ZAPI 4Q Controller Operating and User Manual
The ZAPI 4Q is a small permanent magnet motor controller designed for use at 24V or 36V with a maximum armed current of 70A or 90A. It features a full bridge design, eliminating the need for changeover. The controller can be configured in two different ways: pallet truck (Model 1) and floor washer (Model 2). The parameters, tester, and options can be adjusted using a ZAPI programming console.
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ELECTRONIC INDUSTRIAL DEVICES
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: [email protected]
4Q CONTROLLER
OPERATING AND USER
MANUAL
Index
1.7 General warnings and precautions .................................................... 7
2.5.b Floor washer............................................................................... 12
3.1 Programming with the console ................................................................ 13
3.2.b Floor washer............................................................................... 15
3.3.b Floor washer............................................................................... 16
3.4.b Floor washer............................................................................... 17
3.6.b Floor washer............................................................................... 20
5 Recommended spare parts for the 4Q ...................................................... 27
6 Regular maintenance at set intervals ........................................................ 28
Page 1
= The informations included into the marked paragraphs by this symbol are essential for the safety.
SIGNATURES TABLE
MANAGEMENT EXECUTIVE COMPANY DEPT. SERVICES
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Publication N°: ADMZP0DA
Edition: November 2001
Page 2
1 MAIN FEATURES
The 4Q is the smallest permanent magnet motor controller: it is designed for use at 24Vor 36V with a maximum armed current of 70A or 90A.
The controller is constructed with a full bridge: no changeover necessary.
1.1 FIELD OF APPLICATION
Power
Voltages
Max. current
Continuos current
500W (800W)
24V, 36V
70A (90A)
30A
The following inputs are foreseen:
- tiller / seat microswitch
- quick inversion
- forwards
- reverse
- potentiometer with 3 wires
- speed reduction 1
- speed reduction 2
The controller has 2 outputs:
- EV1 (solenoid valve)
- EV2 (electric brake)
The main contactor (relay) is internal.
The 4Q controller can be configured in two different ways:
- Pallet truck (Model 1)
- Floor washer (Model 2)
The parameters, tester and options may vary according to the model chosen with ZAPI console.
Page 3
1.2 CONTROL UNITS
1.2.a Microswitches
- A contact resistance of less than 0.1
Ω and a current leakage of less than 100µA is required.
- The key contact must be able to take all the current of the loads without causing a voltage drop of more than 01.V between contacts.
- Send a voltage signal to the microchip when a function is requested (e.g. start running).
1.2.b Potentiometer
Potentiometer configured with 3 wires.
The CPOT range varies from 0 to 10V.
Minimum resistance: 500 Ω
Maximum resistance: 10K
Ω
Automatic minimum and maximum signal acquisition must be carried out (PROGRAM
VACC function) using the programming console and in both directions. This function is indispensable when compensating an eventual asymmetry in the mechanical components of the potentiometer and for minimum level adjustment in particular.
The above graphs show the output voltage of a potentiometer that has not been calibrated compared to the mechanical “zero” of the tiller knob (MI and MA indicate the closing points of the microswitches, 0 represents the mechanical angle of rotation of the throttle).
The first graph shows the corresponding motor voltage without acquisition; the second graph shows the corresponding voltage after potentiometer signal acquisition.
Page 4
1.3 SAFETY FEATURES
- Inverted battery polarity:
Connections must be made as indicated in the wiring diagrams to avoid damaging the power unit.
- Connection errors:
All the inputs are protected against wrong connection.
- Thermal protection:
If the temperature of the 4Q exceeds 75°C, the maximum current is automatically reduced in proportion to the temperature increase. The temperature cannot exceed
90°C, at this temperature the maximum current is zeroed. If the temperature drops to below –10°C, the maximum current is reduced by 20%.
- Battery low:
When the battery runs down (<= 10%) the maximum current is reduced by 50%.
This function can be excluded using the console (“Battery Check” option).
- External agents:
The chopper has IP54 protection.
- Protection against accidental starting:
A precise sequence of operations is required to start the machine, if the sequence is not carried out correctly the machine will not start.
The start running command must be given after key-on and activating the seat microswitch, if configured. If on the other hand the tiller is configured, it must be activated with a predefined minimum delay time compared to the activation of a start running microswitch.
- Protection against uncontrolled movement:
The electromagnetic switch does not close if:
- the power unit is not in function,
- the output voltage of the accelerator does not drop to below the recorded minimum value increased by 1V,
- the potentiometer negative is disconnected,
- the logic is not in good working order,
- one of the start microswitches is closed.
- the controller fulfil the requirements specified on the EN1175 (point 5.9.4). The requirements specified on point 5.9.5 have to be fulfil by external solutions.
Page 5
1.4 OPERATING FUNCTIONS
- Speed control.
- Excellent sensitivity at low speeds.
- Maximum speed reduction: the maximum speed in both directions can be adjusted using the programming console.
- Regenerative braking based on deceleration ramps, release braking, inversion braking.
- Speed control in descent: the motor speed is controlled by the accelerator pedal and regenerative braking is activated automatically if the motor speed exceeds the required speed; this results in excellent ramp performance.
- Even without the use of an electric brake anti roll-back.
- Electric brake control (optional).
- Diagnosis with optional led to indicate type of fault.
- Parameter adjustment using console.
- Internal hour-counter, displayed on the console.
- The last 5 alarms are recorded together with the relative hour-counter reading and chopper temperature.
- Tester function using the console to check in real time: inputs, motor voltage, battery, etc.
- Good motor and battery efficiency thanks to high frequency switching.
- Watchdog circuit to check the µC operations.
- An MDI indicator can be connected to display: software version, hour counter, alarms, speed reduction and battery charge.
1.5 CONTROLLER DIAGNOSIS
The µC diagnoses the main chopper functions.
Diagnosis consists of 4 main stages and includes the following tests:
1) Key turned on: test current sensor, test VMN, test main relay, test presence of start command, test accelerator high, test potentiometer connection, test watchdog, test power devices.
2) At rest: test VMN, test main relay, test current sensor, test potentiometer connection, test watchdog, test accelerator up in absence of start microswitch.
3) Running: test VMN, test main relay, test current sensor, test negative wire of potentiometer, test watchdog, test electric brake (if configured).
4) Permanent: check temperature and battery voltage.
Diagnostic messages are coded by counting the number of times the led flashes or by a
2 digit code on the MDI.
The full alarm message can be visualised using the programming console.
Page 6
1.6 THERMAL CONSIDERATIONS
- Since the heat generated by the controller must be dissipated, it is important to install it in a well ventilated area with adequate cooling surfaces.
- The cooling system must be scaled according to the use required of the machine; forced ventilation may be necessary in some cases if air circulation is insufficient and heat exchange is limited by the type of materials used.
- The power dissipated by the module varies according to the current and the duty cycle.
1.7 GENERAL WARNINGS AND PRECAUTIONS
- Do not connect the 4Q module to a battery with a different rated voltage to the one indicated on the module’s rating plate. A higher battery voltage can cause irreparable damage the MOSFETs. With a lower battery voltage the module will not work.
- The 4Q module must be disconnected when the battery is being charged as the module can be damaged by overvoltages generated by the battery charger and ripple currents generated in the capacitors if a low frequency battery charger is used.
- The 4Q module should be powered by batteries for traction only. Do not use rectifier outputs or power supply units. For special applications contact the nearest ZAPI technical service centre.
- When starting the machine for the first time keep the wheels raised to avoid hazardous situations due to possible connection errors.
- When the key is turn off the filter capacitors in the module can stay charged for several minutes. For safety purposes it is advisable to disconnect the battery and short circuit the positive and negative power lines of the chopper for a few seconds using a resistor of between 10 Ω and 100Ω .
- The electromagnetic susceptibility and emission is strongly influenced by the method of installation; particular attention should be paid to the length and lay-out of electrical connections and to shielding.
Zapi declines all responsibility for malfunctions caused by the above mentioned factors, particularly if the machine manufacturer fails to carry out the tests required by current legislation.
Page 7
2 INSTALLATION
If possible, assemble the chopper with its base on a flat metal surface that has not been painted or cleaned. It is advisable to spread a layer of thermo-conductive grease between the two surfaces to improve the transmission of heat.
Although the chopper is protected against external agents, the connector contacts may become oxidised due to the presence of corrosive substances. This factor should be taken into consideration when choosing where to install the chopper on the vehicle.
Secure the chopper using the pre-drilled holes on the aluminium fixing plate. Check to make sure that the cable terminals and connectors are wired correctly. Remember to install a snubber circuit on the horn, relays, solenoid valves and electromagnetic switches not connected to the chopper, such as the motor pump contactor.
2.1 CHOICE OF CONNECTING CABLES
Use cables with a cross section of 0.5mm
2
for auxiliary circuits.
Use 6mm
2
cables for power connections to the motor and to the battery.
The cables connecting the chopper to the battery should be laid side-by-side and be as short as possible.
2.2 FUSES
- Use a 6A fuse to protect auxiliary circuits.
- Use a 50A fuse to protect the power unit.
The values given are the maximum permitted values and can be reduced for special applications or requirements.
For safety purposes is it advisable to use shielded fuses to prevent molten particles being scattered in the event of a blowout.
Page 8
2.3 DESCRIPTION OF CONNECTORS
pin function
A1 CPOTT
A2 NPOTT
A3 PPOTT
A4 TILLER
description
Potentiometer unit: connect to the cursor of the accelerator potentiometer.
Negative pole of accelerator potentiometer.
Positive pole of accelerator potentiometer.
Tiller/seat switch signal input (or hydro request input if the chop per is configured as a floor washer).
A5 BELLY Quick inversion switch input.
A6 FORWARD Forward switch input.
A7 BACKWARD Reverse switch input.
A8 RV1 Cutback switch 1 input
A9 RV2
A10 NEV1
A11 NEB/NEV2
A12 PEV2
Cutback switch 2 input
Negative pole of solenoid valve 1
Negative pole of electric brake or solenoid valve 2.
Positive pole of solenoid valve 2.
A13 PEV1
A14 PEB
A15 CM
A16 KEY
Positive pole of solenoid valve 1.
Positive pole of electric brake.
Common switch (voltage output using battery potential).
Key input.
B1 PCLRXD
B2 NCLRXD
B3 PCLTXD
B4 NCLTXD
B5 GND
B6 +12
B7 ---
B8 ---
Serial reception positive.
Serial reception negative
Serial transmission positive.
Serial transmission negative.
Negative for powering console.
Positive for powering console.
Page 9
Page 10
2.4 DIMENSIONS
2.5.a Pallet truck
2.5 CONNECTIONS
Page 11
2.5.b Floor washer
Page 12
3 CONSOLE MENU
3.1 PROGRAMMING WITH THE CONSOLE
The Zapi console can be used to program various 4Q chopper functions. It is therefore possible to adapt the truck performance to suit the client’s requirements.
The console can be left connected to the controller when it is in use and the parameters can be modified in real time. In this case, if you wish to save the new data entries, get into rest mode and save the data in the controller memory (E
2 prom) before turning the key off.
This section describes the functions of the Zapi console.
The console has six push-buttons that can be used to modify or visualise the chopper parameters as described below:
1 Roll-up press to scroll sub-menus or parameters upwards.
2 Roll-down press to scroll sub-menus or parameters downwards.
3 Enter
4 Out press to access sub-menus. Also used to confirm a new parameter.
press to exit sub-menus. Also used for non-confirmation of a new
5 Set-Up parameter.
press to increase the value of a parameter.
6 Set-Down press to decrease the value of a parameter.
N.B.: When a parameter has been modified, the new value can be recorded by pressing key 4 (Out) followed by key 3 (Enter). By pressing key 4 (Out) twice, the new value is not recorded.
The numbers printed in the triangles on the following console map correspond to the numbers on the keyboard of the console shown in the diagram below. The position of the triangle indicates to which sub-menu or parameter the key refers.
Important
THE CONSOLE SHOULD ONLY BE CONNECTED AND DISCONNECTED WITH THE
PLANT TURNED OFF!
Page 13
3.2.a Pallet truck
3.2 CONSOLE MAP
Page 14
3.2.b Floor washer
Page 15
3.3.a Pallet truck
BATTERY VOLTAGE
VMN
MOTOR CURRENT
TEMPERATURE
ACCELERATOR
FORWARD SWITCH
BACKWARD SWITCH
TILLER SWITCH
CUTBACK SWITCH 1
CUTBACK SWITCH 2
BELLY SWITCH
BACKING INPUT
TOGGLE INPUT
BATTERY CHARGE
3.3.b Floor washer
BATTERY VOLTAGE
VMN
MOTOR CURRENT
TEMPERATURE
ACCELERATOR
FORWARD SWITCH
BACKWARD SWITCH
HYDRO SPEED REQ.
CUTBACK SWITCH 1
CUTBACK SWITCH 2
BELLY SWITCH
BATTERY CHARGE
3.3 "TESTER" MENU
battery voltage
VMN voltage motor current chopper temperature accelerator forward input reverse input tiller switch input speed reduction 1 input speed reduction 2 input (if configured) quick inversion input backing input (if configured) toggle input (if configured) charge status of battery battery voltage
VMN voltage motor current chopper temperature accelerator forward input reverse input request exclusive hydro (if configured) speed reduction 1 input speed reduction 2 input (if configured) quick inversion input charge status of battery
Page 16
3.4.a Pallet truck
ACCELER. DELAY
DECELER. DELAY
RELEASE BRAKING
INVERS. BRAKING
CUTBACK SPEED 1
CUTBACK SPEED 2
MAX FORW. SPEED
MAX BACK. SPEED
TRACTION IMAX
CREEP SPEED
BACKING TIME
BACKING SPEED
SEAT MICRO DELAY
3.4 "PARAMETER CHANGE" MENU
Acceleration time; 9 = maximum time
Deceleration time; 9 = maximum time
Release braking time; 9 = max. braking power, minimum time
Inversion braking time; 9 = max. braking power, minimum time
Speed reduction 1
Speed reduction 2
Maximum forward speed
Maximum reverse speed
Maximum current (it's a function of the parameter
MAXIMUM CURRENT)
Initial step voltage
Backing time
Fixed speed during backing function
Seat microswitch release delay time (if the “Handle
Switch option” is configured as “Seat”); or delay between direction request and tiller (if the “Handle Switch option” is configured as “Present”).
Delayed disengaging of hydro output.
HYDRO TIME
3.4.b Floor washer
ACCELER. DELAY
DECELER. DELAY
RELEASE BRAKING
INVERS. BRAKING
CUTBACK SPEED 1
CUTBACK SPEED 2
MAX FORW. SPEED
MAX BACK. SPEED
TRACTION IMAX
CREEP SPEED
AUXILIARY TIME
HYDRO TIME
Acceleration time; 9 = maximum time
Deceleration time; 9 = maximum time
Release braking time; 9 = max. braking power, minimum time
Inversion braking time; 9 = max. braking power, minimum time
Speed reduction 1
Speed reduction 2
Maximum forward speed
Maximum reverse speed
Maximum current (it's a function of the parameter
MAXIMUM CURRENT)
Initial step voltage
Delayed disengaging of auxiliary output NEV2.
Delayed disengaging of hydro output (NEV1).
Page 17
3.5 "SET MODEL" MENU
Model Type
Option #1
Option #2
The 4Q is configured as a transpallet.
The 4Q is configured as a floor washer.
3.6 "SET OPTION" MENU
3.6.a Pallet truck
Hour counter
Running
Key on
Battery check
Off
On
The hour counter is active during running only.
The hour counter is active at all times.
Battery alarm disengaged.
Low battery alarm engaged (plus current limiting device).
Aux output #1 (NEV2 - NEB output)
Free
Brake
Option #2
Option #3
Unused output
Output used to control an electric brake that receives the positive from the tiller switch (with relative diagnosis).
Output used to control an electric brake that does not receive the positive from the tiller switch (diagnosis disengaged).
Output used to enable the electric brake during release braking. The brake is controlled as in the option "brake".
Quick inversion
Belly
Timed
Quick inversion active while the belly button remains pressed.
Timed quick inversion (fixed duration).
Backing function
This option is effective only if the “Set input #2” is set to “Option #1”
Off
On
The backing function is disengaged; the RV2 input is a speed reduction.
The backing function is enabled; the RV2 input is used to activate the backing function, the direction is chosen using the gears.
Page 18
Handle switch
Present
Seat
Tiller present: incorrect start if pressed at key-on and movement jammed if released during running. A maximum delay time between selecting the running direction and selecting the tiller can be programmed using the “Seat micro delay” parameter.
Seat present: no incorrect start is pressed at key-on, delay if released during running (program the delay time using the
“Seat micro delay” parameter). The seat-running sequence is compulsory.
Aux output #2 (NEV1 output)
This option is only effective if “Set input # 2” is set to “Option #1”.
Option #1
Option #2
The NEV1 output acts as a hydro: it is active during running and is set at rest with a programmable delay time after running.
The NEV1 output is activated when a thermal alarm is present (e.s. can be used to activate a fan)
Set input #2
Option #1
Option #2
The “Aux output #2” and “Backing function” options can be used.
The “Aux output #2” and “Backing function” options have no effect. The “RV2” input is not a speed reduction but is used as a button (Toggle); the NEV1 output is activated by an
“RV2” impulse and disengaged by a second impulse.
Inversion Mode
Option #1
Option #2
Aux function #2
Option #1
The quick inversion input is configured as normally open.
The quick inversion input is configured as normally closed.
Option #2
The potentiometer is configured with an electric range of 0V-
5V. Forward and backward micros are present.
The potentiometer is configured with an electric range of 0V-
2.5V-5V (2.5V is the ‘at rest’ value). Forward and backward micros are not used; the direction is given by the voltage on the potentiometer unit:
2,5V 5V = backward
Page 19
Set battery type
Sets the battery nominal value
24V
36V
24V battery.
36V battery.
3.6.b Floor washer
Hour counter
Running
Key on
The hour counter is active during running only.
The hour counter is active at all times.
Battery check
Off
On
Quick inversion
Belly
Timed
Battery alarm disengaged.
Low battery alarm enabled (plus current limiting device).
Quick inversion is active while the button remains
Timed quick inversion (set duration).
Inversion Mode
Option #1
Option #2
Automatic function
Off
On
To be defined.
The NEV2 output is active during running and is disengaged with a programmable delay time. The output is always disengaged when a low battery alarm is present.
Aux function #2
The tiller/seta switch is not used by cleaning machine, so the input can be used for other purpose.
Option #1 The “Tiller/Seat” input is a switch that activates the NEV1 output. When the switch is opened the output is disengaged with a delay time that is programmed by the
“Hydro Time” parameter.
Option #2 The “Tiller/Seat” input is a button that activates the NEV1 output when pressed once. Pressing a second time disengages the output with a delay time that is programmed by the “Hydro Time” parameter.
Page 20
The quick inversion input is configured as normally open.
The quick inversion input is configured as normally closed.
Option #3
Set battery type
Sets the battery nominal value
If the “Tiller/Seat” input is activated without traction it activates NEV1 for a duration that is programmed by the
“Hydro Time” parameter. If the input is activated with traction then the NEV1 output is permanently active. If traction stops, NEV1 remains active for a certain length of time that can be programmed by the “Hydro Time” parameter. If the “Tiller/Seat” input is disengaged, NEV1 disengages immediately. The low battery alarm disengages NEV1 (used to drive brushes).
24V
36V
24V battery.
36V battery.
Throttle 0 zone
3.7 "ADJUSTMENT" MENU
This parameter is used to set the dead zone of the traction potentiometer. See graph below.
Throttle X zone
Throttle Y zone
This parameter is used to adjust the characteristic of the traction potentiometer signal.
This parameter is used to adjust the characteristic of the traction potentiometer signal.
Adjust battery
Fine adjustment of the battery voltage.
Page 21
Set current
Adjustment #01
Adjustment #02
3.8 "HARDWARE SETTING" MENU
Adjust the bottom of the scale setting of the current reading visualised on the console.
Adjust the maximum value of the low battery curve.
Adjust the minimum value of the low battery curve.
Aux function #1
On
Off
Check up done
On
Off
Page 22
The hour counter of the chopper loads the MDI hour counter.
If the hour counter of the chopper and the MDI have different values, alarm “98” is displayed for one minute; if the option is not set to “On” within the minute then the chopper hour counter overwrites the MDI hour counter (0 hours if the chopper is new).
the programmed check-up has been carried out; the maintenance hour counter and the “Check up needed” alarm are reset.
checkup not done.
Check up type
None
Option #1
Option #2
Option #3
Set temperature
Programmed maintenance function disengaged; no alarm, no reduction, no shut down.
Programmed maintenance function enabled; an alarm message is visualised after 300 hours.
Programmed maintenance function enabled; an alarm message is visualised after 300 hours and a speed reduction is enabled after 340 hours
Programmed maintenance function enabled; an alarm message is visualised after 300 hours, speed reduction is enabled after 340 hours and the traction is blocked after
380 hours.
3.9 "SPECIAL ADJUST" MENU
Fine adjustment of chopper temperature (the chopper temperature is calibrated by Zapi during testing and should not be modified by the client).
Maximum Current
Adjust the maximum chopper current. A password is required in order to modify this setting and remains active until the key is turned off.
3.10 "CLEAR EEPROM" MENU
Clear EEprom can be effected from this menu; this virtually resets the plant and cancels the settings entered up to that moment. At the end of the Clear EEprom operation the original settings (default values) are reloaded. Clear EEprom has no effect on the following settings:
- Model Type
- Maximum Current
- Set temperature
- Adjust Battery
Page 23
4 ALARMS
4.1 DIAGNOSIS
1) POWER FAILURE #1 AL 73 MDI 1 LED FLASH
Short circuit on main relay or on auxiliary outputs (NEV1, NEV2).
2) CAPACITOR CHARGE AL 60 MDI 3 LED FLASHES
This alarm is signalled if the capacitors have not begun re-charging after a certain amount of time has lapsed.
Possible causes: fault in the potentiometer unit.
3) DRIVER SHORTED
Short circuit on driver of main relay.
AL 74 MDI 6 LED FLASHES
4) VMN NOT OK AL 32 MDI 3 LED FLASHES
Test at rest with the main relay open and running. If the VMN is very low and the main relay is open, the chopper goes into alarm. When running, an alarm is signalled if the VMN does not move from the half battery value according to the direction of the duty cycle: for forward running the VMN value should go from Vbatt/
2 to zero, in reverse the VMN should go from Vbatt/2 to Vbatt.
Possible causes: a) incorrect motor connection; b) motor leak to earth; c) fault in the power unit.
5) STBY I HIGH AL 53 MDI 5 LED FLASHES
Test during initial diagnosis and at rest with main relay open. Check to ensure that current signals are nil. If not the chopper goes into alarm and prevents machine functions.
Possible causes: a) faulty current sensor; b) fault in the feedback circuit, in the logic or in the power board.
6) LOW BATTERY AL 66 MDI 32 LED FLASHES
Reduces the traction current to Imax/2. The low battery alarm is activated when the residual charge falls to 10%. If the alarm is activated with the battery fully charged, check the battery value reading in the “TESTER” menu on the console; if the reading is incorrect, carry out fine adjustment in the “CONFIG MENU/
ADJUSTMENT” menu. This alarm can be present only with "battery check" option
ON.
7) CONTACTOR CLOSED AL 37 MDI 6 LED FLASHES
Test before closing the main relay, only if the VMN is at approx. Vbatt/2. Check that the contact of the main electromagnetic switch is open and has not jammed.
Page 24
8) CONTACTOR DRIVER AL 75 MDI 6 LED FLASHES
Test with the main relay closed, check that the driver is not open.
Possible causes: a) driver open; b) fault in the feedback circuit of the main relay coil voltage.
9) I=0 EVER AL 49 MDI 5 LED FLASHES
Test whilst running. Check that the current value is higher than the minimum threshold value. If not the chopper will go into alarm and prevent machine functions.
Possible causes: a) faulty current sensor; b) fault in the feedback circuits, in the logic or in the power board.
10) EB DRIVER KO AL 02 MDI 8 LED FLASHES
The alarm is activated when a problem in the driver of the electric brake is detected
(only for transpallets with brake present and diagnosis enabled).
Possible causes: a) shorted driver; b) the driver is faulty and cannot control the electric brake; c) fault in the feedback circuit of the electric brake coil voltage.
11) WATCHDOG AL 08 MDI 1 LED FLASHES
Test both at rest and running: this is an internal self-diagnosis of the logic. If this alarm is signalled, replace the logic.
12) CHECK-UP NEEDED AL 99 MDI 0 LED FLASH
Indicates that it is time to carry out programmed maintenance; this alarm is activated 300 hours after the last time maintenance was carried out unless the
“Check up type” option is set to “None”; cancel by setting “Check-up done” to ON.
13) FORW + BACK AL 80 MDI 2 LED FLASHES
Test carried out continuously. The alarm is activated when 2 running requests are given simultaneously. The alarm is reset if one of the two requests is cancelled.
Possible causes: a) check wiring; b) if fault persists, replace the logic.
14) VACC NOT OK AL 78 MDI 4 LED FLASH
This alarm indicates that the traction accelerator voltage is 1V higher that the minimum programmed voltage at key-on and when at rest.
Possible causes: a) a potentiometer wire is disconnected; b) the potentiometer is not wired correctly; c) the potentiometer is faulty; d) potentiometer programming has not been carried out correctly.
Page 25
15) INCORRECT START AL 79 MDI 2 LED FLASHES
Forwards/reverse, tiller, quick inversion present at key-on; traction running request given before tiller/seat.
16) THERMAL PROTECTION AL 62 MDI 7 LED FLASHES
Temperature alarm activated if the temperature is >+75°C in which case the maximum armature current is reduced linearly until it reaches nil at a threshold temperature of 90°C; the speed is reduced to 60%; the alarm is reset only if the temperature drops to below 70°C. If the temperature falls to below –10°C the maximum armature current is reduced by 20%.
17) EEPROM OK AL 13 MDI 1 LED FLASH
Fault in the memory area where configuration parameters are recorded. If the fault persists when the key is turned off and turned on again, replace the EEPROM and check the connections between the EEPROM and the µP. If the alarm no longer occurs, remember that the previously recorded parameters have now been cancelled and replaced with default values.
18) PEDAL WIRE KO AL 86 MDI 4 LED FLASHES
Indicates that the negative wire of the potentiometer is disconnected.
Possible causes: a) one of the potentiometer wires is disconnected; b) the potentiometer is not wired correctly; c) the potentiometer is faulty.
19) CURR. PROTECTION AL 96 MDI 5 LED FLASHES
Current protection; if for any reason the current exceeds the calibrated values, the microprocessor disengages the functions until the current drops to the required value.
AL 98 on MDI: MDI and chopper have different counter.
Page 26
5 RECOMMENDED SPARE PARTS FOR THE 4Q
ITEM CODE DESCRIPTION
C12404
C12777
C00077
C18556
C18557
16 way Molex Minifit female connector
Molex Minifit female crimp terminal
Console connector plug
Outer gasket for Molex Minifit connector
Inner gasket for Molex Minifit connector
Page 27
6 REGULAR MAINTENANCE AT SET INTERVALS
Check the pedal microswitch: use a tester to check for the absence of resistance on the contact by measuring the voltage drop at the terminals, also check that the switch clicks clearly; ............................................................................................... EVERY 3 MONTHS
Check the power cables to the battery and to the motor, both cables and the sheathing must be in good condition; ................................................................ EVERY 3 MONTHS
Check the efficiency of the pedal springs; ......................................... EVERY 3 MONTHS
All work must be carried out by qualified staff and original spare parts only should be used.
Follow the assembly diagrams carefully when installing the machine, any modifications must be agreed to with the supplier. The supplier declines all responsibility for problems caused by failure to comply to the proposed solutions.
Any cause for concern that is visible or apparent to the average technician when carrying out the regular check-ups on the equipment, and that could result in damage or faults to the equipment itself, must be reported to ZAPI technicians or to the technical sales network who are responsible for any decisions concerning the safety of the electric vehicle.
THE USER IS PROHIBITED FROM USING THE VEHICLE SHOULD THERE BE ANY
FAULTS IN THE ELECTRICAL EQUIPMENT THAT REPRESENT A HAZARD.

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The public link to your chat has been updated.
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Key features
- Small permanent magnet motor controller
- Full bridge design
- 24V or 36V operation
- Maximum armed current of 70A or 90A
- Pallet truck and floor washer configurations
- Adjustable parameters, tester, and options