Aclzp0cb (SEM ZERO Ing)

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 MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Pubblication n°: ACLZP0CB

Edition: December 2006
LEGEND
B SW = Belly Switch
CM = Common Microswitches
CPOT = Wiper Potemtiometer
EMB = Electromechanical Brake
EV = Lowering Valve
FORW SW = Forward Switch
H&S = Hard & Soft
HORN = Horn
HORN SW = Horn Switch
LIFT SW = Lifting Switch
LOW SW = Lowering Switch
MC = Main Contactor
NEMB = Negative Electromechanical Brake
NEV = Negative Lowering Valve
NHORN = Negative Horn
NMC = Negative Main Contactor
NPC = Negative Pump Contactor
NPOT = Negative Potentiometer
PC = Pump Contactor
PEMB = Positive Electromechanical Brake
PEV = Positive Lowering Valve
PHORN = Positive Horn
PMC = Positive Main Contactor
PPC = Positive Pump Contactor
PPOT = Positive Potentiometer
REV SW = Reverse Switch
SR1 = Speed Reduction 1
SR2 = Speed Reduction 2
T SW = Tiller Switch
COLOUR CODES (SINGLE COLOURS)
The following Codes represent the colours of individual wires used by Zapi (unless
specified otherwise).
A - Orange M - Brown
B - White N - Black
BB - Blue R - Pink
C - Sky Blue RR - Red
G - Yellow V - Green
GG - Grey VV - Purple

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.

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
VOLTAGE DROP IN
VERSIONS MAXIMUM CURRENT BOOSTER CURRENT
FULL CONDUCTION
24 / 36V 150A (3') 180A (10'') 0.23V at 50A, 25°C
24 / 36V 200A (2') 230A (10") 0.23V at 50A, 25°C
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.

2.2.b Potentiometer
The Potentiometer should be wired in the 3 - Wire Configuration.
CPOT (B1) signal ranges from 0 to 10V.
Minimum Potentiometer Resistance : 500Ω
Maximum Potentiometer Resistance : 10kΩ
Faults can occur if the potentiometer is out of this range.
The Procedure for automatic potentiometer signal aquisition is carried out using the
Console. This enables adjustment of the minimum and maximum useful signal level
(PROGRAM VACC function), in either direction. This function is unique when it is
necessary to compensate for asymmetry with the machanical elements associated with
the potentiometer, especially relating to the minimum level.
The two graphs show the output voltage from a non-calibrated potentiometer with
respect to the mechanical “zero” of the control lever. MI and MA indicate the point
where the direction switches close. 0 represents the mechanical zero of the rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
aquisition being made. The Right Hand Graph shows the same relationship after signal
aquisition of the potentiometer.

2.3 SAFETY & PROTECTION FEATURES
- Connection Errors :
All Inputs are protected against connection errors.
- Thermal Protection :
If the chopper temperature exceeds 70°C, the maximum current reduces in
proportion to the thermal increase. The temperature can never exceed 80°C (below
-10°C, the current is reduced to 80%).
- 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 are necessary before the machine will start.
Operation cannot commence if these operations are not carried out correctly.
Requests for drive, must be made after closing the key Switch.
- Protection against uncontrolled movements :
The Line Contactor will not close if :
- The Power Unit is not functioning
- The Logic is not functioning perfectly.
- Main / Line Contactor :
Should be fitted to give protection to the chopper against reverse battery polarity,
and safety.
- External Agents :
The chopper is protected against dust and the spray of liquid to a degree of
protection meeting IP54.
2.4 DIRECTION ORIENTATION
Machines fitted with Tillers, Belly Switches, and Pulse Control Systems providing rapid
reversal should conform to the requirements of Directive prEN 1175. This Directive re-
quires that Direction Orientation should match the following drawing:

2.5 OPERATIONAL FEATURES
- Speed Control .
- Optimum sensitivity at low speeds.
- Speed Reductions in both the directions. Levels can be set using Console.
- Regenerative Braking based on deceleration ramps, in every condition.
- Three different modes of Braking : Release Braking, Inversion Braking, Speed Limit
Braking.
- Speed Control during descent : the motor speed follows the accelerator. The chop-
per automatically brakes if the motor speed overcomes the accelerator set point.
This provides optimum performance on a gradient.
- Starts on a Ramp without roll back, even without an electric brake.
- Programmable Anti Roll Back : When the Key Switch is closed, if the motor is rotat-
ing, the chopper controls the speed and automatically brakes and keeps the motor at
a very low speed during descent on a gradient. This is a very useful safety feature
and is not driver dependent.
- Output for Hourmeter
- The main contactor is open after 45 seconds of stand-by condition.
- Self Diagnosis with indication of fault shown via flashing Red Led. (In addition to
Console Display).
- Modification of the parameters via Digital Console. See the specific description.
- Internal Hour Meter that is displayed on the Console.
- Memory of the last 5 Alarms, with relative Hour meter count and chopper tempera-
ture all displayed on the Console.
- Test Function within Console for checking main parameters. See the specific De-
scription.
- High motor and battery efficiency due to High Frequency Switching.

2.6 SEM-ZERO CHOPPER DIAGNOSIS
The microprocessor continually monitors the chopper and carries out diagnostic proce-
dures on the main functions.
The diagnosis is made in 4 points:
1) Diagnosis on key Switch closing that checks: the Watch Dog Circuits, the current
sensor, VMN point, Contactor Drivers, the switch sequence for operation is correct,
and the output of the accelerator or tiller is correct.
2) Standby Diagnosis at rest that checks: VMN Point, Contactor Drivers, and Current
Sensor.
3) Diagnosis during operation that checks: Watchdog, VMN Point, Current,
Contactor(s), and VMN when in full conduction.
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.
Diagnosis is provided in 2 ways. The Red Led connected to Connector A will flash a
certain number of times for a given Alarm (See Listings), or the Digital Console may be
used. A permanent Alarm will be displayed on the Console immediately and the RED
LED will flash. An intermittent Alarm will be recorded in the Alarm library, but the RED
LED will only flash at the time of the Alarm.
2.7 THERMAL CONSIDERATIONS
- The heat generated by the power block must be dissipated. For this to be possible,
the compartment must be ventilated and the heat sink materials ample.
- The heat sink material and system should be sized on the performance requirement
of the machine. Abnormal ambient air temperatures should be considered. In situa-
tions where either ventilation is poor, or heat exchange is difficult, forced air ventila-
tion should be used.
- The thermal energy dissipated by the power block module varies and is dependent
on the current drawn and the duty cycle.

2.8 GENERAL INSTRUCTIONS AND PRECAUTIONS
- Never combine SCR low frequency choppers with SEM-Zero modules. The filter
capacitors contained in the SEM-Zero module will change the SCR chopper opera-
tion and subject it to excessive workload. If it is necessary to use two or more control
units (eg. Lift + traction), the choppers must be of the High Frequency Zapi family.
- Do not connect the chopper to a battery with a different nominal voltage to the value
indicated on the chopper. A higher battery voltage may cause MOS failure, and a
lower voltage may prevent the logic operating.
- During battery recharge, the SEM-Zero must be completely disconnected from the
battery. As well as altering the charge current read by the battery charger, the mod-
ule can be damaged by higher than normal voltages supplied via the charger.
- The SEM-Zero module should only be supplied by a traction battery. Do not use the
outputs of converters or power supplies. For special applications please contact the
nearest Zapi service centre.
- Start the machine the first time with the drive wheel(s) raised from the floor to ensure
that any installation errors do not compromise safety.
- After operation, even with the Key Switch open, the internal capacitors may remain
charged for some time. For safe operation, we recommend that the battery is discon-
nected, and a short circuit is made between Battery Positive and Battery negative
power terminals of the chopper using a Resistor between 10Ω and 100Ω.
Minimum 5 W.
- The susceptibility and electromagnetic emmission levels are seriously influenced by
installation conditions. Take particular care with the length of cables and wires,
types of electrical connections, and braided/screened wires.
Zapi declines any responsibility for incorrect or bad operation that can be attributed
to the above circumstances. Above all, the manufacturer of the machine must ensure
that the requirements of EN 50081-2 are met.

3 INSTALLATION
Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.
Apply a thin layer of thermo-conductive grease between the two surfaces to permit
better heat dissipation.
Despite the protection provided against external agents, the continuous attack of corro-
sive elements and substances may cause oxidization of connector contacts, resulting in
bad operation. Remember this point when deciding the installation position on the
vehicle.
Fix the chopper using the special holes located on the baseplate.
Verify that the wiring of the cable terminals and connectors has been carried out cor-
rectly. Ensure that suppression devices are fitted to the coils not protected by the
SEM-Zero itself.
3.1 CONNECTION CABLES
For the auxiliary circuits use cables better or equal to 0.5mm² section.
For power connections to the motor armature and battery use cable of 16mm² section.
For the Field connections use cable of 4mm² section.
For the optimum chopper performance, the cables to the battery should be run side by
side and be as short as possible.
3.2 CONTACTORS
A Line Contactor, designed for Continuous Operation should be installed. This contac-
tor should be fitted with a coil corresponding to the battery voltage. The current ab-
sorbed by the coil must not be greater than 3A.
Suppression for this contactor coil is within the chopper. Do not use external suppres-
sion. For any Contactor using external suppression, ensure that connections are made
respecting correct polarity.
3.3 FUSES
- Use a 10 A Fuse for protection of the auxiliary circuits.

- For protection of the power unit, refer to diagrams.. The Fuse value shown is the maxi-
mum 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 fused particles should the fuse blow.

3.4 DESCRIPTION OF SEM-ZERO CONNECTORS.
PIN REFERENCE DESCRIPTION

A1 HOURMETER Output hourmeter; it controls a load to -BATT. Maximum output
current 200mA.
A2 KEY B+ Supply into logic downstream of 10A fuse & key switch.
A3 NMC Negative main contactor coil.
A4 NEMB Negative electro-brake.
A5 TILLER Tiller micro-switch.
A6 -BATT -BATT.
A7 PMC Positive main contactor coil and common positive supply for REV,
FORW, B SW, HORN, LIFT, LOW microswitches.
A8 H&S Hard & Soft function input. It should be connected to A7 through
the H&S switch. Active high (+VB).
B1 CPOT Accelerator's potentiometer wiper, or output of inductive device.

B2 NPOT Provides a negative supply to accelerator's potentiometer.
B3 PPOT Provides a positive supply to accelerator's potentiometer.
B4 REV Reverse direction input, it should be connected to A7 by a micro-
switch. Active HIGH (+VB).
B5 B SW Quick inversion input, it should be connected to belly button.
Active HIGH (+VB).
B6 FORW Forward direction input. It should be connected to A7 by a micro-
switch, active HIGH (+VB).

PIN REFERENCE DESCRIPTION
C1 CM Common positive supply for micro-switch SR1, SR2, (+BATT).
C2 SR1 Input for 1st speed reduction. It should be connected to C1 by
micro-switch, active LOW.
C3 SR2 Input for 2nd speed reduction. . It should be connected to C1 by
micro-switch, active LOW.
D1 REG SIGNAL Regenerative braking status.

Normally high, low while regenerating.
D2 PHORN Positive horn, it should be connected to A7 by the horn
micro-switch.
D3 NHORN Negative horn, it is -BATT.
D4 PPC Positive pump contactor; it should be connected to A7 by lifting
micro-switch LIFT which provides the positive supply to the pump
contactor's coil.
D5 NPC-NEV Negative supply for pump contactor.
D6 PEV Positive electro-valve for lowering.
E1 PCLRXD Positive serial reception.

E2 NCLRXD Negative serial reception.
E3 PCLTXD Positive serial transmission.
E4 NCLTXD Negative serial transmission.
E5 GND Negative console power supply.
E6 +VL Positive console power supply.
E7 --- Free.
E8 --- Free.
3.5 DESCRIPTION OF POWER CONNECTIONS
+BATT = Positive Supply from Battery.

-BATT = Negative Supply from Battery.
VMN = Negative Supply (via chopper) to Motor.
F1, F2 = Connections to Drive Motor Field Winding.

3.6 MECHANICAL DRAWING & DIMENSIONS

4 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE
4.1 ADJUSTMENTS VIA CONSOLE
Adjustment of Parameters and changes to the chopper’s configuration are made using
the Digital Console. The Console is connected to the “E” connector of the SEM-Zero
Chopper.
Pay attention to the polarity of the Console Connector when connecting to
the chopper. The bevel on the connector should be uppermost.
4.2 DESCRIPTION OF CONSOLE & CONNECTION
Digital Consoles used to communicate with SEM-Zero choppers must be fitted with
Eprom CK ULTRA.
4.3 DESCRIPTION OF STANDARD CONSOLE MENU

5 SEM-ZERO: CABLING AND CONFIGURATION
5.1 POWER DIAGRAM

5.2 CONNECTIONS

5.3 DESCRIPTION OF PROGRAMMABLE FUNCTIONS (OPTIONS).
Using the CONFIG MENU of the console, it is possible to select from the following
options:
SUBMENU “SET OPTIONS”:
1 HOUR COUNTER:
- RUNNING: The counter registers travel time only.
- KEY ON: The counter registers when the key switch is Closed.
The A1 output for external hourmeter operates according to internal hourmeter. If the
pump contactor is connected (D4), hourmeter output (A1) is activated during lifting as
well.
2 QUICK INVERSION
- BELLY: Quick inversion is activated while the Belly Button is
pressed.
- TIMED: Quick inversion is activated, while the Belly Button is
pressed, maximum for 2 second.
3 AUX OUTPUT #1:
-FREE: A4 output is not used: the controller carry out monitor
function as described at the paragraph 2.5.
-BRAKE: A4 output drives an electromechanical brake. The con-
troller does not carry out monitor function, but locks the
brake while in rest or alarm status.

Flow Chart showing how to make changes to Configuration Menu using Digital Con-
sole. (Standard Eprom CK ULTRA fitted).
1) Opening Zapi Menu.
2) Press Top Left & Top Right Buttons

simultaneously to enter the Config.Menu.
3) The Display will show :
4) Press ROLL UP (Top Left Button) until

SET OPTIONS appears.
6) Press ENTER to go into this part of the menu.
7) The first “Option” of the menu appears

on the Display.
8) Press either ROLL UP or ROLL DOWN to bring

up the next the Option.
9) A new Option appears on the Display.
10) When the desired Option is displayed, press

PARAM (Top Right) or SET (Bottom Right)
button to change the configuration
11) The new Configuration for the selected

Option appears on the Display.
12) Press OUT to exit the Menu.
13) Press ENTER to accept the changes,

or Press OUT if you do not accept the
changes and wish to make further
modifications to the particular Option.
14) The Display now shows:
15) Press OUT again. Display now shows

the Opening Zapi Menu.

5.4 DESCRIPTION OF PARAMETERS THAT MAY BE PROGRAMMED
In addition to the Configuration, Parameter settings may be made by Zapi using stand-
ard default settings, settings to Customer Specifications, or the customer may make
changes according to the application, using a Digital Console.
During the setting up procedure on the machine, the Console can remain connected to
the chopper during travel. The Parameters can be modified in real time, during opera-
tion.
Pay attention to the polarity of the Console Connector. Refer to Page 15 of this Manual
for connection details.
THE PROGRAMMING CONSOLE MUST BE PLUGGED ONLY WHEN THE
KEY-SWITCH IS OFF.
The following Parameters can be modified :
1 ACC. DELAY = Determines the acceleration ramp.

2 DECELER DELAY = Determines the deceleration ramp according to the accelera-
tor pedal position.
3 RELEASE BRAKING = Determines the deceleration ramp when the travel request
is released.
4 INVERSION BRAKING = Determines the deceleration ramp the the Direction
Switch is inverted during travel.
5 SOFT BRAKING = Determines how much the brakings are reduced when the H&S
function is active.
6 SOFT ACCEL. = Determines how much the acceleration ramps are reduced when
the H&S function is active.
7 CUTBACK SPEED 1 = First speed reduction.
8 CUTBACK SPEED 2 = Second speed reduction.
9 H&S CUTBACK = Speed reduction active when the H&S function is active.
10 MAX SPEED FORW = Maximum Forward Speed, obtained by weakening the Field
Current after it has reached 100% conduction of the Armature. With the Parameter
set at level 0, the armature is in total conduction but the field current does not de-
crease below the Nominal value (low speed).
11 MAX SP FORW FINE = Maximum forward speed.Fine adjustement.
12 MAX SPEED BACK = Maximum Reverse Speed, obtained by weakening the Field
Current after it has reached 100% conduction of the Armature. With the Parameter
set at level 0, the armature is in total conduction but the field current does not de-
crease below the Nominal value (low speed).
13 MAX SP BACK FINE = Maximum reverse speed. Fine adjustement.
14 COMPENSATION = Speed compensation when load is present. It reduces the
difference between maximum speed laden and unladen.
15 MAXIMUM CURRENT = Maximum controller current.
16 ARMA NOM.CURR. = Nominal Armature Current. This parameter fixes a limit for
the armature current above which the Field Current is at least the Nominal Value
(FIELD NOM.CURR.), regardless of accelerator position.

17 WEAK DROPOUT = This Parameter fixes a limit on the Armature Current above
which the Field Current is increased linearly up to the Nominal Field Current (in
proportion to the armature current).
18 FIELD NOM. CURR. = Nominal Field Current. This parameter fixes the minimum
Field Current when the potentiometer is between 0% and 60% without total conduc-
tion of the Armature. Adjustment should be made with reference to the Data on the
Motor Label. (The indication of Nominal Field Current).
19 CREEP SPEED = Minimum Speed. This Parameter sets the minimum voltage
applied to the motor at the start of travel.

5.5 TABLE OF ADJUSTMENTS
The following Table shows the different values that the SEM2 Parameters may be
adjusted to. A suitable acceleration performance assumes: FIELD CURR. NOM is set
to level 5, and MAX SPEED (Fwd or Rev) is set to level 9.
PROGRAMMED LEVEL
PARAMETERS
UNIT 0 1 2 3 4 5 6 7 8 9
ACC. DELAY sec. 0.30 0.50 0.70 0.90 1.10 1.25 1.40 1.55 1.75 2.00
DEC. DELAY * 9 8 7 6 5 4 3 2 1 0
RELEASE BRAKING * 0 1 2 3 4 5 6 7 8 9
INVERS BRAKING * 0 1 2 3 4 5 6 7 8 9
SOFT BRAKING ** % 50 40 33 28 25 22 20 18 16 15
SOFT ACCELERATION *** % 50 40 33 28 25 22 20 18 16 15
CUTBACK SPEED 1 %ACC 30 38 45 51 57 64 72 80 90 100
CUTBACK SPEED 2 %ACC 30 38 45 51 57 64 72 80 90 100
H&S CUTBACK %ACC 30 38 45 51 57 64 72 80 90 100
MAX SPEED FORW. %FCN 100 90 80 71 62 53 45 40 36 33
MAX SP FORW. FINE **** %FCN 0 1 2 3 4 5 6 7 8 9
MAX. SPEED BACK. %FCN 100 90 80 71 62 53 45 40 36 33
MAX SP BACK. FINE **** %FCN 0 1 2 3 4 5 6 7 8 9
COMPENSATION ***** %IA 0 5 10 16 22 27 33 38 44 78
MAXIMUM CURRENT %IMax 82 84 86 88 90 92 94 96 98 100
ARMA CUR. NOM. (ACN) %IMax 45 47 50 52 54 56 58 61 63 65
WEAK DROP OUT %ACN 40 44 48 52 57 62 66 70 75 80
FIELD CURR. NOM. (FCN) A 7.5 8.1 8.7 9.3 10 10.6 11.2 11.8 12.5 13.1
CREEP SPEED %VBatt 4 5 6 7 8 9 10 11 12 13
*= If the current inclines to raise, then also the braking time raises in order to obtain
a smooth braking action. Therefore, the duration of the braking depends on
the type of motor and the operating conditions (laden, unladen, on plane, on
gradient).
**= The values in the table indicate how much the brakings (release, inversion,
deceleration) are reduced while H&S function is active.
***= The values in the table indicate how much the acceleration is reduced while H&S
function is active.
****= Is a percentage of the field current which is subtracted to the value defined by
the parameters MAX SPEED FORW and MAX SPEED BACK.
*****= Indicates the percentage of the armature current (while the machine is at con-
stant maximum speed) that is subtracted to the field current.

Flow Chart showing how to make Programme changes using Digital Console fitted with
Eprom CK ULTRA.
1) Opening Zapi Display.
2) Press ENTER to go into the General Menu.
4) Press ENTER to go into the Parameter Change facility.
5) The Display will show the first Parameter.
6) Press either ROLL UP or ROLL DOWN to display

the next parameter.
7) The names of the Parameters appear on the Display.
8) When the desired Parameter appears, the Display will

show a Level Number that will be between 0 and 9.
press either PARAM (Top Right) or SET (Bottom Right)
buttons to change the Level value.
9) The Display will show the New Level.
10) When you are satisfied with the results of the changes
you have made, Press OUT.
11) The Display asks “ ARE YOU SURE ?
12) Press ENTER to accept the changes, or Press OUT

if you do not wish to accept the changes and wish
to make further modifications to the parameters.

5.4 SEM-ZERO TRACTION STANDARD WIRING DIAGRAMS

5.5 SEQUENCE FOR SEM-ZERO TRACTION SETTINGS.
When the Key Switch is Closed, if no Alarms or Errors are present, the Console Display
will be showing the Standard Zapi Opening Display.
If the chopper is not Configured to your requirements, follow the Sequence detailed on
Page 20. Remember to re-cycle the Key Switch if you make any changes to the chop-
per’s Configuration. Otherwise follow the sequence detailed below :
1) Select the options required (Chapter 5.3).

2) Select and set the Battery Voltage.
3) Confirm correct installation of all wires. Use the Console’s TESTER function to
assist.
4) Perform the accelerator signal acquisition procedure using the Console “PRO-
GRAM VACC”.
5) Set the TRACTION IMAX Current, taking into account any Boost requirements. Use
Table on Chapter 5.5.
6) Set the Acceleration Delay requirements for the machine. Test the parameters in
both directions.
7) Set the CREEP level starting from level 0. The machine should just move when the
accelerator microswitch is closed. Increase the Level accordingly.
8) Set the Speed Reductions as required. Make adjustments to CUTBACK SP.1, 2.
Check the performance with the accelerator pedal totally depressed. If the machine
is a forklift, check the performance with and without load.
9) RELEASE BRAKING. Operate the machine at full speed. Release the accelerator
pedal. Adjust the level to your requirements. If the machine is a forklift, check the
performance with and without load.
10) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst traveling
INVERT the Direction Switch. Set a soft Level of Inversion Braking. When satisfac-
tory, operate the machine at Full Speed and repeat. If the machine is a Forklift,
repeat the tests and make adjustments with and without load. The unladen full
speed condition should be the most representative condition.
11) Set MAX SPEED FORW.
12) Set MAX SPEED BACK (Reverse).
13) Set ARMA CURR. NOM., NOM. FIELD CURR. e WEAK DROPOUT
Check the parameters meaning on Chapter 5.4.

6 SEM-ZERO DIAGNOSTICS
The following list shows likely problems associated with the flashing RED LED.
N° FLASHES MESSAGE NOTES

1 Logic failure #1: Problem with Logic or Line Contactor.
1 Watch-dog: Logic board and/or software failure.
1 EEPROM KO: Problem with EEPROM or Logic.
2 INCORRECT STARTS: Starting sequence for travel not correct.
2 FORW + BACK: Double running requests.
3 CAPACITOR CHARGE Problem in Power Block.
3 VMN NOT OK Problem with Chopper.
3 VFIELD NOT OK Problem with Field Voltage
4 VACC NOT OK Potentiometer Wiper.
4 PEDAL WIRE KO Pedal wire not OK.
5 NO FIELD CUR. Field wiring not OK or field current sensor
not OK.
5 HIGH FIELD CUR. Field wiring not OK or field current sensor
not OK.
5 STBY I HIGH High current at the stand-by sensor of arma-
ture current not OK.
5 I= 0 EVER No current: sensor of armature current not
OK.
6 CONTACTOR DRIVER Contactor Driver not OK.
6 COIL SHORTED Coil contactor shorted.
6 CONTACTOR CLOSED Line Contactor contact not OK.
7 TH. PROTECTION Temperature too much high (>70°C) or low
(<10°C).
32 BATTERY LOW Battery too low.

6.1 ANALYSIS OF ALARMS DISPLAYED ON THE CONSOLE
1 LOGIC FAILURE #1
This test is carried out at the start-up.
Possible cause: failure of the logic board
2 WATCH DOG
The test is executed at the key turn-on, at the stand-by and on running. Possible
causes:
a) Watch-dog hardware circuit not OK;
b) Software not OK.
3 EEPROM OK
Fault in the area of memory where the adjustment parameters are stored. This
Alarm inhibits machine operation. If the fault continues when the Key Switch is re-
cycled, replace the logic. If the fault disappears, the previously stored Parameters
will have been replaced by the default parameters.
4 INCORRECT START
Alarm generated by an incorrect Starting Sequence. Possible causes:
a) The ENABLE microswitch has welded or failed.
b) Error in the starting sequence from the operator.
c) Error in the wiring.
5 FORW + BACK
This check is made continually. The alarm is generated when forward and reverse
direction are requested simultaneously. Possible causes:
a) Error in Wiring.
b) Welding or Failure of a direction switch.
c) Error in the starting sequence from the operator.
6 CAPACITOR CHARGE
This check is made during the initial diagnosis. This Alarm is generated if the Ca-
pacitors are not charged within 500ms after the Key Switch is closed. Probable
cause is failure inside the power block.
7 VMN NOT OK
This test is performed at rest, with the general Contactor Closed, and also during
operation. At rest if VMN is lower than battery voltage this Alarm is generated.
During operation this Alarm is generated if VMN doesn’t follow the duty-cycle of the
chopper. Possible causes:
a) Incorrect Motor connection.
b) Short circuit motor windings to chassis.
c) Defect in the power unit.

8 VFIELD NOT OK
This test is made at standby with the Line Contactor open. In this condition the
voltages on both the connections of field must be to around ½ VBatt. This alarm is
generated if the field voltage is different from this value. Possible causes:
d) Frame fault on the motor to chassis;
e) Incorrect connection of the field winding to the controller;
f) Failure of the controller in the section relative to the field.
9 VACC NOT OK
This Alarm is generated if the accelerator output voltage differs more than 2V from
the acquired minimum during the PROGRAM VACC. Possible causes:
a) the track of the potentiometer has become open.
b) the potentiometer is not wired correctly.
c) the potentiometer itself is defective.
d) the values set in PROGRAM VACC routine have not remained or made
correctly.
10 PEDAL WIRE KO
This Alarm is generated if potentiometer or wiring fault is detected. (NPOT or PPOT
are open circuit).
11 STBY I HIGH
This test is made during the initial diagnosis and at standby. The test verifies that
the current is zero. This Alarm disables the machine. Possible causes:
a) defective current sensor.
b) logic failure. First replace the logic. If fault remains replace the power unit.
12 I = 0 EVER
This check is made during travel. If the current is not higher than a preset minimum
value, this Alarm is generated and the machine disabled. Possible causes: see
STBY I HIGH. Check the motor armature (brush connections).
13 HIGH FIELD CUR, NO FILD CUR
Problem detected with the field winding current. Possible causes:
a) Failure of the field current sensor.
b) Field cables not connected or incorrectly connected.
c) Failure of the Field Power Unit.
14 CONTACTOR DRIVER, COIL SHORTED, DRIVER SHORTED
These Alarms are generated if there is a problem with the General or Line Contac-
tor. Possible causes:
a) The coil of the contactor is either short-circuit, open circuit, or not connected.
b) The Contactor Coil Driver is short-circuit.
c) Defect in the wiring to the contactor, or logic failure.

15 CONTACTOR CLOSED
This check is made during the initial diagnosis. With the coil of the line contactor de-
energized, the capacitors should not be charged, unless there is divert resistor
across the power poles. Possible causes:
a) The line contactor power poles are welded.
b) This alarm could be generated even if the line contactor has opened, but there is
a problem with either the field circuit, or a problem detected by the safety micro-
processor.
16 TH. PROTECTION
If the temperature of the chopper rises higher than 70°C, this alarm is generated.
The chopper current is reduced in proportion to the increase in temperature. At
80°C the chopper totally stops. If the temperature of the chopper is <- 10°C, this
Alarm is also generated and the current is reduced by 80 %. If this alarm is dis-
played when the chopper is temperature is the same as ambient or better than zero
degrees:
a) Check the connection of the temperature sensor.
b) The temperature sensor may be defective.
c) The logic may be defective.
17 BATTERY LOW
This Alarm is generated when the battery becomes 50% discharged from the nomi-
nal value.

6.2 TESTER DESCRIPTION OF THE FUNCTIONS
The most important input or output signals can be measured in real time using the
TESTER function of the console. The Console acts as a multimeter able to read volt-
age, current and temperature. The following definition listing shows the relative meas-
urements :
1) BATTERY VOLTAGE: level of battery voltage measured at the input to the key
switch.
2) MOTOR VOLTAGE: the voltage appearing across the drive motor. It is measured
between B+ and VMN.
3) MOTOR CURRENT: the current flowing in the drive motor armature.
4) FIELD CURRENT: the current flowing in the drive motor field winding.
5) VMN: the voltage effectively dropped across the MOS. It is measured between B-
and VMN.
6) TEMPERATURE: the temperature measured on the aluminum heat sink holding the
MOSFET devices.
7) ACCELERATOR: the voltage of the accelerator potentiometer wiper (CPOT).
The voltage level is shown on the Left Hand Side of the Console Display and the
value in percentage is shown on the Right Hand Side.
8) FORWARD SWITCH: the level of the Forward direction digital entry MA (pin B6).
ON /+ VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
9) BACKWARD SWITCH: the level of the Reverse direction digital entry MI (pin B4).
ON /+ VB = active entry of closed switch.
OFF / GND = non active entry of open switch.
10) HANDLE/SEAT SWITCH: the level of the Handle/Seat Microswitch digital entry
(pin A5).
ON / + VB = active entry of closed seat switch.
OFF / GND = non active entry of open seat switch.
11) QUICK INVERSION: the level of the digital entry from Belly Button microswitch
(pin B5).
ON /+ VB = active entry, B SW closed.
OFF / GND = non active entry, B SW open.
12) CUTBACK SWITCH 1: the level of the Speed Reduction 1 Microswitch SR1.
ON / GND = active entry of speed reduction microswitch.
OFF / + VB = non active entry of microswitch.
13) CUTBACK SWITCH 2: the level of the Speed Reduction 2 Microswitch SR2.
ON / GND= active entry of speed reduction microswitch.
OFF / +VB = non active entry of microswitch.

Flow Chart showing how to use the TESTER function of the Digital Console.
2) Press ENTER to go into the General menu.
4) Press either ROLL UP or ROLL DOWN button until

TESTER MENU appear on the display.
5) The Display shows :
6) Press ENTER to go into the TESTER function.
7) The first variable to be tested is shown on the Display.
8) Press either ROLL UP or ROLL DOWN buttons until your

desired variable for measurement appears on the Display.
9) Next variable is shown.
10) When you have finished, Press OUT.
11) The Display shows :
12) Press either ROLL UP or ROLL DOWN button to show other MENU or press OUT
to finish.
Remember it is not possible to make any changes using TESTER. All you can do is
measure as if you were using a pre-connected multimeter.

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

SAVE PARAM. is shown.
6) Press ENTER to go into the SAVE function.
7) If this facility has been used before the type

of chopper data stored appears on the top line with
a 2 digit reference.
8) Keep pressing either ROLL UP or ROLL DOWN keys until

the second line indicates a FREE storage facility.
9) Press ENTER to commence SAVE routine.
10) You can see the items that are being stored whilst
the SAVE routine is happening.
11) When finished, the Console shows :
12) Press OUT to return to the Opening Zapi Display.

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

RESTORE PARAM. appears on the display.
6) Press ENTER to go into the RESTORE PARAM. function.
7) The Display shows the type of Model stored,

with a Code Number.
8) Keep pressing either ROLL UP and ROLL DOWN buttons

until the desired model appears on the Display.
9) The model is shown
10) Press ENTER to commence the Restore operation.
11) The Display will ask “ARE YOU SURE”.

Press ENTER for YES, or OUT for No.
12) Press ENTER to confirm (OUT to not confirm)
13) You can see the items that are being stored in
the chopper memory whilst the RESTORE
routine is happening.
14) When finished the Console displays :
15) Press OUT to return to the Opening Zapi Display .

6.5 DESCRIPTION OF ALARMS MENU.
The microprocessor in the chopper remembers the last five Alarms that have occurred.
Items remembered relative to each Alarm are : the code of the alarm, the number of
times the particular Alarm occurred, the Hour Meter count, and the chopper tempera-
ture.
This function permits a deeper diagnosis of problems as the recent history can now be
accessed.
Flow Chart showing how to use the ALARMS function via the Digital Console.
4) Press ROLL UP or ROLL DOWN button until

PARAMETER CHANGE appears on the display.
5) The Display will show:
6) Press ENTER to go into the ALARMS function.
7) The Display will show the most recent Alarm.
8) Each press of the ROLL UP button brings up following Alarms.

Pressing ROLL DOWN returns to the most recent.
9) If an Alarm has not occurred, the Display will show:

ALARM NULL.
10) When you have finished looking at the Alarms, press OUT
to exit the ALARMS menu.
11) The Display will ask CLEAR LOGBOOK ?
12) Press ENTER for yes, or OUT for NO.
13) Press OUT to return to the Opening Zapi Display.

6.6 DESCRIPTION OF CONSOLE PROGRAM VACC FUNCTION.
This function looks for and remembers the minimum and maximum potentiometer wiper
voltage over the full mechanical range of the pedal. It enables compensation for non
symmetry of the mechanical system between directions.
The operation is performed by operating the pedal after entering the PROGRAM VACC
function.
Flow Chart showing how to use the PROGRAM VACC function of the Digital Console.
2) Press ENTER to go into the General Menu.
4) Press ROLL UP or ROLL DOWN button until

PROGRAM VACC appears on the display.
5) Tthe Display will show :
6) Press ENTER to go into the PROGRAM VACC routine.
7) The Display will show the minimum and maximum

values of potentiometer wiper output. Both directions can
be shown.
8) Press ENTER to clear these values.
9) Display will show 0.0.
10) Select Forward Direction, close any interlock switches

that may be in the system. Slowly depress the accelerator
pedal (or tiller butterfly) to its maximum value. The new
minimum and maximum voltages will be displayed on
the Console plus an arrow indicating the direction.
11) Select the Reverse Direction and repeat Item 10.
12) When finished , press OUT.
13) The Display will ask : ARE YOU SURE ?.
14) Press ENTER for yes, or OUT for NO.
15) Press OUT again to return to the Opening Zapi Menu.

7 RECOMMENDED SPARE PARTS FOR SEM-ZERO
Part Number Description
C16519 Protected 150A Fuse.
C16503 Protected 200A Fuse
C16520 10 A 5x20mm Control Circuit Fuse
P99060 Red LED
C12372 8 Way Molex Connector
C12769 Insert for Molex Connectors
C29543 SW 80 24V CO
Single Pole Contactor

8 PERIODIC MAINTENANCE TO BE REPEATED
AT TIMES INDICATED
Check the wear and condition of the Contactors’ moving and fixed contacts.
Electrical Contacts should be checked every 3 months.
Check the Foot pedal or Tiller microswitch. Using a suitable test meter, confirm that
there is no electrical resistance between the contacts by measuring the volt drop be-
tween the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the chopper, and cables to the motor. Ensure the
insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller . Are the return springs ok. Do
the potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be free
to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement parts used
should be original. Beware of NON ORIGINAL PARTS.
The installation of this electronic controller should be made according to the diagrams
included in this Manual. Any variations or special requirements should be made after
consulting a Zapi Agent. The supplier is not responsible for any problem that arises
from wiring methods that differ from information included in this Manual.
During periodic checks, if a technician finds any situation that could cause damage or
compromise safety, the matter should be bought to the attention of a Zapi Agent imme-
diately. The Agent will then take the decision regarding operational safety of the ma-
chine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

ELECTRONIC INDUSTRIAL DEVICES
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259
INSTALLATION AND
USER MANUAL
CHOPPER SEM-ZERO

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INDEX

ACLZP0CB - SEM-ZERO - User manual Page 1 of 38

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

ENGINEERING SECTION EXECUTIVE

Pubblication n°: ACLZP0CB

COLOUR CODES (SINGLE COLOURS)

ACLZP0CB - SEM-ZERO - User manual Page 3 of 38

The design has been derived from:

ACLZP0CB - SEM-ZERO - User manual Page 4 of 38

2.1 TECHNICAL SPECIFICATION

Chopper for Separately Excited DC motors ...................................................0.5 ÷ 2.0kW

24 / 36V 150A (3') 180A (10'') 0.23V at 50A, 25°C

24 / 36V 200A (2') 230A (10") 0.23V at 50A, 25°C

2.2 CONTROL UNITS

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ACLZP0CB - SEM-ZERO - User manual Page 6 of 38

2.4 DIRECTION ORIENTATION

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ACLZP0CB - SEM-ZERO - User manual Page 8 of 38

2.7 THERMAL CONSIDERATIONS

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3.1 CONNECTION CABLES

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

ACLZP0CB - SEM-ZERO - User manual Page 11 of 38

PIN REFERENCE DESCRIPTION

B1 CPOT Accelerator's potentiometer wiper, or output of inductive device.

ACLZP0CB - SEM-ZERO - User manual Page 12 of 38

D1 REG SIGNAL Regenerative braking status.

E1 PCLRXD Positive serial reception.

3.5 DESCRIPTION OF POWER CONNECTIONS

+BATT = Positive Supply from Battery.

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ACLZP0CB - SEM-ZERO - User manual Page 14 of 38

4.1 ADJUSTMENTS VIA CONSOLE

4.2 DESCRIPTION OF CONSOLE & CONNECTION

ACLZP0CB - SEM-ZERO - User manual Page 16 of 38

5.1 POWER DIAGRAM

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SUBMENU “SET OPTIONS”:

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1) Opening Zapi Menu.

2) Press Top Left & Top Right Buttons

3) The Display will show :

4) Press ROLL UP (Top Left Button) until

5) The Display will show :

6) Press ENTER to go into this part of the menu.

7) The first “Option” of the menu appears

8) Press either ROLL UP or ROLL DOWN to bring

9) A new Option appears on the Display.

10) When the desired Option is displayed, press

11) The new Configuration for the selected

12) Press OUT to exit the Menu.

13) Press ENTER to accept the changes,

14) The Display now shows:

15) Press OUT again. Display now shows

ACLZP0CB - SEM-ZERO - User manual Page 20 of 38

The following Parameters can be modified :