COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI

42028 - POVIGLIO - (R.E.) Via della Costituzione,32 - ITALIA

Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259

CONSOLE MANUAL
MANUAL

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Publication n.: 550108
Edition : November 1991

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INDEX
Page
Legend 4
ZAPI console description 5
Keyboard 5
General description of functions 6
- Hour meter 6
- Alarm display 6
- Parameter programming 6
- Tester 6
- Save 6
- Restore 6
- Accelerator max. stroke programming 6
- Chopper hardware configuration 6
- Data motor 7
Operator’s manual 8
Menu A description 9
- List of pins suitable for configuration 11
Menu B description 12
- Basic information about the equipment 12
- Description menu B 12
- Description of menu 1 - Program 13
- Item list for menu 1 - Program 13
- Description of menu 2 - Tester 14
- List of measurements taken by the tester 14
- Description of menu 3 - Save 18
- Description of menu 4 - Restore 19
- Description of menu 5 - Alarms 20
- List of alarms on display 21
- Description of menu 6 - Accelerator setting 23
- Description of menu 7 - Data motor 24
Re-configuration of chopper or connected I/O 25

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LEGEND
VMN = Mosfet drain voltage
I / O = Input, Output connection ( pin configuration see pag. 11 )

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 ZAPI CONSOLE DESCRIPTION

KEYBOARD

Description of key functions:

Key 1 = Allows selection of an option or the next menu item.

Key 2 = Allows select of an option or the previous menu item.

Key 3 = Allows confirmation of selected options.

Key 4 = Retains the current function.

Key 5 = Allows an increase in the parameters or selects the type of connected I/O.

Key 6 = Allows a reduction in the parameters or selects the type of connected I/O.

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 GENERAL DESCRIPTION OF FUNCTIONS
HOUR METER
The hour meter appears in the second line of the display when the chopper is connected.
The hour meter has a sensitivity of one minute and a full scale value of 65,534 hours and
59 minutes.

ALARM DISPLAY
The console features the possibility to read the last five alarm messages stored in the
chopper and displayed together with the time of occurrence, the number of times the alarm
was sent and the temperature value at the time of the alarm.

PARAMETER PROGRAMMING
The chopper parameters can be displayed and programmed via the keyboard thereby
making it possible to set the chopper easily.

TESTER
It makes it possible to display the state of the chopper analogue and digital values and
thereby have a useful tool for the analysis of chopper operation and external cables.

SAVE
It makes it possible to store all values relating to the parameters and the chopper hardware
configuration into the console with a program which can be selected from the keyboard.

RESTORE
It makes it possible to program a chopper with the parameters contained in a program
generated by a SAVE.

ACCELERATOR MAX. STROKE PROGRAMMING

It allows to program the accelerator max. stroke.
The max. permissible value is 5 Volts while the minimum value is 3 Volts.

CHOPPER HARDWARE CONFIGURATION

It allows chopper configuration though there is no logic configuration.
You should answer the console guided questions and abandon automatically once the
questions are over.

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DATA MOTOR
This function allows the engineer to record the motor's electrical parameters in the chopper
memory the characteristics memorized varies between motors and are used during
reversal, allowing more efficient control of the motor current.
This procedure requires an input of answers to questions displayed on the console,
automatically leaving " motor data " routine upon completion.

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 OPERATOR'S MANUAL

When switched on, the console tries to become connected with the chopper and displays
the following messages:

If connection is not successful the console displays the following message:

At this stage you should check whether connections have been correctly performed as per
the attached drawings.

If connection is made properly two situations may occur:

In case of no chopper configuration the console runs menu A (chopper

configuration), otherwise it runs menu B (console functions).

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 DESCRIPTION OF MENU A (Chopper configuration)

The display shows the following:

To continue chopper programming press ENTER (key No. 3).

By running this command the following is displayed:

You can choose from a maximum of 10 different menu items, namely:

1- H1 3 CABLES
2- H1 4 CABLES S
3- H1 4 CABLES T
4- H1 SPECIAL
5- NO CONFIG.
6- NO CONFIG.
7- NO CONFIG.
8- NO CONFIG.
9- NO CONFIG.
10 - NO CONFIG.

By means of the ROLL UP (key No. 1) and ROLL DOWN (key No. 2) keys you can scroll
the possible configurations of selectable choppers while the ENTER key (No. 3) confirms
the selection made.

The NO CONFIG. item shows that the selected model number has not yet been set.

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When a menu item is confirmed via the ENTER key (No. 3) the display shows:

At this stage if you confirm by pressing ENTER (key No. 3) the chopper configuration is as
per the selected model.
By pressing OUT (key No. 4) you can have access to the previous menu (SELECT MODEL).
After setting the model configuration the console enters the I/O CONFIGURATION MENU.
The display shows the number of pins requiring configuration and the meaning that a pin
may acquire.
Example:

By pressing SET-UP (key No. 5) and SET-DOWN (key No. 6) you scroll the different
possible states of a pin.
Any time you confirm by pressing ENTER (key No. 3) the display shows:

Confirming again with the ENTER key (No. 3) the state of the pin is stored in the chopper
while the OUT key (No. 4) allows you to repeat pin programming.
Once pin programming is completed the display shows:

At this point chopper configuration is complete. To move to the B menu simply switch off
and on again.

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LIST OF PINS SUITABLE FOR CONFIGURATION:

FREE (free pin)

Pin 5E : Selectable states: RV1 (speed 1 cut back)
SPARE (to be defined)

FREE (free pin)

Pin 4E : Selectable states: RV2 (speed 2 cut back)
SPARE (to be defined)

FREE (free pin)

Pin 2D : Selectable states: INVERS (rapid inversion)
SPARE (to be defined)

FREE (free pin)

Pin 1E : Selectable states: SEAT (seat)
HANDLE (handle)

FREE (free pin)

Pin 3E : Selectable states: WEAK (weakening)
BY-PASS (by-pass)

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 MENU B DESCRIPTION (Console functions)

BASIC INFORMATION ABOUT THE EQUIPMENT

If chopper configuration is available when the equipment is switched on, a set of information
is displayed, namely:
1) Manufacturer’s name
2) Chopper model
3) Program release version
4) Hour meter value
Example:

where: ZAPI is the Manufacturer’s name

V.1.0 is the program release number
H1 SP is the chopper model
35 is the hour meter value.

MENU B DESCRIPTION
By pressing the ENTER key you enter the main menu which consists of the following
functions:
1 - Program
2 - Tester
3 - Save
4 - Restore
5 - Alarms
6 - Accelerator setting
7 - Motor data

By means of the ROLL UP (No. 1) and ROLL DOWN (No. 2) keys you can scroll the
functions while with the ENTER key (No. 3) you can confirm the selected function.
By selecting OUT (key No. 4) you return to the menu B.

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DESCRIPTION OF MENU 1 - PROGRAM
When you enter the Program menu the display shows the name of the first programmable
parameter with the corresponding level number.
The parameter level ranges from 0 to 9.
Example:

By means of the ROLL UP (No. 1) and ROLL DOWN (No. 2) keys you can scroll the
parameters while with the SET-UP (No. 5) and SET-DOWN (No. 6) keys you can change
the levels.
The UP key allows you to increase the level while by pressing the DOWN key you decrease
the level.

LIST OF MENU ITEMS FOR MENU 1 - PROGRAM:

1.1 ACCEL. DELAY : Acceleration time

1.2 BRAKING
1.3 CUT BACK SPEED 1
1.4 CUT BACK SPEED 2
1.5 COMPENSATION
1.6 CREEP SPEED
1.7 I MAX.
1.8 MAX. SPEED FORWARD
1.9 MAX. SPEED REVERSE
2.0 WEAK DROPOUT
: Current braking threshold
: Speed 1 reduction
: Speed 2 reduction
: Compensation for speed reduction
: Min. acceleration threshold
: Max. current
: Highest speed forward
: Highest speed reverse
: Weakening output current threshold

By pressing the OUT key (No. 4) you return to the main menu.

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DESCRIPTION OF MENU 2 - TESTER:
When you enter the TESTER menu the display shows:

The displayed message shows the voltage level available at the chopper output terminals
with reference to VMN forward and VMN reverse.
Where:
< 30% Indicates that on output connector there is a voltage less than 30% of battery
voltage
> 30% Indicates that on output connector there is a voltage greater than 30% of battery
voltage

By means of the ROLL UP (No. 1) and ROLL-DOWN (No. 2) keys you can scroll all the
signals available on the chopper connectors.
By pressing the OUT key you can return to the main menu.

LIST OF MEASUREMENTS TAKEN BY THE TESTER:

1) Measures VMN 2/3 voltage.
Example:

where:
< 80% Indicates that on output connector there is a voltage less than 80% of battery
voltage
> 80% Indicates that on output connector there is a voltage greater than 80% of battery
voltage

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2) Measures contactor driver voltage.
Example:

where:
Ø Means that low voltage is available at the output connector

VB Means that on output connector there is the battery voltage

3) Measures connector voltage with reference to forward and reverse.

Example:

4) Measures connector voltage with reference to speed reduction 1 and speed

reduction 2 .
Example:

where:
Ø Means that low voltage is available at the output connector
VB Means that on output connector there is the battery voltage

5) Measures connector voltage with reference to rapid inversion.

Example:

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 where:
Ø Means that low voltage is available at the output connector
VB Means that on output connector there is the battery voltage

6) Measures connector voltage with reference to the handle/seat microswitch.

Example:

where:
Ø Means that low voltage is available at the output connector
VB Means that on output connector there is the battery voltage

7) Reads the accelerator analog value.

Example:

where:
5000 is the accelerator mVolt value
100% is the percent accelerator value

8) Reads motor current.

Example:

where:
50 is motor current in Ampere.

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9) Reads the power block temperature value.
Example:

where:
30 is the power block temperature value in degrees centigrade.

10) Reads battery voltage.

Example:

where:
23.5 Volt is battery voltage read during the tester phase
24 Volt is the type of battery used by the chopper.

11) Reads motor voltage

Example:

where:
22 Volt is voltage applied to the motor.

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DESCRIPTION OF MENU 3 - SAVE:
To store all parameter values into the console you simply have to specify on the display in
which program the data should be stored.
Example:

The ROLL UP (No. 1) and ROLL DOWN (No. 2) keys allow you to select the number of the
program while the parameters should be saved while by pressing ENTER (No. 3) you can
confirm the selection made.
You can select up to 10 programs.
When confirming by pressing ENTER (key No. 3) the display shows:

By pressing the OUT key you return to the menu B. If you confirm by pressing ENTER (key
No. 3) the display shows:

The chopper parameters are now transferred to the console in the showed point..
Once this transfer has occurred the program returns to the menu B.

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DESCRIPTION OF MENU 4 - RESTORE:
To program a chopper with the parameters contained in a program generated by a SAVE
you should select the program for storage.
Example:

The ROLL UP (No. 1) and ROLL DOWN (No. 2) keys make it possible to select the number
of the program to be stored into the chopper while by pressing the ENTER key (No. 3) you
confirm the selection made.
When confirming by pressing ENTER (key No. 3) if the selected program has not been
generated by a SAVE the display shows:

and after approximately 2 sec. the program returns to the menu B.

If, on the contrary, the selected program has been generated by a SAVE the display shows:

By pressing the OUT key you return to the menu B. If you confirm by pressing ENTER (key
No. 3) the display shows:

The parameters of the console program are now transferred to the chopper. Once transfer
has occurred the program return to the menu B.

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DESCRIPTION OF MENU 5 - ALARMS
When you enter the ALARMS menu the display shows the first alarm stored in the chopper
memory.
By means of the ROLL Up (No. 1) and ROLL DOWN keys (No. 2) you can scroll the last
5 alarms which have been sent.
Furthermore the display shows the state of the hour meter at the time of the alarm, the
number of times that the alarm was sent and the temperature at the time of the alarm.
Example:

where:
23 is the time at which the alarm was sent
2 is the number of times that the alarm was sent
25 is the temperature in degrees centigrade at the time of the alarm
If the display shows

then no alarm has been stored in the chopper.

By selecting the OUT key (No. 4) you return to the menu B.

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 LIST OF ALARMS ON DISPLAY

1- Chopper no conf. Alarm generated if no logic configuration has occurred.

2- VMN forw low VMN 1/3 at rest or VMN 1/3 when operating with PWM 80%
(forward).
3- VMN Back low VMN 1/3 at rest or VMN 1/3 when operating with PWM 80%
(reverse).

4- No full cond. VMN 1/3 with total conduction.

5- Cont don't close Contactor is not closed.

6- I=0 ever No current during operation.

7- I hight at stand Current is available at rest.

8- Watch - dog Watch-dog.

9- Forw back Double request for running.

10 - Incorrect start Running request at starting.

11 - VACC > 1Volt Accelerator 1 Volt at rest.

12 - Contactor driver Shorted driver.

13 - EEprom data ko EEprom data area not OK.

14 - EEprom par. ko EEprom parameter data area not OK.

15 - EEprom conf. ko Chopper configuration data area not OK.

16 - EEprom ko EEprom off line.

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17 - Err. by-pass By-pass output error VMN 1/3.
18 - Protection High temperature 70o.
19 - Battery Battery dis-charged.

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DESCRIPTION OF MENU 6 - ACCELERATOR SETTING
When you enter this menu the display shows the value in Volt of the max. possible
accelerator stroke referred to both running directions.
Example:

By confirming with the ENTER key (No. 3) you enter the programming phase and the display
shows:

By pressing the OUT key you return to the menu B.

During this programming phase the operator is required to bring the throttle completely
forward and completely backward.
During this operation the potentiometer values are displayed until the max. value is reached.
At this stage if you want to store the displayed voltage values into the chopper you simply
confirm by pressing the ENTER again (key No. 3) so that the display shows:

If you confirm by pressing ENTER again (key No. 3) the values are stored in the chopper
and the program returns to the menu B.

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DESCRIPTION OF MENU 7 - DATA MOTOR
When entering this menu the display shows:

The console display requires that the operator stops the motor from rotating.
If ENTER (No. 3) is pressed the display shows:

The console display requires that the operator selects the forward direction.
If you press ENTER (key No. 3) the display shows:

By pressing ENTER again (key No. 3) again the display shows:

If all console instructions have been accurately followed the motor parameters are
calculated and stored into the chopper memory.
At the end of processing the program returns to the menu B.
The above procedure can be interrupted at any time returning to the menu B by simply
pressing the OUT key.

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 RE-CONFIGURATION OF CHOPPER OR CONNECTIONS I/O

If chopper configuration obtained with menu A is not in compliance with the selected model
or if an error has been made during the programming phase re-configuration is possible
both for the chopper model and the chopper I/O.
For this purpose choose the menu basic information about product and simultaneously
press ROLL UP (No. 1) and SET-UP (No.5) for approximately 1sec.

The display thus shows:

By means of the ROLL UP (No. 1) and ROLL DOWN (No. 2) keys you can scroll all menu
functions while by pressing the ENTER key (No. 3) you can confirm the selected function.
Menu items are as follows:
1 - SEL. MODEL
2 - CONFIG. I/O

The operations to do are the some of menu' A (see instructions of menu' A).

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