Zapi 4Q Manuale utente
Page 1
Index
1 Main features ................................................................................................. 3
1.1 Field of application .................................................................................... 3
1.2 Control units .............................................................................................. 4
1.2.a Microswitches ............................................................................... 4
1.2.b Potentiometer ............................................................................... 4
1.3 Safety features .......................................................................................... 5
1.4 Operating functions ................................................................................... 6
1.5 Controller diagnosis ................................................................................... 6
1.6 Thermal considerations ............................................................................. 7
1.7 General warnings and precautions .................................................... 7
2 Installation...................................................................................................... 8
2.1 Choice of connecting cables...................................................................... 8
2.2 Fuses ......................................................................................................... 8
2.3 Description of connectors .......................................................................... 9
2.4 Dimensions .............................................................................................. 10
2.5 Connections ............................................................................................ 11
2.5.a Pallet truck.................................................................................. 11
2.5.b Floor washer............................................................................... 12
3 Console Menu .............................................................................................. 13
3.1 Programming with the console ................................................................ 13
3.2 Console Map ........................................................................................... 14
3.2.a Pallet truck.................................................................................. 14
3.2.b Floor washer............................................................................... 15
3.3 "Tester" Menu .......................................................................................... 16
3.3.a Pallet truck.................................................................................. 16
3.3.b Floor washer............................................................................... 16
3.4 "Parameter Change" Menu ...................................................................... 17
3.4.a Pallet truck.................................................................................. 17
3.4.b Floor washer............................................................................... 17
3.5 "Set Model" Menu .................................................................................... 18
3.6 "Set Option" menu ................................................................................... 18
3.6.a Pallet truck.................................................................................. 18
3.6.b Floor washer............................................................................... 20
3.7 "Adjustment" Menu .................................................................................. 21
3.8 "Hardware Setting" Menu ........................................................................ 22
3.9 "Special Adjust" Menu ............................................................................. 23
3.10 "Clear EEprom" Menu ........................................................................... 23
4 Alarms .......................................................................................................... 24
4.1 Diagnosis ................................................................................................. 24
5 Recommended spare parts for the 4Q ...................................................... 27
6 Regular maintenance at set intervals ........................................................ 28
Page 2
SIGNATURES TABLE
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publication N°: ADMZP0DA
Edition: November 2001
= The informations included into the marked paragraphs by this symbol are
essential for the safety.
Page 3
1 MAIN FEATURES
The 4Q is the smallest permanent magnet motor controller:
it is designed for use at 24Vor 36V with a maximum armed current of 70A or 90A.
The controller is constructed with a full bridge: no changeover necessary.
1.1 FIELD OF APPLICATION
Power 500W (800W)
Voltages 24V, 36V
Max. current 70A (90A)
Continuos current 30A
The following inputs are foreseen:
- tiller / seat microswitch
- quick inversion
- forwards
- reverse
- potentiometer with 3 wires
- speed reduction 1
- speed reduction 2
The controller has 2 outputs:
- EV1 (solenoid valve)
- EV2 (electric brake)
The main contactor (relay) is internal.
The 4Q controller can be configured in two different ways:
- Pallet truck (Model 1)
- Floor washer (Model 2)
The parameters, tester and options may vary according to the model chosen with ZAPI
console.
Page 4
1.2 CONTROL UNITS
1.2.a Microswitches
- A contact resistance of less than 0.1Ωand a current leakage of less than 100µA is
required.
- The key contact must be able to take all the current of the loads without causing a voltage
drop of more than 01.V between contacts.
- Send a voltage signal to the microchip when a function is requested (e.g. start running).
1.2.b Potentiometer
Potentiometer configured with 3 wires.
The CPOT range varies from 0 to 10V.
Minimum resistance: 500 Ω
Maximum resistance: 10KΩ
Automatic minimum and maximum signal acquisition must be carried out (PROGRAM
VACC function) using the programming console and in both directions. This function is
indispensable when compensating an eventual asymmetry in the mechanical components
of the potentiometer and for minimum level adjustment in particular.
The above graphs show the output voltage of a potentiometer that has not been calibrated
compared to the mechanical “zero” of the tiller knob (MI and MA indicate the closing points
of the microswitches, 0 represents the mechanical angle of rotation of the throttle).
The first graph shows the corresponding motor voltage without acquisition; the second
graph shows the corresponding voltage after potentiometer signal acquisition.
Page 5
1.3 SAFETY FEATURES
-Inverted battery polarity:
Connections must be made as indicated in the wiring diagrams to avoid damaging
the power unit.
-Connection errors:
All the inputs are protected against wrong connection.
-Thermal protection:
If the temperature of the 4Q exceeds 75°C, the maximum current is automatically
reduced in proportion to the temperature increase. The temperature cannot exceed
90°C, at this temperature the maximum current is zeroed. If the temperature drops to
below –10°C, the maximum current is reduced by 20%.
-Battery low:
When the battery runs down (<= 10%) the maximum current is reduced by 50%.
This function can be excluded using the console (“Battery Check” option).
-External agents:
The chopper has IP54 protection.
-Protection against accidental starting:
A precise sequence of operations is required to start the machine, if the sequence is
not carried out correctly the machine will not start.
The start running command must be given after key-on and activating the seat
microswitch, if configured. If on the other hand the tiller is configured, it must be
activated with a predefined minimum delay time compared to the activation of a start
running microswitch.
-Protection against uncontrolled movement:
The electromagnetic switch does not close if:
- the power unit is not in function,
- the output voltage of the accelerator does not drop to below the recorded
minimum value increased by 1V,
- the potentiometer negative is disconnected,
- the logic is not in good working order,
- one of the start microswitches is closed.
- the controller fulfil the requirements specified on the EN1175 (point 5.9.4). The
requirements specified on point 5.9.5 have to be fulfil by external solutions.
Page 6
1.4 OPERATING FUNCTIONS
- Speed control.
- Excellent sensitivity at low speeds.
- Maximum speed reduction: the maximum speed in both directions can be adjusted
using the programming console.
- Regenerative braking based on deceleration ramps, release braking, inversion
braking.
- Speed control in descent: the motor speed is controlled by the accelerator pedal and
regenerative braking is activated automatically if the motor speed exceeds the
required speed; this results in excellent ramp performance.
- Even without the use of an electric brake anti roll-back.
- Electric brake control (optional).
- Diagnosis with optional led to indicate type of fault.
- Parameter adjustment using console.
- Internal hour-counter, displayed on the console.
- The last 5 alarms are recorded together with the relative hour-counter reading and
chopper temperature.
- Tester function using the console to check in real time: inputs, motor voltage, battery,
etc.
- Good motor and battery efficiency thanks to high frequency switching.
- Watchdog circuit to check the µC operations.
- An MDI indicator can be connected to display: software version, hour counter,
alarms, speed reduction and battery charge.
1.5 CONTROLLER DIAGNOSIS
The µC diagnoses the main chopper functions.
Diagnosis consists of 4 main stages and includes the following tests:
1) Key turned on: test current sensor, test VMN, test main relay, test presence of start
command, test accelerator high, test potentiometer connection, test watchdog, test
power devices.
2) At rest: test VMN, test main relay, test current sensor, test potentiometer
connection, test watchdog, test accelerator up in absence of start microswitch.
3) Running: test VMN, test main relay, test current sensor, test negative wire of
potentiometer, test watchdog, test electric brake (if configured).
4) Permanent: check temperature and battery voltage.
Diagnostic messages are coded by counting the number of times the led flashes or by a
2 digit code on the MDI.
The full alarm message can be visualised using the programming console.
Page 7
1.6 THERMAL CONSIDERATIONS
- Since the heat generated by the controller must be dissipated, it is important to install
it in a well ventilated area with adequate cooling surfaces.
- The cooling system must be scaled according to the use required of the machine;
forced ventilation may be necessary in some cases if air circulation is insufficient and
heat exchange is limited by the type of materials used.
- The power dissipated by the module varies according to the current and the duty
cycle.
1.7 GENERAL WARNINGS AND PRECAUTIONS
- Do not connect the 4Q module to a battery with a different rated voltage to the one
indicated on the module’s rating plate. A higher battery voltage can cause irreparable
damage the MOSFETs. With a lower battery voltage the module will not work.
- The 4Q module must be disconnected when the battery is being charged as the
module can be damaged by overvoltages generated by the battery charger and
ripple currents generated in the capacitors if a low frequency battery charger is used.
- The 4Q module should be powered by batteries for traction only. Do not use rectifier
outputs or power supply units. For special applications contact the nearest ZAPI
technical service centre.
- When starting the machine for the first time keep the wheels raised to avoid
hazardous situations due to possible connection errors.
- When the key is turn off the filter capacitors in the module can stay charged for
several minutes. For safety purposes it is advisable to disconnect the battery and
short circuit the positive and negative power lines of the chopper for a few seconds
using a resistor of between 10Ωand 100Ω.
- The electromagnetic susceptibility and emission is strongly influenced by the method
of installation; particular attention should be paid to the length and lay-out of
electrical connections and to shielding.
Zapi declines all responsibility for malfunctions caused by the above mentioned
factors, particularly if the machine manufacturer fails to carry out the tests required by
current legislation.
Page 8
2 INSTALLATION
If possible, assemble the chopper with its base on a flat metal surface that has not been
painted or cleaned. It is advisable to spread a layer of thermo-conductive grease
between the two surfaces to improve the transmission of heat.
Although the chopper is protected against external agents, the connector contacts may
become oxidised due to the presence of corrosive substances. This factor should be
taken into consideration when choosing where to install the chopper on the vehicle.
Secure the chopper using the pre-drilled holes on the aluminium fixing plate. Check to
make sure that the cable terminals and connectors are wired correctly. Remember to
install a snubber circuit on the horn, relays, solenoid valves and electromagnetic
switches not connected to the chopper, such as the motor pump contactor.
2.1 CHOICE OF CONNECTING CABLES
Use cables with a cross section of 0.5mm2for auxiliary circuits.
Use 6mm2cables for power connections to the motor and to the battery.
The cables connecting the chopper to the battery should be laid side-by-side and be as
short as possible.
2.2 FUSES
- Use a 6A fuse to protect auxiliary circuits.
- Use a 50A fuse to protect the power unit.
The values given are the maximum permitted values and can be reduced for special
applications or requirements.
For safety purposes is it advisable to use shielded fuses to prevent molten particles
being scattered in the event of a blowout.
Page 9
2.3 DESCRIPTION OF CONNECTORS
pin function description
A1 CPOTT Potentiometer unit: connect to the cursor of the accelerator
potentiometer.
A2 NPOTT Negative pole of accelerator potentiometer.
A3 PPOTT Positive pole of accelerator potentiometer.
A4 TILLER Tiller/seat switch signal input (or hydro request input if the chop
per is configured as a floor washer).
A5 BELLY Quick inversion switch input.
A6 FORWARD Forward switch input.
A7 BACKWARD Reverse switch input.
A8 RV1 Cutback switch 1 input
A9 RV2 Cutback switch 2 input
A10 NEV1 Negative pole of solenoid valve 1
A11 NEB/NEV2 Negative pole of electric brake or solenoid valve 2.
A12 PEV2 Positive pole of solenoid valve 2.
A13 PEV1 Positive pole of solenoid valve 1.
A14 PEB Positive pole of electric brake.
A15 CM Common switch (voltage output using battery potential).
A16 KEY Key input.
B1 PCLRXD Serial reception positive.
B2 NCLRXD Serial reception negative
B3 PCLTXD Serial transmission positive.
B4 NCLTXD Serial transmission negative.
B5 GND Negative for powering console.
B6 +12 Positive for powering console.
B7 ---
B8 ---
Page 10
2.4 DIMENSIONS
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