INDEX

Page
Legend 2
Characteristics 3
Control Unit 4
Speed 4
Safety Devices 5
Performance 6
Connector's description 7
Power connector description 9
Settings 10
Parameter change via consolle 11
Description of digital consolle functions 12
Diagram: Tiller and 3 cable motor 13
Diagram: Tiller and 3 cable motor with changeover contactors 14
Diagnosis 15
Decode displayung alarms console 17
Mainteinance 21

Publication n.: 550119

Edition : October 1993

Pagina 1
LEGEND

AV = Forward
IN = Reverse
IND = Weakening
1Q = 1 Quadrant
2Q = 2 Quadrants
VMN = Motor minus voltage
MA = Forward microswitch
MI = Reverse microswitch
MU = Up microswitch
MD = Down microswitch
NT = Contactor minus
MCL = Horn switch
MEF = Electric brake switch
CH = Key
MT = Tiller switch
M.UM = Belly switch
DF = Brake diode in plugging
DV = Flywheel diode

Pagina 2
 CHARACTERISTICS

TECHNICAL SPECIFICATIONS

Voltage : 24 Vcc (16 : 30)

Maximum Current : 220A (5 minutes continuos)
Booster Current : 280A (for 3 seconds)
Maximum Frequency : Max. 300Hz
Ambient temperature : -30° : 40°C
Maximum temperature that can be reached by the chopper : 85°C

3 CABLES CONNECTION 4 CABLES CONNECTION

Pagina 3
CONTROL UNIT
- Pedal with AV-IN microswitch and 2 or 3-wire potentiometer.
- Handle with AV-IN microswitch (rapid inversion, handle microswitch and 2 or 3-wire
potentiometer).

In either case the potentiometer signal should vary from zero (machine not operating) to
a max. of 5 Volts.
Max. useful signals between 3 and 5 Volts are acceptable.
An automatic procedure for automatic potentiometer signal acquisition is also provided.
It allows operation with signals between 3 and 5 Volt but also with different signals between
AV and IN.
The handle microswitch makes it possible to check the starting sequence.
In the pedal version the handle microswitch is replaced by the seat microswitch ( 5 sec.
delayed ).
If connected to 2 wires the potentiometer should provide a resistance ranging from zero
to a value of 600ohm.
If the potentiometer is connected in the 3-wire version no potentiometers with resistance
lower that 500 ohm should not be used.

SPEED
Speed may be adjusted:
- Max. speed adjustment from 10 to 100% ( via the programming console only ).
- Speed reduction device with microswitch go-ahead: RV1 ( from 10 to 100% ).
- Speed reduction device with microswitch go-ahead: RV2 ( from 10 to 100% ).

When one of the three reduction devices is in automatic function the chopper adjusts the
voltage to keep speed constant.
The feed - back parameter can be changed from the console to obtain the desired
characteristic.

Pagina 4
SAFETY DEVICES

- Battery Inversion
It is necessary to follow the connections between contactors and motor show in the
plans.

- Connection errors
All the inputs are protected against connections mistakes.
Input NT1 end NT2 does not accept loads over 3A. It is any way protected against
over loads.

- Thermal protection
If temperature exceeds 75°C the maximum current is reduced proportionally to the
temperature rise.
Temperature is never allowed to exceed 85°C.

- Discharged battery
If the battery is down discharged, maximum current is reduced by 50%.
This condition is displyed by diagnostic led.

- External agents
The chopper is protected against dust and fluid splashes (IP54) as it is semi
enclosed.

- Safety against accidental starting

A precise sequence of operations is required to start the machine. If such operations
are not correctly performed the machine will not start.
They are as follows:
1) - Key
- Handle microswitch
- Running microswitch

2) - Key
- Seat microswitch ( 5sec. delayed )
- Running microswitch

Pagina 5
- Safety against uncontrolled movements
Contactors will not close if:
- The power unit is not operating.
- The accelerator is not allowed to reach below 1 Volt.
- The logic unit is not operating correctly.
- One of the running microswitches is closed.
- Request for rapid inversion is available independently
of the running microswitches.

PERFORMANCE

- Very good sensitivity at low speed

- Anti-Roll-Back
- Rapid inversion
- Braking with current control
- Diagnosis with failure indication by means of an optional LED.
- Parameter adjustment via the console (see specific paragraph).
- Internal hour meter suitable for being displayed on the console.
- Storing of the last 5 alarms which have occurred with the corresponding hour meter
values which can be displayed in the console and chopper temperature.
- Tester function via the console to check main parameters in real time, i.e. inputs, motor
voltage and battery.
- Automaticaly release braking.

Pagina 6
 L1 CONNECTOR'S DESCRIPTION

Position Function Description

A1 -LED Alarm Led minus: to be connected to the cathode.
A2 +LED Alarm Led plus: to be connected to the anode.
Output current 12mA for standard Led.

B1 PCLRXD Serial reception plus.

B2 NCLRXD Serial reception minus.
B3 PCLTXD Serial transmission plus.
B4 NCLTXD Serial transmission minus.
B5 GND Console supply minus.
B6 +12 Console supply plus.
B7 Fun. Sel. Economic console channel.
B8 UP/DOWN Economic console channel.

C1 CPOT Potentiometer central: to be connected to the potentiometer

slider. For speed adjustment the useful signal ranges from
ØVolt (lowest speed) to 5Volt (highest speed).
C2 NPOT Potentiometer minus: This is a battery negative.
C3 PPOT Potentiometer plus: This is a 12Volt output.
It is not used if the potentiometer is wired with 2 cables.
Do not short this terminal to battery negative and do not apply
a resistance load of less than 500ohm.

D1 +CH To be connected to key switch return.

D2 IR Signal for handle safety device activation.
The safety device is activated with opened microswitch or if the
applied voltage is less than 12Volt.
If not used it can be wired to Key positive or disconnected from
the programmable console.

Pagina 7
E1 / Not used.
E2 PT Positive coils contactors.
E3 NT2 Driver reverse contactor.
E4 RV2 Input for speed reduction operation (RV2).
If connected to a potential of more than 12Volts, reduction is
inhibited.
If left free or connected to B-' ve it performs the reduction
function operates. This is a console input and it is programmable
as tiller or seat input.

E5 RV1 Input for speed reduction operation (RV1).

If connected to a potential of more than 12Volt reduction is
inhibited while if left free or connected to Battery negative, the
reduction function operates. Activation of this input can be
programmed from the console.
E6 IN Selects reverse.
It should be connected to the reverse microswitch and activates
the contactor when greater than 12Volts.
E7 AV Selects forward.
It should be connected to the forward microswitch and activates
the contactor when greater than 12Volts.
E8 NT1 It operates the forward contactor.
When active it provides connection to B-' ve.
E9 / Not used.

Pagina 8
 POWER CONNECTOR DESCRIPTION

1 It is the forward direction driver (VMNA).

It supplies a B-' ve via a mosfet circuit when the direction is active.
For connections see diagrams.

DV It is the cathode of the flywheel diode.

B-' VE It is connected to the B-' re.

This feed is also common to the control logic circuit.

DF It is the cathode of the braking diode.

Pagina 9
 SETTINGS

Similarly to chopper configuration, parameter settings can be directly made at ZAPI

according to the customer’s specifications or by the customer via the programming console
or the economic console which allows changes only to the parameters indicated with an
asterisk*.
The chopper parameters shown below can be changed between ten intermediate levels
within the specified range:

LIVELLO PROGRAMMATO

PARAMETRI UNITA' 0 1 2 3 4 5 6 7 8 9
ACCELERATION DELAY* Sec. 0.55 0.64 0.84 1 1.21 1.41 1.62 1.77 2.02 2.20
BRAKING* (con Vacc = min.) % IMax. 36 42 48 54 60 67 73 79 85 91
BRAKING* (con Vacc = max.) % IMax. 61 67 73 79 85 92 98 104 110 110
CUT BACK SPEED 1 E 2 (IMot = 80A) % VBatt. 44 54 58 64 73 76 83 86 90 96
CREEP SPEED* % VBatt. 1 3.8 6.7 9.8 12.9 16.6 19.6 22.8 25.2 29.4
IMAX. Amp. 110 122 134 146 159 171 183 195 208 220
MAX. SPEED FORWARD E BACK (IMot = 80A) % VBatt. 26 31.4 42 52 62 72 84 93 100 100
RELEASE BRAKING % IMax. # 42 48 54 60 67 73 79 85 91

# When level "0" is select, no autostop function.

The console can be kept constantly connected to the chopper and parameters may be
changed in real time during operation.
The parameters set and optimized can be recorded via the console (SAVE) and then re-
loaded (RESTORE) into another chopper thereby making it possible to obtain rapid and
standard settings (see console manual for further details).

DESCRIPTION OF VARIABLE PARAMETERS

Acceleration delay = Acceleration

Braking = Braking
Cut back speed 1 = Speed 1 reduction
Cut back speed 2 = Speed 2 reduction
Creep speed = Lowest speed ( First ramp )
IMax. = Max. current
Max. speed forward = Highest speed forward
Max. speed reverse = Highest speed reverse

Pagina 10
 PARAMETER CHANGE VIA ECONOMIC CONSOLE

The parameters which can be changed are as follows:

1 CREEP SPEED
2 ACCELERATION DELAY
3 BRAKING
4 CUT BACK SPEED 1
5 CUT BACK SPEED 2
0 NOT CONNECTED

Adjustments are possible within the range specified on Page 19 at 10 intermediate

adjustment levels.

- Connect the economic console to the chopper ( B ) connector ( this operation should be
performed when the machine is off ).

- Riconnect the battery, switch on the machine by turning the key.

- Position the rotating selector to the function requiring change.

By pressing the SET-UP button the parameter value can be increased while pressing the
SET-DOWN button the same value can be decreased.
Warning! Changes are made by counting the number of pulses sent by the
push - buttons. Therefore to increase or decrease one parameter by several points you
should release and press the button again as required.
Keeping a push-button continuously pressed does not allow you to obtain continuous
parameter variation.

- Parameter variation occurs in real time making it possible to immediately check the set
values.

Pagina 11
 DESCRIPTION OF DIGITAL CONSOLE FUNCTIONS

- Input configuration : RV1, RV2, IR

- Parameter programming : Acceleration

Braking
Cut back speed 1
Cut back speed 2
Creep speed
Max. current
Max. speed forward
Max. speed reverse
Release braking

- Tester : VMN 30%

VMNI 80%
T1 driver
IN, AV, RV1, RV2, IR inputs
Accelerator voltage
Current
Temperature
Battery voltage
Motor voltage

- Display of stored alarms

- Internal hour meter
- Accelerator stroke programming, forward and reverse
- SAVE function (data storage)
- Restore function (parameter loading onto a chopper)

Pagina 12
Pagina 13
Pagina 14
 DIAGNOSIS

The diagnostics message is sent via a LED which should be connected to connector A
(driving current 12mA).
Alarm decoding takes place according to the following table:
1 Flash : Logic unit alarm : the control card does not operate correctly. There are
special storage problems.
A console is required to identify the specific problem. The solutions are as
follows:
1^ Change the logic unit
2^ Re-program the logic unit.
If the data is lost the chopper starts again with preset values.
Example:
If the hour meter value is lost the chopper starts again with hour meter at
zero.
If the parameters for functional programming are lost, operation occurs
with fixed values on EPROM.
If the fixed parameters are essential to operate (3-4 cable motor, etc.) the
logic unit should be re-programmed or replaced.

2 Flashes : There is a running request at starting. Check and perform troubleshooting.

3 Flashes : Power unit problem: Mos or motor short-circuited. If no external cause is

found change the power unit.

4 Flashes: The accelerator is not calibrated:

At switching on, while the running microswitches are open the signal
exceeds 1Volt.
This prevents speed control.
Reposition the potentiometer.

5 Flashes : The problem is within the power transducer.

Power unit replacement is required.

6 Flashes : The transistor which supplies contactor 1 ( NT1 ) is short - citcuit and thus
safety is not ensured.
The contactor closes but the machine will not start.
Change the logic unit.

Pagina 15
7 Flashes : Overheating alarm.
Shows that temperature is too high. Current is reduced proportionately.

8 Flashes : The main contactor does not close or provide B+' ve to the motor.
Keeping the contactor closed check where B+' ve lost (Battery, Fuse,
B+' ve on Chopper, Bar 1, Motor, Bar 1, Bar 3).
Change the logic unit only if bar 1 has +Batt.

9 Flashes : By pass contactor does not open.

Continuous flashing : The battery is very discharged and max. current is reduced
of 50%.

Lamp always on : Double running request.

Check whether +Batt is simultaneously on the AV and IN pin.
Otherwise change the logic unit or check cabling and handle.

Pagina 16
 DECODE DISPLAYING ALARMS CONSOLE

1) VMN 1/4 LOW

The test is done at rest, if you find the voltage VMN (clamp 1) lower than a 1/4 of the
voltage you give the alarm.
a) Check that the cabling of the motor is correct.
b) Check that the motor have no-dispersion insulation to the frame.
c) Chopper damaged, replace it.

2) NO FULL COND
The test is done in full conduction.
If in this condition you find out that the VMN is higher than 1/3 VBATT it means that
something doesn't work in the current of diagnostics, with danger for the safety,
therefore the vehicle jams. If the defects persists replace the logic.

3) VMN 3/4 HIGH

Test done at rest.
If the voltage of VMN is higher thaw 3/4 VBatt you give the alarm.
Possible causes:
a) Stuck contactor.
b) Short circuit between +Batt and VMN.
c) Chopper damaged.

4) CONT. DONT CLOSE

Test done at the request of run.
It happens that the contactor closes, controlling the VMN becomes higher than 2/3
VBatt, if that doesn't happen you give the alarm.
Possible causes:
a) Direction contactor disconnected or damaged, breaken points insulated or very
dirty.
b) Motor not correctly connected or disconnected.
c) Breakage of the chopper's power, replace it.

5) I=OVER
Test done during the run.
It happens that the current during the run is higher than a minimum value, if this is not
true the alarm appears and the vehicle jams.
Possible causes:
a) The current-sensor is damaged, replace the power.
Pagina 17
6) HIGH AT STAND
Test done at rest, you check that the current is null.
If this doesn't append the alarm appears, it is jamming.
Possible causes:
a) The current-sensor is broken or the logic is damaged.
Replace before the logic, if the defect remain replace the power.

7) WATCH-DOG
The test is done both at rest and at run.
It is an autodiagnosis inside the logic.
Replace the logic in case of alarm.

8) DRIVER SHORTED
The test is done at the moment of request of run, this consists on checking that the
voltage on the coherent value with the expected conduction.
Possible causes:
a) Outside short circuit to -Batt of the cabling that comes out from NT1.
b) Break of the driver because of on over voltage or a short circuit to +Batt. Of the
cabling NT1 or NT2, replace the logic after having removed the cause.

9) COIL SHORTED
At the input of E8 (NT1) or E3 (NT2) there is on overcharge or a short circuit to +Batt.
Possible causes:
a) The coil of the contactor is in short circuit or absorbs more than 5Amp. continuous
b) Short circuit with +Batt of the cablings that go out from connectors E8 - E3.
The alarm displays an happened overcharge not the break of a component of the
chopper, where you have removed the outside cause you can start again.

10) FORW. BACK

At the input of E8 (NT1) or of E3 (NT2) there is a overcharge or a shorted circuit to +Batt.
Possible causes:
a) defecting cabling.
b) stuck direction micro-switch.
c) wrong switching
d) If the defect remains replace the logic

Pagina 18
11) INCORRECT START
Incorrect sequence of power.
The vehicle starts only if you obser the sequence: Key wheel (or start) run.
Possible causes;
a) Direction microswitch or stuck wheel.
b) Wrong sequence of the operator.
c) Wrong cabling.

12) VACC NOT OK

The test is done at rest.
The alarm displays that the voltage of the accelerator is nigher of 1V than memorized
minimum value.
Possible causes:
a) It is disconnected wire of the potentiometer.
b) The potentiometer is uncalibrated.
c) The potentiometer is defective.

13) TH PROTECTION
It is an indication that the temperature of the chopper has overcomes 73°C.
The maximum current is gradually reduced untill a null value correspondent to a value
of 75°C.
If the alarm is lower than 60°C:
a) Check the connection of thermic sensor.
b) Thermic sensor damaged.
c) Connection on the switched off power (control the connector that the logic)

14) BATTERY
The battery is discharged.
The alarm appears at the same time of the stop of the vehicle, than the vehicle starts
again making a request of run.
The maximum current is reduce of the 50%.

15) EPROM DATA KO

The details about the area of memory are wrong that operates on the contactor, the
alarm is not jamming , if turning on the vehicle the alarm disappears, remember that
must have taken off the particulars in the hour-meter.

Pagina 19
16) EPROM PAR: KO.
Defect in the area of memory that conteins the particulars of the adjusting parameter.
The alarm is jamming. If turning off and turning on the key, the defect remains replace
the logic.
If the alarm disappears remember that the memoryzed parameters before are
cleaned, and therefore replaced with values of default.

17) EPROM OFF LINE

Defect in the area of memory that contents the particulars of the hour-meter, and of
the memory red alarm.
The alarm is jamming
If turning off and turning on the key the alarm remains replaced the logic.
If the alarm disappears remember that the watch starts from zero again the alarm area
is cleaned.

Pagina 20
 MAINTEINANCE

Check outwear of electric contacts: they should be replaced when matchboard is

too strong and wornout. Electric contacts should be checked every 3 months.
Check pedal microswitch: verify with a tester that there is no electric resistance
between the contacts by measuring the voltage drop between its terminals. Also the
release should have a firm sound. The pedal microswitch should be checked
every 3 months.
Check motor-battery power links: they should be in excellent shae as well as the
wires' claddings. Wires should be checked every 3 months.
Control of the pedal and contactors springs. They should be able to extend to its
full extention and checked every 3 months.
Check contactors mecanical movements. They should be frictionfree and not stick.
Mechanical movements of the contactors should be checked every 3 months.

CHECKS SHOULD BE DONE BY SKILLED PERSONNEL ONLY AND, ALL SPARE PARTS
SHOULD BE ORIGINAL.
INSTALLATION OF THIS ELECTRONIC CONTROLLER SHOULD BE DONE ACCORDING TO THE
DIAGRAMS INCLUDED IN THIS MANUAL AND ANY VARIATION SHOULD BE DONE
ACCORDINGLY WITH THE SUPPLIER. THE SUPPLIER IS NOT RESPONSIBLE FOR ANY
PROBLEM THAT ROSE FROM USING WIRING SOLUTIONS DIFFERENT FROM THE ONES
SUGGESTED ON THIS MANUAL.

DO NOT USE A VEHICLE WITH A

FAULTY ELECTRONIC CONTROLLER

Pagina 21
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) Via Parma, 59 - ITALIA
Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259

Controller L1
USER's MANUAL