INDEX

Page

1 Introduction to the Zapimos family ............................................................. 3

2 Specification .................................................................................................. 4
2.1 Technical specifications ........................................................................ 4
2.2 Control Units.......................................................................................... 5
2.2.a Microswitches ............................................................................... 5
2.2.b Potentiometer ............................................................................... 5
2.3 Protection features ................................................................................ 6
2.4 Direction orientation .............................................................................. 7
2.5 Functional features ................................................................................ 7
2.6 Controller's diagnostics ......................................................................... 8
2.7 Thermal precautions ............................................................................. 8
2.8 General warnings ......................................................................... 9

3 Installation ................................................................................................... 10
3.1 Connection cables ............................................................................... 10
3.2 Contactor ............................................................................................. 10
3.3 Fuses .................................................................................................. 10
3.4 Description of connectors .................................................................... 11
3.5 Description of power connectors ......................................................... 12
3.6 Mechanical drawing ............................................................................ 13

4 Programming and settings using a console ............................................ 14

4.1 Setting by console ............................................................................... 14
4.2 Programming console functions .......................................................... 14
4.3 Programming console ......................................................................... 15
4.4 Map of the console functions............................................................... 16

5 Configuration function ............................................................................... 17

5.1 Adjustment: description and programming instructions ...................... 19
5.2 Parameter regulation ........................................................................... 21
5.3 Start up: programming instructions ..................................................... 24
5.3.1 Adjustment sequence ................................................................ 24

6 Diagnosis ..................................................................................................... 25
6.1 Alarms displayed on console............................................................... 25
6.2 Tester: functions descriptions ............................................................. 27
6.3 Save parameters: description ............................................................. 29
6.4 Restore parameters: description ......................................................... 30
6.5 Alarms: menu description .................................................................... 31
6.6 Program vacc: description ................................................................... 32

SEM1 Page 1
 Page

7 Connection drawing .................................................................................... 33

7.1 Diagram part list .................................................................................. 33
7.2 Colour coding ...................................................................................... 33
7.3 Connections ........................................................................................ 34
7.3.1 Control input / output connections ............................................. 34
7.3.2 Power configuration................................................................... 35

8 Periodic maintenance to be regularly repeated ....................................... 36

9 Suggested spare-parts ............................................................................... 37

= Information included into the marked paragraphs by this symbol is essential for
the safety.

SIGNATURES TABLE

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

ENGINEERING SECTION EXECUTIVE

EXPORT MANAGER

Publication N°. ABJZP0AD

Edition: September 1997

Page 2 SEM1
 1 INTRODUCTION TO THE ZAPIMOS FAMILY

The ZAPIMOS chopper family is ZAPI’s answer to the needs of users of the ’90s.
To ensure that the product stays on the market without running the risk of becoming
technologically obsolete, ZAPI has designed the ZAPIMOS family offering the following
features:
- Advanced technology and economical costs
- Maximum safety
- Maximum flexibility
- 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
behaviour of the machine, with self-diagnosis of the checking circuits themselves.
- Stored programme machine (SPC) where the hardware is completely separate from
the functions to be configured. The programme 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
possibilities of interaction.For this reason, the ZAPIMOS family offers a standard
dialogue mode with external systems, for easy interfacing with commercially
available machines. ZAPI offers a range of programming consoles with various
features and prices.
Within the ZAPIMOS family, the SEM1 choppers are the models suitable for operating
at voltages from 16V to 48V with separately excited motors.
Power ratings will be between 0.5kW to 3.5kW.
This chopper is particularly suited for medium power machines, such as transpallets,
golf cars etc. Its goal is to join optimized performances and low cost.

SEM1 Page 3
 2 SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS

Separately excited DC motor chopper.

Regenerative braking function.
Operating voltages: ........................................................................... 16-24-36-48V.
Operating frequency: ....................................................................................... 8kHz.
Max external temperature: .............................................................................. 40°C.
Min external temperature: ............................................................................... -30°C
Max chopper temperature: .............................................................................. 85°C.

VOLTAGE DROP ON
VERSION MAXIMUM CURRENT BOOSTER CURRENT
FULL CONDUCTION

16V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C

24V / 200A 200A (2' 00'') 250A (5'') 0.39V a 70A, 25°C

24V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C

36V / 300A 300A (1' 30'') 350A (5'') 0.24V a 100A, 25°C

48V / 180A 180A (1') 220A (5'') 0.39V a 70A, 25°C

Block diagram:

Page 4 SEM1
 2.2 CONTROL UNITS

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

2.2.b. 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 - 10 KW range. Faults can occour if it is outside this
range.

The procedure for automatic potentiometer signal acquisition is carried out from 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 sequence of procedure is described in the programming console manual.

SEM1 Page 5
The two graphs show the output voltage 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 correspondence of the motor voltage without having made
the acquisition, while the second graph shows the same correspondence after signal
acquisition by the potentiometer.
The acquisition procedure is invalidated by the machine if the signals do not reach at
least 3V. It is possible to use a normal 3-wire pot., instead of one with central zero, set
on the mean value of its full stroke.

2.3 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 startup:
a precise sequence of operations is necessary for starting the machine; if these
operations are not carried out correctly, the machine will not start; the request for
running must be activated after the key.
- Protection against uncontrolled movements:
the contactor will not close if:
- the power unit is not functioning;
- the logic is not perfectly operating;
- Main contactor:
is to be installed in order to protect against reverse battery polarity;
- The chopper is protected against dust and liquid (IP41).

Page 6 SEM1
 2.4 DIRECTION ORIENTATION

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

2.5 FUNCTIONAL FEATURES

- Speed control.
- Optimum sensitivity to low speeds.
- Quick inversion: it is activated if the belly-switch is closed when travelling in the
forward direction.
- Regenerative braking based upon adjustable deceleration ramps.
- Three different kinds of braking: release braking, inversion braking, speed limit braking.
- 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 on a gradient.
- Start on a ramp without roll back even without the electric brake.
- Programmable anti roll-back: with the key on, the chopper controls the motor speed;
if the motor is moving, the chopper automatically brakes and keeps the motor at a
very low speed during the descent (this function is very useful for the safety even
without the driver).
- The chopper controls also an electromechanical brake.
- Self diagnosis with indication of the fault through a flashing led.
- Parameters modification via console ( see the specific description).
- Internal hour-meter. The value 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 the main parameters (see the specific description)
- High efficiency of motor and battery due to high frequency commutation.

SEM1 Page 7
 2.6 CONTROLLER’S DIAGNOSTICS

The microprocessor carries out the diagnostics of the main operating functions of the
controller.
The diagnostics is organised in four main stages:
1) Check at the start-up (key on) includes: watch-dog test, current sensor test, VMN
test, driver of the line contactor’s coil test, test of the running request, test high
accelerator input.
2) Check while stand-by includes: watch-dog test, current sensor test, VMN test, driver
of the line contactor’s coil test.
3) Check while running includes: watch-dog test, current sensor test, VMN test, driver
of the line contactor’s coil test, VMN full conduction test.
4) Continuous check: temperature test, battery state of charge test.
The diagnostics message can be read through the number of periodic flashes of the
alarm LED fitted or simply connected to the B connector.
By means of the programming console is possible to display the alarm message rela-
tive to the current and already occurred alarms.

2.7 THERMAL PRECAUTIONS

- The heat generated by the controller must be dissipated. The housing of the
controller and the cooling surfaces must be wide enough to allow the necessary
dissipation.
- The cooling system must be sized depending on the performances requested. In
some cases of poor ventilation, where the heat exchange is difficult because of the
materials, a forced ventilation is advisable.
- The power dissipated by the controller is a function of the current and the working
cycle.

Page 8 SEM1
 2.8 GENERAL WARNINGS

- Never connect SCR low frequency chopper with SEM1 because the SEM1 filter
capacitors alter the SCR choppers' work. If it is necessary to use two or more control
units (traction + lift. for ex.), they must belong to the ZAPIMOS family.
- 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 does not "power up".
- During battery charge, disconnect SEM1 from the battery.
- Supply the SEM1 only with battery for traction; do not use a power supply.
- When the chopper is installed, make tests with the wheels raised from the ground, in
order to avoid dangerous situations due to connection errors.
- After the chopper is switched off (key off), the filter capacitor remains charged for
some minutes; if you need to work on the chopper, discharge them using a
10W ÷ 100W resistance connected from the +Batt to the -Batt.
- 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
noncompliance if correct testing is not made (the irradiated emission directive is
EN50081-2).

SEM1 Page 9
 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 in
order to allow 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 16 mm².
For the field winding connections use cable with a 4mm² section.
In order improve the chopper performance, the battery cables must be as short as
possible and near each other.

3.2 CONTACTOR

The general contactor is installed on the chopper. Use a contactor the same voltage as
the battery. The current coil must be lower than 3A. The coil transient suppression is
integrated 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 event of a blowout.

Page 10 SEM1
 3.4 DESCRIPTION OF CONNECTORS

PIN NAME DESCRIPTION

A1 NEF Negative output of the electromechanical brake's coil (max. 3A).
A2 CPOT Potentiometer wiper (range: 0V (min) to 10V (max)).
A3 NPOT Negative potentiometer.
A4 PPOT Potentiometer positive: 12V output. Keep load >500W .
A5 PTG Positive of the main contactor's coil (max. 3A).
A6 NTG Negative of the main contactor's coil (max. 3A).
A7 RV2 Input for 2nd speed reduction request. If left free or connected to
battery negative the reduction function operates. If connected to A13,
the reduction is inhibited.
A8 RV1 Input for 1st speed reduction request. If left free or connected to
battery negative the reduction function operates. If connected to A13,
the reduction is inhibited. This speed reduction is linked to an adjust-
able braking (curve braking).
A9 MA Forward direction microswitch. It should be connected to the forward
microswitch, active HIGH (+VB).
A10 MI Backward direction microswitch. It should be connected to the back-
ward microswitch, active HIGH (+VB).
A11 TIM/SEAT It should be connected to the tiller microswitch or to the seat
microswitches (2 sec delay). It is active high (+VB).
A12 IR Quick inversion input, it is active HIGH (+VB).
A13 CMM Common IR/TIM/MI/MA/RV1/RV2 microswitch (+VB).
A14 CH Connected to the power supply through a 6.3A fuse and the key-
switch.
SEM1 Page 11
B1 PCLRXD Positive serial reception.
B2 NCLRXD Negative serial reception.
B3 PCLTXD Positive serial trasmission or positive of the diagnostic LED if the
(PLED) console is not connected.
B4 NCLTXD Negative serial trasmission or negative of the diagnostic LED if the
(NLED) console is not connected.
B5 GND Negative console power supply.
B6 +14 Positive console power supply.
B7 -----
B8 -----

3.5 DESCRIPTION OF POWER CONNECTORS

F1, F2: motor field windings

VMN, SH: motor rotor windings
+BATT: battery positive
-BATT: battery negative

Page 12 SEM1
3.6 MECHANICAL DRAWING

SEM1 Page 13
 4 PROGRAMMING AND SETTINGS USING A CONSOLE

4.1 SETTING BY CONSOLE

Adjustments of the parameters and the configurations are to be carried out by the pro-
grammable Console. The Console is connected to the relative connector B.
The connection is to be carried out with the key sw. open or the battery disconnected.
Pay attention to the connector polarity of the console when it is connected
to the controller.

4.2 PROGRAMMING CONSOLE FUNCTIONS

- Configuration Function.
- Parameter Settings.
- 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 output values
of the accelerator unit, optimising in this way the full stroke.

Page 14 SEM1
 4.3 PROGRAMMING CONSOLE

The console to be connected the controller SEM1 is to be equipped with the EPROM
"CK ULTRA".

SEM1 Page 15
 4.4 MAP OF THE CONSOLE FUNCTIONS

Page 16 SEM1
 5 CONFIGURATION FUNCTION

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

SUBMENU "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 battery charge is continuosly monitored .
- 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 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 5.2).
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 one for
backward direction).
- PRESENT: running selector + single pedal.
7. ANTI ROLL-BACK:
- ON: when left on a ramp without a running request the ma-
chine does not roll-down.
- OFF: this function is not activated.
8. TRANSPALLET MODE:
- ON: in this mode the acceleration and braking ramps are faster
(twice).
- OFF: standard ramps (switched for golf-car).

SEM1 Page 17
Programming "options", using the console:

1) Opening Display

2) Press ROLL UP + SET UP to simultaneously

enter the menu SET.

3) Headline of the menu SET MODEL.

4) Press ROLL UP to select the menu SET OPTIONS.

5) Headline of the menu SET OPTIONS.

6) Press ENTER to enter the menu.

7) The first item of the menu appears.

8) Press ROLL UP or ROLL DOWN to

scroll the different items.

9) A new item appears.

10) Press SET UP or SET DOWN to modify the configuration.

11) The new configuration appears.

12) Press OUT to come out of the menu.

13) Confirmation of the modification request appears.

14) Press ENTER to confirm the modifications

or press OUT to cancel.

15) Headline of the menu SET OPTIONS appears.

16) Press OUT to return back to the opening display.

Page 18 SEM1
 5.1 ADJUSTMENT: DESCRIPTION AND PROGRAMMING INSTRUCTIONS

This functions allows fine tuning of the internal measurement of the battery voltage.
The tuning permits to compensate the possible voltage drops along the wires in order to
get the voltage value displayed on the console equal to the true voltage value of the
battery.

ADJUSTMENT operations with the console:

1) Opening display.

2) Press ROLL UP + SETUP to enter

the menu CONFIG.
3) Headline of the menu
SET MODEL (function not available) appears.
4) Press ROLL UP to select the menu ADJUSTMENT.

5) Headline of the menu ADJUSTMENT appears.

6) Press ENTER to enter the menu.

7) The first item of the menu: SET BATTERY TYPE.

8) Press the SET PARAM buttons to select the suitable
nominal battery voltage.

9) The new value appears.

10) Press ROLL UP for a new menu.

11) The ADJUST BATTERY menu appears.

12) The button SETUP increases the value shown on the
display, the button SET DOWN decreases it.
Set to the same value as measured on the battery
with a multimeter.
13) The new voltage value appears.

SEM1 Page 19
14) Press OUT to quit the menu.

15) Confirmation of the modification request appears.

16) Press ENTER to confirm the modifications

or press OUT to cancel.

17) Headline of the menu appears.

18) Press OUT to return to the main menu.

Page 20 SEM1
 5.2 PARAMETER REGULATION

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

upon Customer specifications, or directly by the Customer using the programming
console. The following parameters can be modified:

NAME FUNCTION
1 ACC. DELAY: Determines the acceleration ramp.
2 RELEASE BRAKING: Controls the deceleration ramp when the running request
is released.
3 INVERSION BRAKING: Controls the deceleration ramp when an inversion of the
direction 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 accelerator
pedal position is changed (but not completely released).
6 RV1: First speed reduction.
7 RV2: Second speed reduction.
8 MAX SPEED FORW: This is the maximum speed in forward direction; this
speed is got by weakening the field current after the full
conduction on the rotor has been reached; when the
parameter is programmed to LEVEL = 0, if the motor is in
full conduction, the field current will not be decreased
under the nominal value (low speed).
9 MAX SPEED BACK: This is the maximum speed in backward direction; this
speed is got by weakening the field current after the full
conduction on the rotor has been reached; when the
parameter is programmed to LEVEL = 0, if the motor is in
full conduction, the field current will not be decreased
under the nominal value (low speed).
10 CREEP SPEED: Minimum speed.
11 MAX CURRENT: Maximum armature current of the controller.
12 FIELD NOM. CURR.: Nominal field current: this is the minimum field current when
the accelerator is in the range from 0% to 60% (no full
conduction on the armature); must be adjusted to the nomi-
nal value of field current of the motor (stated by the motor
manufacturer on the motor identification plate).
13 ARMA NOM. CURR.: This is the nominal armature current; this establishes an
armature current level above which the field current is at
least at its nominal value (FIELD NOM. CURR.) or more,
regardless of the accelerator position.
14 WEAK DROPOUT: This parameter establishes an armature current level
above which the field current is proportionally increased
up to the nominal value.

SEM1 Page 21
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 %Acc 10 20 30 40 50 60 70 80 90 100

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

MAX SPEED FORW. %FNC 100 92 84 76 68 60 52 44 36 28

MAX SPEED BACKW. %FNC 100 92 84 76 68 60 52 44 36 28

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

I MAX (version 180A) Amp 155 158 160 163 166 169 172 175 178 180

I MAX (version 200A) Amp 170 173 177 180 183 187 190 193 197 200

I MAX (version 300A) Amp 250 255 260 265 270 275 280 285 290 300

ARMA NOM. CURR.

Amp 77 80 83 86 88 90 93 96 100 103
(version 180A)
ARMA NOM. CURR.
Amp 85 88 92 95 98 102 105 108 112 115
(version 200A)
ARMA NOM. CURR.
Amp 128 133 138 142 145 150 155 160 165 170
(version 300A)
WEAK DROPOUT
Amp 40 43 46 49 52 56 60 64 68 70
(version 180A)
WEAK DROPOUT
Amp 44 47 51 54 57 60 64 68 71 75
(version 200A)
WEAK DROPOUT
Amp 65 70 75 80 85 90 95 100 105 110
(version 300A)

FIELD NOM CURR (FNC) Amp 5.0 5.3 5.6 5.9 6.2 6.5 6.8 7.1 7.4 7.7

Page 22 SEM1
Programming operations through the console:

1) Opening display.

2) Press ENTER to enter the main menu .

3) The headline of the first item,

PARAMETER CHANGE appears.

4) Press ENTER to enter to the function PARAMETERS.

5) The first parameter of the list appears.

6) Scroll the list of the parameters with the

buttons ROLL UP and ROLL DOWN.

7) Another parameter appears.

8) Change the programmed level by means of the

SET UP and SET DOWN buttons.

9) The new set value appears.

10) Press OUT when programming is finished.

11) The confirmation request appears.

12) Press ENTER to confirm the modifications
or OUT to cancel.

13) The headline of the menu

PARAMETER CHANGE appears.

14) Press ROLL UP or ROLL DOWN for scrolling

the other items, or press OUT for coming back
to the opening display.

SEM1 Page 23
 5.3 START UP: PROGRAMMING INSTRUCTIONS

With the machine switched off, connect the programming console and then switch the
key on. If no errors are found, the display will show the manufacturer's name, program
release, configuration, and hourmeter value.

5.3.1 Adjustment sequence

1) Select the desired options.
2) Select and set battery voltage.
3) Check the operation of all the wired inputs, including the potentiometer, by means
of the tester functions on the console.
4) Carry out accelerator signal acquisition on the “PROGRAM VACC” menu.
5) Set the maximum current by selecting the level corresponding to the desired value
shown on the table of modifications.
6) Set the FIELD NOMINAL CURRENT, referring to the value stated on the motor's
identification plate.
7) Adjust ARMA. NOM. CURRENT and WEAK DROPOUT depending on the operating
requirements.
8) Set ACCELERATION DELAY by moving the machine forward and backward.
9) Set CREEP speed starting from level 0. With the machine stopped, press the pedal
lightly in order to close the direction microswitch, leaving the potentiometer at the
minimum value. Try several values of CREEP until the machine begins to move.
10) Set the speed reduction RV1 and RV2, and try several values pressing the accel-
erator pedal completely, with the request speed is obtained.
11) RELEASE BRAKING is set by running the machine and then completely releasing
the accelerator pedal without pressing other pedals.
12) INVERSION BRAKING, is set by running run the machine and invert the direction
with the pedal pressed down.
13) Set CURVE BRAKING if the speed reduction RV1 is linked to the steering angle.
14) Set MAX SPEED FORW and MAX SPEED BACK, running up to the maximum
speed.
15) Set MAX SPEED LIMIT BRAKING. Run the truck and test the deceleration ramps
obtained by reducing partially the accelerator.

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

Page 24 SEM1
 6 DIAGNOSIS

Description of the alarms signalled by the diagnostic LED. The alarm code is shown
within brockets. A detailed description is given in section 6.1.
1 Blink: Logic failure (WATCHDOG, EEPROM KO).
2 Blinks: Running request on startup or error in handle/seat sequence
(INCORRECT START).
3 Blinks: VMN or capacitor charge failure.
(CAPACITOR CHARGE, VMN NOT OK).
4 Blinks: Failure of the accelerator (PEDAL WIRE KO, VACC NOT OK).
5 Blinks: Failure of current sensor (I HIGH AT STAND, I=0 EVER,
HIGH FIELD CUR., NO FIELD CUR.).
6 Blinks: Failure of contactor driver (DRIVER SHORTED, COIL SHORTED).
7 Blinks: Excessive temperature, higher than 70°C (HIGH TEMPERATURE).
32 Blinks: Low battery charge (BATTERY LOW).
LED ON: Double direction request (FORW + BACK).

6.1 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 logic.
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. PEDAL WIRE KO
This alarm is signalled if a potentiometer fault is detected (NPOT or PPOT cable is
interrupted).
4. INCORRECT START
An incorrect starting sequence. Possible causes:
a. running microswitch or handle microswitch failure;
b. error in the starting sequence made by the operator;
c. incorrect wiring.
5. VACC NOT OK
The test is made while in standby. This alarm indicates that the accelerator voltage
is 1V greater than the minimum stored value. Possible causes:
a. a potentiometer wire is interrupted.
b. the potentiometer is not correctly calibrated.
c. the potentiometer is defective (interrupted).

SEM1 Page 25
6. FORW + BACK
The test is carried out continouosly. An alarm is signalled when a double running
request is made simultaneously. Possible causes:
a. defective wiring;
b. running microswitch failure;
c. incorrect operation;
d. if the defect persists, replace the logic.
7. CAPACITOR CHARGE
The test is carried out during initial diagnosis. The alarm is signalled if the capacitor
charge is slower than 2 sec. A possible cause is a failure in the power unit.
8. DRIVER SHORTED, COIL SHORTED
This alarm is signalled if there is a failure of the main contactor. Possible causes:
a. the contactor coil is shorted;
b. the main contactor driver is broken;
c. failure on the logic.
9. I HIGH AT STAND
Test carried out in standby. Check if the current is 0. If not verified, an alarm is
signalled which inhibits machine operations. Possible causes:
a. current sensor failure;
b. logic failure: first replace the logic; if the defects persists, replace the power unit.
10. I = 0 EVER
Test carried out during travel. It checks if the current is greater than a minimum
value. If not, an alarm is signalled and the machine operation is inhibited. Possible
cause: the current sensor has failed. Replace the power unit.
11. 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.
12.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 board failure.
13. BATTERY LOW
The battery is discharged. This alarm is present only if the "battery check" option
has been selected.

Page 26 SEM1
14 HIGH FIELD CUR., NO FIELD CUR.
Problem in the FIELD current. Possible causes:
a. Failure of the current trasducer.
b. Field cables not connected.
c. Failure of the field power unit.

6.2 TESTER: FUNCTIONS DESCRIPTIONS

Some of the most importantly input/output signals are tested or measured in real time
(only stand-by status) and it is possible to read them through the menu TESTER of the
console.

1) BATTERY VOLTAGE: is the value of the battery voltage, measured on the "key
input".
2) MOTOR VOLTAGE: voltage across the motor's armature.
3) MOTOR CURRENT: armature current.
4) FIELD CURRENT: field current.
5) TEMPERATURE: temperature of the aluminium coding plate, close to the power
Mosfets.
6) ACCELERATOR: voltage measured on the CPOT (wiper of the potentiometer). On
the left of the display there is the voltage value, instead, on the right the percentage
of the stroke.
7) FORWARD SWITCH: status of the digital input corresponding to the forward direc-
tion microswitch (MA: pin A9).
ON / +VB = active, closed microswitch.
OFF / GND = not active, open microswitch.
8) BACKWARD SWITCH: status of the digital input corresponding to the backward
direction microswitch (MI: pin A10).
ON / +VB = active, closed microswitch.
OFF / GND = not active, open microswitch.
9) CUTBACK SWITCH 1: status of the digital input corresponding to the speed reduc-
tion microswitch n° 1 (RV1: pin A8).
10) CUTBACK SWITCH 2: status of the digital input corresponding to the speed reduc-
tion microswitch n° 1 (RV2: pin E2).
11) QUICK INVERSION: status of the digital input corresponding to the belly switch (IR:
pin A12).
ON / +VB = active, closed microswitch.
OFF / GND = not active, open microswitch.
12) HANDLE / SEAT SWITCH: status of digital input corresponding to the microswitch
tiller / seat (MT / MSED: pin A11).
ON / +VB = active, closed microswitch.
OFF / GND = not active, open microswitch.

SEM1 Page 27
How to enter the TESTER function of the console:

1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP

or ROLL DOWN. Select TESTER.

5) The selected item (TESTER) appears.

6) Press ENTER to enter the function TESTER.

7) The first signal tested appears.

8) Scroll the signals tested with the buttons

ROLL UP and ROLL DOWN.

9) The following signal appears.

10) Press OUT to return to the item list.

11) The selected item appears.

12) Press ROLL UP and ROLL DOWN for scrolling

the remaining items, or press OUT to return
to the opening display.

Page 28 SEM1
 6.3 SAVE PARAMETERS: DESCRIPTION

The function SAVE PARAM. allows loading on the console memory parameter values
and the controller configuration data. It is possible to load max 64 configurations.
The data stored on the console memory can be loaded again on another controller by
means of the function RESTORE.
Data loaded with the function SAVE is:
- all the parameters values (PARAMETERS CHANGE);
- the settings of the options (SET. OPTION);
- the setting of the battery (ADJUST BATTERY).

How to enter the SAVE function by the console:

1) Opening Display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP

or ROLL DOWN. Select SAVE PARAM.

5) The selected item (SAVE PARAM.) appears.

6) Press ENTER to enter the SAVE function.

7) In the first line the model code selected, appears
in the second line it appears FREE if the memory
box is free or the name of the model if it is busy.

8) Select the model code with the buttons ROLL UP

and ROLL DOWN.
9) The new model code selected and its
condition (FREE/BUSY) appears.

10) Press ENTER to confirm the reading operation.

11) On the second line the items of the parameters

stored scroll.

12) At the end of the operation it returns to

the main menu SAVE PARAM.

SEM1 Page 29
 6.4 RESTORE PARAMETERS: DESCRIPTION

The function RESTORE PARAM allows transfer of data stored in the console memory
to the controller in the same way of the model loaded with the function SAVE PARAM.
Data loaded in the controller by means of the function RESTORE PARAM. is:
- all the parameters values (PARAMETERS CHANGE);
- the settings of the option (SET. OPTION);
- the setting of the battery (ADJUST BATTERY).

ATTENTION: the function RESTORE overwrites all the data of the controller.
After this operation, old configuration data is cancelled.

How to enter in the RESTORE function by the console:

1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or ROLL DOWN.

Select RESTORE PARAM.

5) The selected item (RESTORE PARAM.) appears.

6) Press ENTER to enter the function RESTORE PARAM.

7) In the first line the model code selected appears

and in the second line the type of controller stored
in the memory appears.
8) Select the model code with the buttons ROLL UP
and ROLL DOWN.
9) The model code selected and the type
of controller stored appears.

10) Press ENTER to confirm the loading operation.

11) The confirmation request for the operation appears

(ENTER = YES, OUT = NO).
12) Press ENTER to confirm the loading operation
(OUT for cancelling).

13) The list of the parameter items during the

loading phase appears.

14) At the end of the operation it returns to the

main menu RESTORE PARAM.
Page 30 SEM1
 6.5 ALARMS: MENU DESCRIPTION

The controllers stores the last five alarms, recording the following information: alarm
code; how many times this is occurred; the temperature and the hourmeter value in the
occurrence of the alarm. In the menu ALARMS of the console, it is possible to enter in
this data memory.
This function allows a deeper diagnosis, knowing the sequence of the alarms occurred.

How to enter the menu ALARMS.

1) Opening display.

2) Press ENTER to enter the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or

ROLL DOWN. Select ALARMS.

5) The selected item (ALARMS) appears.

6) Press ENTER to enter the function ALARMS.

7) The first alarm occurred with the number

of times, hourmeter and temperature, appears.

8) The button ROLL UP scrolls the previous alarms,

the button ROLL DOWN returns to the more recent.

9) If there are no other alarms, ALARM NULL appears.

10) Press OUT to leave the menu ALARMS.

11) The confirmation request for cancelling

all the alarms stored, appears.

12) Press ENTER to confirm the operation

(OUT for returning to the main menu).

SEM1 Page 31
 6.6 PROGRAM VACC: DESCRIPTION

This function allows to store the minimum and maximum values of the accelerator
output signal in each running direction. This is necessary to compensate for the asym-
metry of the potentiometer.

How to enter in the menu PROGRAM VACC and carry out the necessary operations:

1) Opening display.

2) Press ENTER to enter in the main menu.

3) The first item of the list appears.

4) Scroll the list with the buttons ROLL UP or

ROLL DOWN. Select PROGRAM VACC.

5) The selected item (PROGRAM VACC) appears.

6) Press ENTER to enter the function

PROGRAM VACC.

7) The maximum current values matched to the

forward and backward running directions appear.

8) Press ENTER.

9) The controller is now ready to record the

minimum and the maximum value of the
potentiometer signal.
10) Press the pedal. Move slowly at the start and complete
the stroke.
N.B. : select the direction before pressing the pedal.

11) The new maximum and minimum values for each

running direction appear.
The arrow indicates the selected direction.

12) Press OUT.

13) The confirmation request for storing new

values appears.

14) Press ENTER to confirm or OUT to cancel.

Page 32 SEM1
 7 CONNECTIONS DRAWING

7.1 DIAGRAM PART LIST

AV = Forward
BEF = Electromechanical brake coil
BTG = Main contactor coil
CH = Key
CMM = Microswitch common
CPOT = Wiper potentiometer
IN = Backward
MA = Forward microswitch
MI = Backward microswitch
MIR = Quick inversion microswitch
NEF = Electromechanical brake negative
NPOT = Negative of potentiometer
RV = Speed reduction
SH = Motor cable connection for current feedback
TG = Main contactor
VMN = Motor to negative voltage

7.2 COLOUR CODING

The following codes are used to identify the colours of the wires in the wiring drawings.

A ORANGE G YELLOW
B WHITE N BLACK
BB BLUE R PINK
C SKY-BLUE RR RED
G YELLOW V GREEN
GG GREY VV PURPLE

SEM1 Page 33
 7.3 CONNECTIONS

7.3.1 Control input / output connections

Page 34 SEM1
7.3.2 Power configuration

FUNCTIONAL DRAWING

WIRING DIAGRAM

SEM1 Page 35
 8 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

Page 36 SEM1
 9 SUGGEST SPARE-PARTS

Code Description

E07008 Potentiometer 5kW 1 turn

C16504 Power fuse 300A
C16503 Power fuse 200A
C16520 Fuse 5X20 6.3A
C12372 Molex connector Fe 8 pin
C12761 Pin female (molex)
P99060 Diagnostic red led
C12403 Molex connector minifit 14 pin female
C12771 Pin female for minifit
C29548 Contactor SW80 24V
C29504 Contactor SW80 36V
C29554 Contactor SW80 48V

SEM1 Page 37
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259

SEM1
User' s Manual