1997
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1 INTRODUCTION TO THE ZAPIMOS FAMILY

The ZAPIMOS Chopper family is ZAPI’s answer to the needs of users of the 90’s. To
ensure that the product stays on the market without running the risk of becoming tech-
nologically obsolete, ZAPI has designed the ZAPIMOS family offering the following
features:
- Advanced technology and economical costs.
- Maximum safety.
- Open to future technological innovations.
- Optimum level of protection.
This implies:
- High frequency Mos technology.
- Real-time control over the internal and external parts that can influence the behav-
iour of the machine, with self-diagnosis of the checking circuits themselves.
- Stored program machine (SPC) where the hardware is completely separate from the
functions to be configured. The program is parametric and can also be modified by
the end user.
- Various chopper functional configurations can be selected by the user, without the
need for hardware modifications.
- Any future technological updates are made clear to the user.
- The communication protocol will continue to evolve, thus offering increasing possibili-
ties of interaction. For this reason, the ZAPIMOS family offers a standard dialogue
mode with external systems, for easy interfacing with commercially available ma-
chines. ZAPI offers a range of programming consoles with various features and
prices.
- Within the ZAPIMOS family, the PM1 choppers are the models suitable for operating
at voltages from 24V to 48V with maximum currents of 200-300Amps.
Power ratings for magnet motors will be up to 3.5KW.

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2 SPECIFICATION

2.1 TECHNICAL SPECIFICATIONS

Chopper for permanent magnet motor.

Regenerative braking function.
Operating voltages ................................................................................... 24-36-48V
Maximum current (24-36V) ..................................................... 200A/300A (for 1’30")
Maximum current (48V) ......................................................................... 180A (for 1')
Current booster (version 24-36V) ................................................ 250A/350A (for 5')
Current booster (version 48V) .............................................................. 220A (for 5")
Operating frequency .........................................................................................8KHz
External temperature range............................................................. -30°C to + 40°C
Max chopper temperature ................................................................................ 85°C
Voltage drop on full conduction at 70A/100A (24-36V) ......................... 0.49 / 0.28V

BLOCK DIAGRAM

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2.2 CONTROL UNITS

2.2a Microswitches
- The microswitches must have a contact resistance lower than 0.1 Ohms and a
leakage current lower than 100µA.
- When full load connected, the voltage between the keyswitch contacts must be lower
than 0.1V.
- The handle/tiller microswitch must operate the electromechanical brake coil (if the
electromechanical brake is used).
- The microswitches send a voltage signal when a function request (example: running
request) is made.

2.2b Potentiometer
Potentiometer should be in the 3-wire configuration.
CPOT (A2) signal ranges from 0 to 10V.
Pot value should be in the 0.5 - 10K Ohm range. Faults can occur if it is outside this
range.

The procedure for automatic potentiometer signal acquisition is carried out using the
console. This makes it possible to adjust the minimum and maximum useful signal in
the respective directions. 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 Procedure is described in the programming console manual.

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The two graphs show the output from an uncalibrated potentiometer with respect to the
mechanical “zero” of the knob of one handle (MI and MA indicate the point at which the
speed microswitches close, 0 is the mechanical zero of the handle rotation).
The first graph shows the relationship of the motor voltage without having made the
acquisition, while the second graph shows the same relationship after signal acquisition
by the potentiometer.
The acquisition procedure is invalidated by the logic if the signals do not reach at least
3V.

2.3 FUNCTIONAL FEATURES

- Speed control.
- Optimum sensitivity to low speeds.
- Rapid inversion: activated if the belly-switch is closed during travel in the forward
direction.
- Speed Reduction: levels set via Console.
- Regenerative braking based upon deceleration ramps.
- Speed control on a descent: the motor speed follows the accelerator, the chopper
automatically brakes if the motor speed overcomes the accelerator set point; this
provides optimum performance of a gradient.
- The chopper manages an electromechanical brake.
- Self diagnosis with indication of the fault shown by a flashing led ( in addition to
Digital Console).
- Modification of parameters from the console (see the specific description).
- Internal hour-meter with values that can be displayed on the console.
- Memory of the last five alarms, with relative hour-meter and temperature displayed
on the console.
- Console tester for checking of the main parameters (see the specific description).
- High efficiency of motor and battery due to high frequency commutation.

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2.4 DIRECTION ORIENTATION

Machines with tiller and belly-switch follow the PREN 1175 directive. This directive
establishes that the direction microswitches (MA and MI) connections must match the
following drawing.

2.5 PROTECTION FEATURES

- Connection Errors:
All the inputs are protected against connection errors.
- Thermal Protection:
If the temperature exceeds 75°C, the maximum current is reduced in proportion to
the thermal increase. The temperature never exceeds 85°C.
- Low Battery Charge:
When the battery charge is low, the maximum current is reduced proportionally to the
battery discharge.
- Protection Against Accidental Start-Up:
A precise sequence of operations is necessary for starting the machine, if these
operations are not carried out correctly, the machine will not start.
- Protection Against Uncontrolled Movements:
The contactor will not close if;
- The power unit is not functioning correctly;
- The logic is not functioning correctly;
- Main Contactor:
Is to be installed in order to protect against reverse battery polarity.
- The Chopper Is Protected:
Against Dust and Liquid (IP41).

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2.6 GENERAL WARNINGS

- Never connect a SCR low frequency chopper with PM1 because the PM1 filter ca-
pacitors alter the SCR choppers’ work. If it is necessary to use two or more control
units (traction + lift, for example), they must belong to the ZAPIMOS family at high
frequency.
- Do not connect the chopper to a battery with a nominal value different from the value
indicated on the chopper plate. If the battery value is greater, the MOS may fail; if it
is lower, the control unit may not “power up”.
- During battery charge, disconnect PM1 from the battery.
- Supply the PM1 only with a traction battery. 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.
- After the chopper is switched off (key off), the filter capacitor remains charged for
some minutes; If it is necessary to work on the chopper, discharge the Capacitors
using a 10 Ohm ¸ 100 Ohm resistance connected from the +Batt to the -Batt.

2.7 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION

Electromagnetic susceptibility and emission are strongly influenced by the installation.

Special attention must be given to the lengths and the paths of the electric connections
and the shields.
This situation is beyond ZAPI’s control. Therefore ZAPI declines any responsibility for
non-compliance if correct testing is not made (the irradiated emission directive is
EN50081-2).

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3 INSTALLATION

Install the chopper with the base-plate on a flat metallic surface that is clean and
unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to
permit better heat dissipation.
Ensure that the wiring of the cable terminals and connectors is carried out correctly.
Fit transient suppression devices to the horn, solenoid valves and contactors not con-
nected to the chopper such as those for activating the pump motor or steering motor.

3.1 CONNECTION CABLES

For the auxiliary circuits, use cables of 0.5mm² section.

For power connections to the motor and to the battery, use cables having section of
16mm².
In order improve the chopper performance, the battery cables must be as short as
possible and near to each other.

3.2 CONTACTORS

A main contactor and direction contactors should be installed on the chopper. Use
Contactors with the same voltage as the battery. The current drawn by each coil must
be lower than 3A. Transient suppression for the coils are inside the chopper.

3.3 FUSES

- In order to protect the auxiliary circuits , use a 6.3A fuse.

- 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 the event of a blow-out.

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3.4 DESCRIPTION CONNECTORS

A1 NEF Electromechanical Brake Negative output.

A2 CPOT Potentiometer wiper.
A3 NPOT Potentiometer Negative
A4 PPOT Potentiometer Positive: 12V . Keep load > 500 Ohms.
A5 PT Positive to coils of Forward and Reverse Contactors.
A6 Not used.
A7 RV2 Input for speed reduction. If left free or connected to battery nega-
tive the reduction function operates. If connected to A13, the
reduction is inhibited.
A8 RV1 Input for speed reduction. If left free or connected to battery nega-
tive the reduction function operates. If connected to A13, the
reduction is inhibited.
A9 MA Forward direction microswitch. It should be connected to the for-
ward microswitch, active HIGH.
A10 MI Reverse direction microswitch . It should be connected to the
reverse microswitch, active HIGH.
A11 TIM/SEAT It should be connected to the tiller microswitch or to the seat
microswitch (see options).
A12 IR Quick inversion input, it is active HIGH.
A13 CMM Common IR/TIM/MI/MA/RV1/RV2 microswitch (+Batt).
A14 CHIN Connected to the power supply through a 6.3A fuse.

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B1 PCLRXD Positive serial reception.

B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial transmission or positive of the diagnostic LED if the
console is
(PLED) not connected.
B4 NCLTXD Negative serial transmission or negative of the diagnostic LED if
the console
(NLED) is not connected.
B5 GND Negative console power supply.
B6 + 12 Positive console power supply.
B7
B8

3.5 DESCRIPTION OF POWER CONNECTIONS

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3.6 MECHANICAL DRAWING

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4 REGULATIONS

4.1 CONFIGURATION FUNCTION

Using the CONFIG MENU of the programming console, the user can configure the
following functions:

SUB MENU “SET OPTIONS”.

1. HOUR COUNTER:
- RUNNING The hour counter is active only when running.
- KEYON The hour counter is active when the key is ON.
2. BATTERY CHECK:
- ON The state of battery charge is continuously moni-
tored (see section 5.1 alarm description).
- OFF The battery test is not carried out.
3. QUICK INVERSION:
- FREE The IR is active in standby, it has no timeout and
finishes only when the operator switches all the
input signals off.
- HANDLE The IR finishes after a timeout; the chopper starts
again only when the operator switches all the input
signals off.
4. CURVE BRAKING:
- ON When the RV1 is held at ACTIVE during running,
the new speed is reached by braking with an
intensity established by the CURVE BRAKING
parameter (see 4.2).
-OFF The new speed is reached with a deceleration
whose intensity is established by the SPEED
LIMIT BRAKING parameter. (see 4.2)
5. SAFETY SWITCH:
- NONE The safety switch is not present.
- HANDLE A Tiller is present.
- SEAT A Seat Switch is present.
6. DIR. SELECTOR:
- NONE Double pedal (one for forward direction, the other
for reverse direction).
- PRESENT Running selector and single pedal.
7. TRANSPALLET MODE:
- ON In this mode the acceleration and braking ramps
are faster (twice).
- OFF Standard ramps (switched for golf-car).
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SUB-MENU “ADJUSTMENT”.

1. SET ACCELERATOR Min and Max.

2. SET BATTERY TYPE Selects the Nominal Battery Voltage.

3. ADJUST BATTERY The actual value of the battery can be adjusted

with fine resolution.

4.2 PARAMETER REGULATION

In addition to the input configuration, parameter modification is made directly by ZAPI

on customer specification, or the customer may make adjustments using the program-
ming console. The following parameters can be modified using the Programming Con-
sole.

1. ACC. DELAY Determines the acceleration ramp.

2. RELEASE BRAKING Controls the deceleration ramp when the running re-
quest is released.
3. INVERSION BRAKING Controls the deceleration ramp when inversion of direc-
tion is requested.
4. CURVE BRAKING Controls the deceleration ramp when RV1 is held active
during running (see 4.1).
5. SPEED LIMIT BRAKING Controls the deceleration ramp when the pedal position
is changed (but not completely released).
6. RV1 First speed reduction.
7. RV2 Second speed reduction.
8. MAX SPEED FORW The maximum FORWARD SPEED.
9. MAX SPEED BACK The maximum REVERSE SPEED.
10. CREEP SPEED Minimum speed.
11. MAX CURRENT The maximum current of the chopper.

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The following table shows the different values at which the parameters can be set.
(The standard ramps are shown; remember that in the TRANSPALLET MODE these
ramps are quicker).

PROGRAMMED LEVEL
PARAMETERS
UNIT 0 1 2 3 4 5 6 7 8 9

ACC. DELAY sec 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.56 2.75

RELEASE BRAKING sec 5 4.5 4 3.5 3 2.5 2 1.5 1.0 0.5

INV. BRAKING sec 5 4.5 4 3.5 3 2.5 2 1.5 1.0 0.5

CURVE BRAKING sec 5 4.5 4 3.5 3 2.5 2 1.5 1.0 0.5

SPEED LIMIT BRAKING sec 10 9.5 8.6 7.8 7.0 6.2 5.5 4.6 3.9 3

RV1 %VBatt 10 20 30 40 50 60 70 80 90 100

RV2 %VBatt 10 20 30 40 50 60 70 80 90 100

MAX SPEED FORW. %VBatt 10 20 30 40 50 60 70 80 90 100

MAX SPEED BACKW. %VBatt 10 20 30 40 50 60 70 80 90 100

CREEP SPEED %VBatt 1 2 3 4 5 6 7 8 9 10

I MAX Amp 150 166 183 200 216 233 250 266 283 300

After changing a parameter, press ENTER to confirm data when requested by the
Display on the console.
Parameters modified and optimized on one unit can be stored by the console (SAVE)
and then reloaded (RESTORE) on another chopper, thus allowing fast and standard-
ized settings. (See console manual for details).

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4.3 PROGRAMMING CONSOLE FUNCTIONS

- Configuration Function. (4.1)

- Parameter Settings (4.2)
- Tester - When the chopper is running, this function is not available.
In Standby Mode the following can be tested:
- Battery Voltage
- Internal Temperature of the Chopper
- Accelerator Potentiometer Wiper
- Forward Switch
- Reverse Switch
- Handle/Seat Switch
- Cut Back Switches 1 & 2
- Quick Inversion.

- Save Function - Saves Program Configuration.

- Restore Function -Restores Program Configuration.
- 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 useful accel-
erator moment values for both direction of travel.
Refer to the Specific Console Manual for a more detailed description of the func-
tions and procedures.

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5 DIAGNOSIS

Description of the alarms signalled by the diagnostic LED.

The alarm code is shown in parentheses.
A detailed description is given in section 5.1.

1 FLASH: Logic failure (WATCHDOG, EEPROM KO)

2 FLASHES: Running request on start-up or error in handle/seat sequence (IN-
CORRECT START).
3 FLASHES: VMN Failure. (VMN NOT OK).
4 FLASHES: Failure in accelerator (PEDAL WIRE KO, VACC NOT OK).
5 FLASHES: Failure of current sensor (I HIGH AT STAND, 1=0 EVER)
6 FLASHES: Failure of contactor driver (DRIVER SHORTED, COIL SHORTED,
COIL INTERRUPTED).
7 FLASHES: Excessive temperature, higher than 75°C (HIGH TEMPERATURE).
32 FLASHES: Battery Discharged (BATTERY LOW).
FIXED ON-FLASH: Failure in march request: there at the same time the request of
MA and MI (FORW. + BACK.).

5.1 ALARMS DISPLAYED ON CONSOLE

1 WATCH DOG
The test is made in both running and standby. It is a self-diagnosing test within the
logic. If an alarm should occur, replace the controller.

2 EEPROM KO.
Fault in the area of memory in which the adjustment parameters are stored; this
alarm inhibits machine operation. If the defect persists when the key is switched
OFF and ON again, replace the logic. If the alarm disappears, remember that the
parameters stored previously have been cancelled and replaced by the default
values.

3 INCORRECT START
An incorrect starting sequence. Possible causes:
a) Running microswitch or handle microswitch failure.
b) Error in sequence made by the operator.
c) Incorrect wiring.

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4 VMN NOT OK
The test is carried out in standby and until the 70% of the PWM is reached. If the
VMN voltage is lower than 1/3 battery voltage, an alarm is signalled. Possible
causes:
a) Problems with the motor power circuit.
b) Check if there is a dispersion of the motor towards ground (motor frame fault).
c) Chopper failure, replace it.

5 PEDAL WIRE KO
This alarm is signalled if a potentiometer fault is detected (NPOT or PPOT cable is
interrupted).

6 VACC NOT OK
The test is made in standby. This alarm indicates that the accelerator voltage is
greater than 1V. Possible causes:
a) A potentiometer wire is interrupted.
b) The potentiometer is not correctly calibrated.
c) The potentiometer is defective (interrupted).

7 I HIGH AT STAND
Test carried out in standby. Check if the current is Zero. If it is not verified, an
alarm is signalled which inhibits machine operations. Possible causes:-
a) Current sensor failure.
b) Logic failure; replace the controller.

8 I = 0 EVER
Test carried out during travel. It checks that the current is greater than a minimum
value. If not, an alarm is signalled and the machine operation is inhibited.
Possible causes: the current sensor has failed. Replace the unit.

9 DRIVER SHORTED, COIL SHORTED, COIL INTERRUPTED

This alarm is signalled if there is a failure of the direction contactors. Possible
causes:
a) The contactor coil is shorted.
b) A contactor driver has failed.
c) Failure of the logic.

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10 HIGH TEMPERATURE
Chopper temperature is greater than 75°C. The maximum current is reduced pro-
portionally to the temperature increase. The chopper stops at 85°C. If the alarm is
signalled when the chopper is cold:
a) Check the wiring of the thermal sensor.
b) Thermal sensor failure.
c) Logic failure.

11 BATTERY LOW
The battery is discharged. This alarm is present only if the “Battery Check” option
has been selected.

12 FORW + BACK
The test is carried out continuously. An alarm is signalled when a double running
request is made simultaneously. Possible causes:
a) Defective wiring.
b) Direction microswitch failure.
c) Incorrect operation.
d) If the defect persists, replace the logic.

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6 CONNECTIONS DRAWING

6.1 ABBREVIATIONS

AV = Forward
BEF = Electromechanical brake coil
CH = Key
CMM = Microswitch common
CPOT = Potentiometer Wiper
IN = Reverse
MA = Forward microswitch
MI = Reverse microswitch
MIR = Quick inversion microswitch
NEF = Electromechanical brake negative
NPOT = Negative of potentiometer
RV = Speed reduction
SH = Motor cable connection for current feedback
VMN = Motor to negative voltage
IR = Emergency Reverse.
PT = Positive Coil.
PPOT = Positive of Potentiometer.

6.2 COLOUR CODING

A Orange
B White
BB Blue
C Sky-Blue
G Yellow
GG Grey
N Black
R Pink
RR Red
V Green
VV Purple

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6.3 CONNECTIONS

6.3.1 Control Input/Output connections.

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6.3.2 Power configuration

In this configuration, at rest, the motor is short-circuited.

FUNCTIONAL DRAWING

POWER CIRCUIT WIRING DIAGRAM

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6.3.3 Power connections using single pole contactors

In this configuration, at rest, the motor's power circuit is open, and an electromechanical
brake (controlled by the chopper) is necessary to ensure its stop.

POWER CIRCUIT WIRING DIAGRAM

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7 PERIODIC MAINTENANCE TO BE REGULARLY REPEATED

Check the wear of electric contacts: they should be replaced when matchboard is too
strong and worn out. Electric Contacts should be checked every 3 months.

Check pedal microswitch: verify with a tester that there is no electrical resistance be-
tween the contacts by measuring the voltage drop between its terminals. Also the
release should have a firm sound. The pedal microswitch should be checked every
3 months.

Check motor battery power links: they should be in excellent condition as well as the
cable insulation. Wires should be checked every 3 months.

Check the mechanical movement of all contactors. They should be free to move with-
out problem. Mechanical movements of the contactors should be checked every 3
months.

Checks should be done only by suitably trained personnel. All spare parts should be
original. Installation of the electronic controller should be done according to the dia-
grams included in this manual and any variation should be done accordingly with the
supplier. The supplier is not responsible for any problem that rises from using wiring
solutions different from the ones suggested in this manual.

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.

NEVER USE A VEHICLE WITH A

FAULTY ELECTRONIC CONTROLLER

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8 RECOMMENDED SPARE-PARTS

CODE DESCRIPTION

E07008 Potentiometer 5KOhm 1 turn

C16504 Power fuse 300A
C16503 Power fuse 200A
C16520 Fuse 5X20 6.3A
C12372 Molex connector FE8 pin
C12761 Pin female (Molex)
P99060 Diagnostic red led
C12403 Molex connector minifit 14 pin female
C12771 Pin female for minifit

Relevant Contactors. Check with Supplier for details.

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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

INSTALLATION AND
USER MANUAL
FOR
ZAPI PM1 CHOPPER