ZAPI (SEM-O-ing).pdf

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INDEX
Page
LEGEND .............................................................................................................................3
COLOUR CODES (Single Colours) ...................................................................... 3
1 Introduction to the ZAPI-MOS family .......................................................... 4
2 General characteristics ................................................................................. 5
2.1 Technical Specification .......................................................................... 5
2.2 Control Units .......................................................................................... 5
2.2.a Microswitches ............................................................................... 5
2.2.b Potentiometer ............................................................................... 6
2.3 Safety & Protection Features ................................................................ 7
2.4 Direction Orientation ............................................................................. 7
2.5 Operational Features ............................................................................ 8
2.6 SEM-Zero chopper diagnosis ................................................................ 9
2.7 Thermal Considerations ........................................................................ 9
2.8 General Instructions and Precautions ................................................. 10
3 Installation ................................................................................................... 11
3.1 Connection Cables .............................................................................. 11
3.2 Contactors ........................................................................................... 11
3.3 Fuses .................................................................................................. 11
3.4 Description of SEM-Zero Connectors. ................................................. 12
3.5 Description of Power Connections ...................................................... 13
3.6 Mechanical Drawing & Dimensions ..................................................... 14
4 Programming & Adjustments using Digital Console ............................... 15
4.1 Adjustments via Console ..................................................................... 15
4.2 Description of Console & Connection .................................................. 15
4.3 Description of Standard Console Menu............................................... 16
5 SEM-Zero: cabling and configuration ....................................................... 17
5.1 Power diagram .................................................................................... 17
5.2 Connections ........................................................................................ 18
5.3 Description of Programmable Functions (Options). ............................ 19
5.4 Description of Parameters that may be Programmed ......................... 21
5.5 Table of Adjustments ........................................................................... 23
5.4 SEM-Zero Traction Standard Wiring Diagrams ................................... 25
5.5 Sequence for SEM-Zero Traction Settings. ......................................... 26
6
SEM-Zero Diagnostics ................................................................................ 27
6.1 Analysis of Alarms displayed on the Console ..................................... 28
6.2 Tester Description of the Functions .................................................... 31
6.3 Description of the Console SAVE Function ......................................... 33
6.4 Description of Console RESTORE Function. ...................................... 34
6.5 Description of Alarms Menu. ............................................................... 35
6.6 Description of Console PROGRAM VACC function. ........................... 36
7 Recommended Spare parts for SEM-Zero .................................................... 37
8 Periodic Maintenance to be repeated at times indicated ............................ 38
ACLZP0CB - SEM-ZERO - User manual
Page 1 of 38
SIGNED IN APPROVAL
COMPANY DEPT. SERVICES
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
MANAGEMENT EXECUTIVE
Pubblication n°:
ACLZP0CB
Edition:
December 2006
ACLZP0CB - SEM-ZERO - User manual
Page 2 of 38
LEGEND
B SW
CM
CPOT
EMB
EV
FORW SW
H&S
HORN
HORN SW
LIFT SW
LOW SW
MC
NEMB
NEV
NHORN
NMC
NPC
NPOT
PC
PEMB
PEV
PHORN
PMC
PPC
PPOT
REV SW
SR1
SR2
T SW
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Belly Switch
Common Microswitches
Wiper Potemtiometer
Electromechanical Brake
Lowering Valve
Forward Switch
Hard & Soft
Horn
Horn Switch
Lifting Switch
Lowering Switch
Main Contactor
Negative Electromechanical Brake
Negative Lowering Valve
Negative Horn
Negative Main Contactor
Negative Pump Contactor
Negative Potentiometer
Pump Contactor
Positive Electromechanical Brake
Positive Lowering Valve
Positive Horn
Positive Main Contactor
Positive Pump Contactor
Positive Potentiometer
Reverse Switch
Speed Reduction 1
Speed Reduction 2
Tiller Switch
COLOUR CODES (SINGLE COLOURS)
The following Codes represent the colours of individual wires used by Zapi (unless
specified otherwise).
A
B
C
G
- Orange
- White
- Sky Blue
- Yellow
M
N
R
V
VV
-
-
-
-
-
Brown
Black
Pink
Red
Green
Purple
BB - Blue
RR -
GG - Grey
ACLZP0CB - SEM-ZERO - User manual
Page 3 of 38
1 INTRODUCTION TO THE ZAPI-MOS FAMILY
The ZAPIMOS chopper family represents 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 offers the following features:
- Advanced technology.
- Economical costs.
- Maximum safety.
- Maximum flexibility.
- Open to future technical innovations.
- Optimum level of protection.
The design has been derived from:
- High Frequency Mos Technology .
- Real time control over the internal and external components that influence the be-
haviour 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 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 increas-
ing 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 machines. Zapi can offer a range of individually designed
Console Software with various features and prices.
- SEM-Zero meets the requirements of (IP54). 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 replace-
ment.
- The SEM-Zero family of Choppers are suitable for operating on DC voltages from 24
to 36V inclusive, with maximum armature current up to 200A.
The choppers may be used to control DC Separately Excited Motors with power
ratings up to 2.0kW.
ACLZP0CB - SEM-ZERO - User manual
Page 4 of 38
2 GENERAL CHARACTERISTICS
2.1 TECHNICAL SPECIFICATION
Chopper for Separately Excited DC motors ................................................... 0.5 ÷ 2.0kW
Regenerative Braking.
Voltage Range ................................................................................................. 24-36VDC
Maximum Field Current (all the versions) ................................................................. 35 A
Armature Switching Frequency ............................................................................... 16kHz
Field Switching Frequency ........................................................................................ 1kHz
Maximum Ambient temperature ............................................................................. + 40°C
Minimum Ambient temperature ................................................................................-30°C
Maximum temperature of Chopper ........................................................................ + 80°C
VERSIONS
MAXIMUM CURRENT
BOOSTER CURRENT
VOLTAGE DROP IN
FULL CONDUCTION
0.23V at 50A, 25°C
0.23V at 50A, 25°C
24 / 36V
24 / 36V
150A (3')
200A (2')
180A (10'')
230A (10")
2.2 CONTROL UNITS
2.2.a Microswitches
- Microswitches should have a contact resistance lower than 0.1Ω, and a leakage
current lower than 100 µA.
- When full load current is being drawn, the voltage drop across the Key Switch con
tact must be lower than 0.1V.
- If an Electromagnetic Brake is used, the Handle Microswitch must be able to operate
the Brake Coil.
- The Microswitches send a voltage signal to the microprocessor when an operating
request (running) is made.
ACLZP0CB - SEM-ZERO - User manual
Page 5 of 38

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