Index

1 General characteristics ................................................................................. 3

1.1 Technical specifications............................................................................. 3
1.2 General description ................................................................................... 3
1.3 Main features ............................................................................................. 3
1.4 Safety & protection features ...................................................................... 4
1.5 Thermal considerations ............................................................................. 4
1.6 Combi Sem-1 chopper diagnosis .............................................................. 5
1.7 Main Contactor and emergency switch .............................................. 5

1.8 General instructions and precautions ................................................. 6

2 Installation...................................................................................................... 7
2.1 Connection cables ..................................................................................... 7
2.2 Contactors ................................................................................................. 7
2.3 Fuses ......................................................................................................... 7
2.4 Combi Sem-1 controller mechanical drawing ............................................ 8
2.5 Serial tiller mechanical drawing ................................................................. 9
3 Connection ................................................................................................... 10
3.1 Combi Sem-1 connection drawing ........................................................... 10
3.2 Serial tiller connection drawing ................................................................ 11
3.3 Description of combi sem-1 connectors .................................................. 12
3.3.1 Connector "A" description .......................................................... 12
3.3.2 Connector "B" description .......................................................... 12
3.3.3 Connector "C" description .......................................................... 13
3.3.4 Connector "D" description .......................................................... 14
3.3.5 Connector "E" description .......................................................... 14
3.3.6 Connector "F" description ........................................................... 16
3.4 Combi Sem-1 power connection ............................................................. 16
4 Regulation .................................................................................................... 17
4.1 Zapi Programming handly console .......................................................... 17
4.2 Description of standard console menu .................................................... 18
4.3 "Parameter Change" menu ...................................................................... 19
4.4 "Tester" menu .......................................................................................... 20
4.5 "Adjustment" menu .................................................................................. 21
4.6 "Set Option" menu ................................................................................... 21
4.7 Special adjust menu ................................................................................ 23
4.8 Hardware setting menu ........................................................................... 23
5 Alarms .......................................................................................................... 24
6 Recommended spare parts ........................................................................ 28
7 Periodic maintenance to be repeated at times indicated ......................... 29

Page 1
 = The informations included into the marked paragraphs by this symbol are
essential for the safety.

SIGNATURES TABLE

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

ENGINEERING SECTION EXECUTIVE

EXPORT MANAGER

Publications N°: AD3NA0AB

Edition: April 2004
Page 2
 1 GENERAL CHARACTERISTICS
1.1 TECHNICAL SPECIFICATIONS

Motor Types (Traction): .............................................................................. DC SEM

Motor Types (Pump): ............................................................................. DC SERIES
Power ratings (Traction): ........................................................................... 1 to 2 kW
Supply Voltage: .................................................................................................. 24V
Armature Switching frequency: ..................................................................... 16 kHz
Field Switching frequency: ............................................................................ 800 Hz
Temperature range: ....................................................................... -30 °C to +40 °C
Maximum controller temperature: .................................................................... 75 °C

Version Maximum Traction current Maximum Pump current

200+250 200 A 250 A
300+300 300 A 300 A
400+250 400 A 250 A

1.2 GENERAL DESCRIPTION

ZAPI COMBI SEM-1 controller performs all the electric functions that are usually
presents in transpallet, stacker, low order picker etc.
The controller can perform the following functions:
- Traction controller for SEM motor; full-bridge on the field, half-bridge on the armatu-
re.
- Lifting controller for series excited motors.
- Drivers for ON/OFF electrovalves and for one proportional valve (electrodistributor)
- Interface for serial tiller head
- MDI interface (Multifunction Digital Instrument) battery discharge indicator,
hourmeter, alarms, programmed maintenance.

1.3 MAIN FEATURES

- High frequency MOSFET controller (high efficiency, silent, etc.).

- Speed control with regenerative braking (controls the truck also on the slope)
- Hydraulic functions control with different programmable speeds and ramps, It is
possible to use proportional functions.
- Lowering speed control through proportional valve.
- All the parameters are programmable by means of the ZAPI console.
- Complete diagnosis through console or MDI.
- High temperature protection with current reduction.
- Drivers real time diagnosis (electro-brake, general contactor and proportional valve.
- Electrobrake and general contactor are controlled with a PWM.
- Drivers protected against short-circuits.
Page 3
 1.4 SAFETY & PROTECTION FEATURES

- Reverse Battery Polarity

Electrical Circuit diagrams must be followed in order to avoid damage to the power
unit. A Main contactor, controlled by the logic unit, is necessary to protect the system
against reverse battery polarity.
- Connection errors
All inputs are protected against connections errors. Contactor drivers are suitable for
loads up to 2 Amps, and are protected against overload.
- Thermal protection
If the controller temperature exceeds 77°C, the maximum current will be reduced
proportionally to the thermal increase. The temperature can never exceed 90°C.
- Low Battery charge
When the battery charge is low, the maximum current is reduced.
- External Agents
The chopper is protected against dust and spray of liquid to a degree of protection
meeting IP64.
- Protection against accidental Start Up
A precise sequence of operations is necessary before the machine starts. If these
operations are not carried out correctly the machine stops. Driving requests must be
made after closing the Key Switch.
- Protection against uncontrolled movements.
The Main Contactor will not close if:
- The Power Unit is not operating correctly.
- The Logic Unit is not operating correctly.
- The Serial Tiller is not operating correctly.

1.5 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
situations where either ventilation is poor, or heat exchange is difficult, forced air
ventilation should be used.
- The thermal energy dissipated by the power block module varies and is dependent
on the current drawn and the duty cycle.

Page 4
 1.6 COMBI SEM-1 CHOPPER DIAGNOSIS

The microprocessor continually monitors the chopper and carries out diagnostic
procedures on the main functions.
The diagnosis is made in 4 points:
1) Diagnosis on key switch closing that checks: watch-dog, Current Sensors, VMN
point, contactor drivers, presence of a start requirement, and connection with the
Serial Tiller.
2) Standby Diagnosis that checks: watch-dog, VMN Point, Contactor Drivers, Current
Sensors.
3) Driving diagnosis that checks: Watchdog, VMN Point, Current, Contactor(s).
4) Continuos Diagnosis that checks: Chopper temperature, Battery Voltage.

1.7 MAIN CONTACTOR AND EMERGENCY SWITCH

- Battery disconnection should be made according to the drawing below.

- In order to avoid damage to the controller during the regenerative phase, the Key
Switch must be cut off at the same time.

Wiring with cut off in series to positive supply.

- An internal protection is activated when the voltage on B12 connector is greater than
1,3 time of the battery voltage, or when the key switch is opened.

Page 5
 1.8 GENERAL INSTRUCTIONS AND PRECAUTIONS

- In the first instance, start the machine with the drive wheels raised from the floor to
ensure that any installation error 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
disconnected, and a short circuit is made between Battery Positive and Battery Ne-
gative power terminals of the chopper using a Resistor between 10W and 100W.
Minimum 5 W.
- The susceptibility and electromagnetic emission 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 12895 are met.

Page 6
 2 INSTALLATION

Install the chopper baseplate onto a flat metallic surface that is clean and unpainted.
Apply a very 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 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 (maximum screwing
torque: 3 Nm for M5 and 4Nm for M8 screws).
Verify that the wiring of the cable terminals and connectors has been carried out
correctly.

2.1 CONNECTION CABLES

For the auxiliary circuits use cables bigger or equal to 0.5mm2 section.
For power connections to the motor (pump and traction rotor) and to the battery use
cables of 16÷25 mm2 section. The cables from chopper to battery should be run side by
side and be as short as possible.

2.2 CONTACTORS

A Main Contactor, designed for Continuous Operation should be installed. This

contactor should be fitted with a coil corresponding to the battery voltage. The current
absorbed by the coil must not be greater than 2A.
Suppression for this contactor coil is inside the chopper logic. Do not use any
additional external suppression.

2.3 FUSES

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

- The power fuse is already installed on the chopper by Zapi. For special applications
or requirements this value can be reduced.

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 2.4 COMBI SEM-1 CONTROLLER MECHANICAL DRAWING

Page 8
2.5 SERIAL TILLER MECHANICAL DRAWING

Page 9
 3 CONNECTION
3.1 COMBI SEM-1 CONNECTION DRAWING

Page 10
 3.2 SERIAL TILLER CONNECTION DRAWING
The following drawing is an example of typical tiller head functions.

Page 11
 3.3 DESCRIPTION OF COMBI SEM-1 CONNECTORS

3.3.1 Connector "A" description

The "A" connector is connected by Zapi.

A1 KEY OUT This pin is connected to the pin1 of the F connector; is a key signal.
A2 BACKING This pin is connected to the pin2 of the F connector; is a backing
signal.

3.3.2 Connector "B" description

The "B" connector managed the main contactor, the brake and the electrovalves coils.

B1 + BATT Positive after the main contactor; is the electrovalves positive.

B2 NMC Negative of the main contactor
B3 -BATT Negative free for the customer.
B4 -BATT Negative free for the customer.
B5 NEB Negative of the electromechanical brake.
B6 NEVP Negative of the proportional electrovalve.
B7 NEV2-NHO Negative of the electrovalve 2; (option: negative of the horn).
B8 NEV1 Negative of the electrovalve 1.
B9 NEV4 Negative of the electrovalve 4.
B10 NEV3 Negative of the electrovalve 3.
B11 NEV5 Negative of the electrovalve 5.
B12 KEY IN Input of the Key switch signal.

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B13 PMC Positive of the main contactor.
B14 KEY OUT Output of the Key switch signal.
B15 NOT USED Free.
B16 PEB Positive of the electromechanical brake.
B17 PEVP Positive of the proportional electrovalve.
B18 PEV2 Positive of the electrovalve 2.
B19 PEV1 Positive of the electrovalve 1.
B20 PEV4 Positive of the electrovalve 4.
B21 PEV3 Positive of the electrovalve 3.
B22 PEV5 Positive of the electrovalve 5.

Note:
Proportional valve can be programmed by console as proportional or ON/OFF: if
proportional the valve has an acceleration and deceleration ramp and its current is
controlled by the lifting potentiometer.
If ON/OFF the valve is completely opened/closed without ramps.
The positive supply to the main contactor is provided from the key (pin 12) trough a
diode against polarity inversion. The positive supply for the electrobrake is available in
the pin 16 only if the tiller switch is closed.
The positive for the brake and all the other ON/OFF valves comes from the main
contactor, so these loads do not affect the key input but only the auxiliary fuse.

3.3.3 Connector "C" description

The "C" connector manages the serial link of the tiller card.

C1 -BATT Negative free for the customer.

C2 BELLY Quick inversion microswitch input. This signal is directly connected
with the Combi for safety reason.
C3 SNAIL + T Snail microswitch input. It is necessary that the tiller microswitch is
cabled in the serial tiller card; in this case it is possible to run the
truck also with the handle released at a slow speed.
C4 TILLER Tiller microswitch input. In this case the tiller is directly connected
with the Combi.
C5 DRFT Data from the serial tiller
C6 -BATT Negative for the serial tiller card.
C7 KEY OUT Positive for the serial tiller card (is a key switch signal).
C8 KEY OUT Positive for the tiller microswitch (is a key switch signal).

Note:
The tiller microswitch can be cabled in the serial tiller (see ‘serial tiller’ drawing) or
directly in the controller (PIN 4 and 8 for the key in the serial tiller).

Page 13
3.3.4 Connector "D" description

The "D" connector manages the MDI instrument or a Zapi console.

D1 NOT USED Free.

D2 PCLRXD Positive of the reception from the console or the MDI instrument.
D3 -BATT Negative of the console or the MDI instrument.
D4 +12 Positive of the console or the MDI instrument.
D5 NOT USED Free.
D6 NOT USED Free.
D7 NCLTXD Negative of the transmission to the console or the MDI instrument.
D8 PCLTXD Positive of the transmission to the console or the MDI instrument.
D9 NCLRXD Negative of the reception from the console or the MDI instrument.
D10 NOT USED Free.

Note:
The console must be connected to "D" at the place of MDI by means of an adapter
(follow the table for the right connections).

3.3.5 Connector "E" description

The "E" connector manages the inputs from the chassis of the truck.

E1 INPUT 1 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E2 -BATT Negative free for the customer.
E3 CM Positive for the "Input 2"; is a key switch signal interrupted by a diode
for safety reason.

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E4 INPUT 3 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10 (CUTBACK SPEED).
E5 -BATT Negative free for the customer.
E6 INPUT 4 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10 (BATTERY MODEL).
E7 CM Positive for the "Input 5"; is a key switch signal interrupted by a diode
for safety reason.
E8 CM Positive for the "Input 6"; is a key switch signal interrupted by a diode
for safety reason.
E9 SELECT 1 This is a digital input for model configuration.
E10 SELECT 2 This is a digital input for model configuration.
E11 CM Positive for the "Input 1"; is a key switch signal interrupted by a diode
for safety reason.
E12 -BATT Negative free for the customer.
E13 INPUT 2 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E14 CM Positive for the "Input 3"; is a key switch signal interrupted by a diode
for safety reason.
E15 -BATT Negative free for the customer.
E16 CM Positive for the "Input 4"; is a key switch signal interrupted by a diode
for safety reason.
E17 INPUT 5 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10 (LIFTING BLOCK).
E18 INPUT 6 This is a digital input free for customer request. The meaning
depends on the software installed (made by Zapi) and the model
selected with the input E9 and E10.
E19 -BATT Negative of the "Select 1" input.
E20 -BATT Negative of the "Select 2" input.

Note:
For the inputs is acceptable a PNP sensor with a 24V output. The maximum load for
single inputs is less than 5mA.

Page 15
3.3.6 Connector "F" description

The "F" connector is connected by Zapi.

F1 KEY OUT This pin is connected to the pin1 of the A connector; is a key signal.
F2 BACKING This pin is connected to the pin2 of the A connector; is a backing
signal.

3.4 COMBI SEM-1 POWER CONNECTION

+BATT before FUSE Positive of the battery after the main contactor
+BATT after FUSE Positive of the battery after the main cont. and after the fuse.
-BATT Negative of the battery.
F1, F2 Field connections for traction motor.
VMNT Traction motor current sensor input.
VMNP Pump motor input (without the current sensor).

Page 16
 4 REGULATION
4.1 ZAPI PROGRAMMING HANDLY CONSOLE

In Combi Sem-1 controller is possible to program several functions through the console.
In this way is possible to modify the performances of the truck following the customer
needing.

The console can remain connected to the controller while running and the parameters
can be changed in real time. In this case it is important to go in stand by condition
before switch off the controller in order to give the possibility to store the new values in
the Eeprom.

This section describes the ZAPI console functions.

Six buttons provide the capability of changing or reading the parameter of the Combi:

1 Roll-Up push to scroll up the submenu and to select a parameter;

2 Roll-Down push to scroll down the submenu and to select a parameter;
3 Enter push to have access to the selected submenu or to confirm a
changement;
4 Out push to exit the selected menu or to refuse a changement;
5 Set-Up push to increase a parameter;
6 Set-Down push to decrease a parameter;

Note: After a modify, memorize the new value pushing the "4" (Out) button and the "3"
(Enter) button. Double pushing of the "4" (Out) button doesn't save the value.

Numbers inside the triangles in the following map correspond to the same number on
the console keyboard buttons shown in the figure below. The orientation of the triangle
indicates the way to the next function.

Important
CONNECT AND DISCONNECT THE CONSOLE ONLY WITH THE CONTROLLER
SWITCHED OFF.

Page 17
 4.2 DESCRIPTION OF STANDARD CONSOLE MENU

Page 18
 4.3 "PARAMETER CHANGE" MENU

The following parameters are an example of a typical Parameter Change menu; some
of this parameters could be changed from customer requests.
The parameters with (p) symbol are related to the pump, those with (t) are related to the
traction motor.

COMBI has a software protection of the parameters:

* the protection is an OEM password: without introducing this password only a few
parameters can be seen on the console. With this password all parameter are visible,
but not all parameters can be changed
For every parameter in the following list, There is an indication of its security state:
F = free parameter
O = OEM password needed

1) ACCELERATION DELAY (t) = Sets the acceleration ramp. (F).

2) FLD ACCELERATION (t) = Field acceleration ramp: is the time needed to lower the
field till to the weakened value, is a function of "Acceler. delay". (O).
3) DECELERATION DELAY (t) = Sets the deceleration ramp according to the
accelerator potentiometer position. (F).
4) RELEASE BRAKING (t) = Sets the deceleration ramp when the driving request is
released. (F).
5) INVERS BRAKING (t) = Sets the deceleration ramp when is inverted the driving
direction. (F).
6) CUTBACK SPEED 1 (t) = Speed reduction 1. (O).
7) MAX. SPEED FORW. (t) = Maximum Forward speed, obtained by weakening the
field current after reaching 100% conduction on the armature. With the parameter
set at level 0, the armature is in full conduction but the field current does not
decrease below the nominal value (low speed). (F).
8) MAX SPEED BACK (t) = Maximum Reverse speed, obtained by weakening the
field current after reaching 100% conduction on the armature. With the parameter
set at level 0, the armature is in full conduction but the field current does not
decrease below the nominal value (low speed). (F).
9) TRACTION I MAX (t) = Sets the maximum current of the Chopper (Armature). (O).
10) ARMA NOM. CURR (t) = 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. (O).
11) WEAK DROPOUT (t)= This parameter fixes a limit on the armature current above
which the field current is increased linearly up to the nominal field current
(proportionally to the armature current). (O).
12) FIELD CURR. MAX. (t) = Maximum field current. This parameter fixes the
maximum field current when the armature reaches the maximum value. (O).
13) FIELD NOM. CURR. (t)= Nominal field current. This parameter fixes the minimum
field current when the accelerator is between 0% and 60% without full conduction

Page 19
 on the armature. Adjustment should be made with reference to the data on the
motor label. (The indication of Nominal Field Current). It's a function of FIELD
CURR MAX. (O).
14) CREEP SPEED (t)= Minimum speed. This parameter sets the minimum start
voltage applied to the motor. (O).
15) SOFT WORKING (t) = Sets the entity of the acceleration and deceleration curves
with the Snail (H&S) function selected. (O).
16) PUMP ACC DELAY (p) = Pump motor acceleration time: during this time the
voltage on the pump motor goes to the desired value. (O).
18) PUMP DEC DELAY (p) = Pump motor deceleration time: during this time the
voltage on the pump motor decreases to the desired value. (O).
19) PUMP CREEP (p) = This parameter sets the minimum voltage applied to the pump
motor. (O).
20) 1ST SPEED COARSE (p) = Main lift maximum speed. (O).
21) FORK LIFT SPEED (p) = Forks lift maximum speed. (O).
22) EVP ACC. DELAY (p) = Sets the acceleration time of the EVP. (O).
23) EVP DEC. DELAY (p) = Sets the deceleration time of the EVP. (O).
24) LIFT MAX TIME (p) = Sets the maximum lifting time. The timer is cleared after a
lowering function selection. (O).

4.4 "TESTER" MENU

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
voltage, current and temperature.

Page 20
 4.5 "ADJUSTMENT" MENU

1 ADJUST BATTERY = Battery voltage reading adjustment according with the real
battery voltage. (O).
2 ADJUSTEMENT #01 = Sets the maximum value of the battery discharge curve. (O).
3 ADJUSTEMENT #02 = Sets the minimum value of the battery discharge curve. (O).
4 MIN VALVE VOLT = Sets the minimum voltage applied to the EVP. (O).
5 MAX VALVE VOLT = Sets the maximum voltage applied to the EVP. (O).
6 AUX VOLTAGE #1 = Sets the maximum voltage applied to the EVP when fork
lowering function is selected. (O).
7 THROTTLE 0 ZONE = Sets a dead zone in the pedal. (O)
8 THROTTLE X POINT = Sets the X point of the pedal conversion curve (pedal input
voltage at which the output is Y point voltage). (O)
9 THROTTLE Y POINT = Sets the Y point of the pedal conversion curve (pedal
output voltage at which the input is X point voltage). (O)

4.6 "SET OPTION" MENU

1 HOUR COUNTER
Keyon hourmeter always updated with main contactor closed. (O).
Running hourmeter updated only if traction, lifting or hydraulics functions are
activated. (O).
2 BATTERY CHECK
On the battery discharge level check is carried on; when the battery level
reaches 20%, an alarm is signaled, the maximum current is reduced
to the half of the programmed value and lift is blocked. (O).
Off the battery discharge level check is carried on but no alarm is
signaled. At 20% maximum current is reduced to the half of the
programmed value. (O).

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3 AUX FUNCTION 2
Present Proportional electrovalve present on B6 output. (O).
Absent Proportional electrovalve not present. B6 output will be driven like an
On/Off electrovalve. (O).
4 LIFTING BLOCK
On The lifting block input switch is enabled. (O).
Off Lifting block input switch disabled. (O).
5 QUICK INVERSION
Belly the truck goes backward direction (at 50% of maximum speed) till the
belly button is pressed. (O).
Timed the truck goes backward direction (at 50% of maximum speed) only
for some seconds and with belly button pressed. (O).
6 AUX FUNCTION #1
On the Combi hour-meter is immediately over-written by that of MDI
instrument. (O).
Off In this configuration the alarm "AL94" will be displayed on the MDI for
1 minute. If during this minute the user doesn't set ON the "Aux
function #1", the MDI hour-meter will be over-written by that of the
controller. (O).
7 CHECK UP DONE
On This option enables to reset the check-up hour-meter and the alarm
"Check Up Needed". (O).
Off This function is disabled. (O).
8 CHECK UP ENABLE
On This function sets an alarm (wrench ON on MDI, Check Up Needed
on ZAPI console) after 250 hours which informs the operator that it is
necessary to make assistance service on the machine. (O).
Off This function is disabled. (O).
9 BATTERY TYPE
12V 12V Battery. (O).
24V 24V Battery. (O).
10 DRIVE MODES
On The truck has three performance modes, each with a fixed set of
parameters. This function is enabled by setting
DRIVE MODES = ON. (F).
Off DRIVE MODES disabled. (F).
11 BRAKE IN RELEASE
On The electrobrake is used during release braking to increase the
braking strength. (O).
Off The electrobrake is used only at the end of the braking. (O).

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 4.7 SPECIAL ADJUST MENU

1 SET TEMPERATURE = adjust the temperature value of the chopper thermal

sensor.

4.8 HARDWARE SETTING MENU

1 PERFORMANCE TYPE = sets the performance of the truck; works only with DRIVE
MODE option "ON".
2 SET CURRENT = sets the armature maximum current for the ZAPI console tester
menu.
3 SET FIELD CURR = sets the field maximum current for the ZAPI console tester
menu.
4 FIELD CURR MIN = sets the minimum field value of the chopper independently
from FIELD CUR NOM, FIELD CURR MAX, MAX SPEED F/B parameters.

HOW TO INSERT PASSWORD (OEM)

* Select the READ EEPROM menu
* Select the address F000 with the UP/DOWN/ROLL UP/ROLL DN keys
* Press ENTER: the menu will change from READ EEPROM to WRITE EEPROM and
the cursor will move to the right to accept the value
* Write the value that is the password and press ENTER.
Now the password is active, so restricted functions are accessible.

HOW TO CHANGE DRIVE MODES WITHOUT CONSOLE

It's possible to change the drive mode only if DRIVE MODES option is ON.
Put DRIVE MODES ON, save changes and turn off the key.
The change can be done with ZAPI console (PERFORMANCE TYPE) or without it:
* Turn on the key with the horn button pressed and without pulling down the tiller.
Hold until the horn sounds
* Use lifting/lowering keys to change the performance mode. The horn will chirp one,
two, or three times indicating the new mode. It is necessary to pull the tiller to save the
new mode. Key-off without tiller will reject the mode changes.

Page 23
 5 ALARMS

"ZAPI CONSOLE" "MDI" "LED FLASHES"

1 POWER FAILURE #1 8 8
Short-circuit on the ON/OFF valves, or in the main contactor coil, or in the
electrobrake coil.
2 EEPROM KO 10 Constant "ON" LED
Fault in the area of memory where the parameters are stored. If the fault continues
when the Key switch is turned off and on again, replace the logic. If the fault
disappears, the previously stored parameters will be replaced by the default
parameters.
3 INCORRECT START No alarm No flashes
Alarm generated by an incorrect starting sequence. Possible reasons:
a) The Enable microswitch has welded or failed.
b) Error in the starting sequence from the operator.
c) Error in the wiring.
d) Lifting operation awaiting when the key is turned on.
4 CAPACITOR CHARGE 10 Constant "ON" LED
This check is made during the initial diagnosis. This Alarm is generated if the
capacitors are not charged within 500 mSec after the Key switch on. Probable
cause is a failure within the power block.
5 VMN NOT OK 10 Constant "ON" LED
This test is performed at rest, with the Main Contactor closed, and also during
operation. This Alarm is generated if the VMN is lower than battery voltage in stand-
by. This alarm is generated if VMN does not follow the duty-cycle of the chopper
while driving. Possible causes:
a) Incorrect motor connection.
b) Frame fault of motor to chassis.
c) Defect in the power unit.
6 VACC NOT OK 1 1
This Alarm is generated if the accelerator output voltage from the serial tiller is
higher than 1V. Possible causes to be checked on the serial tiller:
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 during the acquisition procedure are wrong.

Page 24
7 VFIELD NOT OK 10 Constant "ON" LED
This test is made in standby with the Main Contactor open. In this condition the
voltage on both the connections of field must be around ½ VBatt. This alarm is
generated if the field voltage is different from this value. Possible causes:
a) Frame fault on the motor to chassis.
b) Incorrect connection of the field winding to the chopper.
c) Failure of the chopper in the section relative to the field.
8 PUMP VACC NOT OK 1 1
This alarm is generated if the lifting potentiometer output voltage from the serial tiller
is higher than 1V. Possible causes to be checked on the serial tiller:
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 during the acquisition procedure are wrong.
9 I = 0 EVER 6 6
This check is made while driving. 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" alarm.
10 HIGH FIELD CURR 6 6
Problem detected with the field current sensor. Possible causes:
a) Failure of the field current sensor.
b) Failure of the field power unit.
11 NO FIELD CURR 6 6
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.
12 DRIVER SHORTED 10 Constant "ON" LED
The test is carried out with Main Contactor open. The logic unit verifies that the coil
of the Main Contactor is not shorted. Possible causes:
a) Driver shorted.
b) Problems in the feed back circuit of the Main Contactor coil.
c) Wiring error.
d) Fault in the protection circuit.

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13 CONTACTOR DRIVER 2 2
This alarm is generated if there is a problem with the Main Contactor. Possible
causes:
a) The Main Contactor coil driver is open-circuit.
c) Defect in the Main Contactor coil voltage feed back circuit.
14 CONTACTOR CLOSED 2 2
This check is made before closing Main Contactor. It checks that the driver is not
open. Possible causes:
a) the contactor’s power poles are not welded.
b) This alarm could be generated if the line contactor is opened, but there is a
problem within the field circuit.
15 FORW + BACK 1 1
This check is made continuously. The Alarm is generated when forward and reverse
directions are requested simultaneously. Possible causes:
a) Incorrect Wiring.
b) Welding or failure of a direction switch.
c) Incorrect operation from the operator.
16 BATTERY LOW Green LEDS Flashing Continuous flashes
This Alarm is generated when the battery becomes 90% discharged from the
nominal value. If there is the alarm and the battery is not discharged, check the
battery value in the “Tester” menu of the console; if it is incorrect, re-adjust via the
“Adjustment” menu.
17 STBY I HIGH 6 6
This test is made during the initial diagnosis and in standby. The test verifies that
the currents are zero. This alarm disables the machine. Possible causes:
a) Defective current sensor.
b) Feed back circuit failure or logic failure or power unit failure.
18 BRAKE DRIVER KO 5 5
The alarm is present when there is a problem on the electrobrake driver. Possible
causes:
a) driver in short-circuit
b) driver broken, cannot drive the brake;
c) current feedback circuit for the brake coil faulted
19 EVP NOT OK 4 4
At stand: proportional valve opened. Running: the proportional valve doesn’t follow
the applied PWM.
20 SERIAL ERROR #1 1 1
Wrong message or no message from serial tiller
21 INPUT ERROR #1 1 1
No belly switch on the tiller card

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22 INPUT ERROR #2 1 1
No belly switch on the controller
23 THERMAL PROTECTION 7 7
This alarm is generated if the chopper temperature rises above 77°C, . If this alarm
is displayed when the chopper’s temperature is the same as ambient:
a) check the connection of the temperature sensor.
b) the temperature sensor may be defective.
c) the logic may be defective.
24 WATCHDOG 10 Constant "ON" LED
The test is executed at key on, in stand-by and on running. Possible causes:
a) Watch-dog hardware circuit not OK;
b) Software not OK.
25 BATTERY KO 99 Continuous flashes
The battery voltage after closing the main contactor is too low. The battery has
some problems: check the battery voltage on the battery and if it is too low, fix it. If
not check the wiring; if it's ok change the controller.
26 CHECK UP NEEDED Wrench ON NO flashes
The check up time is elapsed. It's necessary to make assistance service on the
machine.

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 6 RECOMMENDED SPARE PARTS

PART
NUMBER DESCRIPTION

C12370 2 pins Molex Minifit connector.

C12372 8 pins Molex Minifit connector.
C12397 10 pins Molex Minifit connector.
C12408 20 pins Molex Minifit connector.
C12499 22 pins Molex Minifit connector.
C12777 Female receptacle 5556 for Molex Minifit
C16530 250A protected fuse
C16505 355A protected fuse
C16506 425A protected fuse
C29564 SW 200 24V contactor
E60305 Buzzer

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7 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
between 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 only and each replacement part
used should be original. Beware of NOT 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 different
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
brought to the attention of a Zapi Agent immediately. The Agent will then take the
decision regarding operational safety of the machine. Remember that Battery Powered
Machines feel no pain.

NEVER USE A VEHICLE WITH A FAULTY

ELECTRONIC CONTROLLER

Page 29
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: [email protected]

CHOPPER COMBI NACCO

OPERATING AND USER
MANUAL