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ZAPI™ Controllers

Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................

1

Description ..........................................................................................................................................................

1

ZAPI™ Transistor Motor Controller .................................................................................................................

1

Principles of Operation....................................................................................................................................

2

Controller Safety..................................................................................................................................................

2

Controller Adjustments ........................................................................................................................................

3

Modes of Operation .............................................................................................................................................

3

User-Selectable Operating Modes ..................................................................................................................

3

Programming .......................................................................................................................................................

4

Custom Performance Mode ............................................................................................................................

4

Controller Parameters .....................................................................................................................................

4

Tester Menu ....................................................................................................................................................

5

Set Option Menu .............................................................................................................................................

6

ZAPI™ Handset ..............................................................................................................................................

6

Troubleshooting ...................................................................................................................................................

10

Control Card Functional Test ...............................................................................................................................

34

ZAPI™ PC Interface ............................................................................................................................................

36

Connecting PC to ZAPI™ Controller...............................................................................................................

36

File Menu ........................................................................................................................................................

39

Open File ....................................................................................................................................................

39

TX From File ...............................................................................................................................................

40

Save File .....................................................................................................................................................

42

Print Settings ..............................................................................................................................................

44

Exit ..............................................................................................................................................................

45

Connection Menu ............................................................................................................................................

46

Function Menu ................................................................................................................................................

46

Parameter ...................................................................................................................................................

47

Memory Menu.............................................................................................................................................

51

Set Options .................................................................................................................................................

52

Tester ..........................................................................................................................................................

54

Data Logger ................................................................................................................................................

56

Alarm Logbook............................................................................................................................................

59

Alarms.........................................................................................................................................................

60

Programming Tilt and Sideshift on the ZAPI Controller (Laptop) ....................................................................

61

Repair ..................................................................................................................................................................

62

Remove ...........................................................................................................................................................

62

Brass Stud Replacement ................................................................................................................................

62

Remove.......................................................................................................................................................

62

Install ..........................................................................................................................................................

62

Install...............................................................................................................................................................

62

Repair..............................................................................................................................................................

62

This section is for the following models:

MPW045-E [B802];

MPW050-E [C802]

©2010 Yale Materials Handling Corp.

i

Summary of Contents for ZAPI MPW045-E

Page 1: ...Maintenance ZAPI CONTROLLERS MPW045 E B802 MPW050 E C802 PART NO 524188546 2200 YRM 1067...

Page 2: ...cifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to...

Page 3: ...g 10 Control Card Functional Test 34 ZAPI PC Interface 36 Connecting PC to ZAPI Controller 36 File Menu 39 Open File 39 TX From File 40 Save File 42 Print Settings 44 Exit 45 Connection Menu 46 Functi...

Page 4: ......

Page 5: ...the controller with auxiliary relay board for different truck models The controller software provides self diagnostics which are accessed by means of a ZAPI handset or a PC with specialized ZAPI softw...

Page 6: ...nd reverse contactors The SEM motor controller operates on the principle of controlling the motor field circuit and the motor armature circuit independently The controller has many programmable featur...

Page 7: ...is made at startup or key ON Perfor mance parameters that vary are acceleration decel eration regenerative neutral braking and top travel speed The three operator selectable performance modes are fac...

Page 8: ...ness to handset NOTE It may be necessary to remove the MDI harness connector from the controller to install the adapter har ness NOTE Connect and disconnect the handset only with the key switch in the...

Page 9: ...URRENT armature current during trac tion positive value or braking negative value 4 FIELD CURRENT field current in the selected traction direction 5 TEMPERATURE controller temperature C 6 ACCELERATOR...

Page 10: ...standby condition truck at rest before switching OFF the controller in or der to store the new values in the EEPROM This section describes the ZAPI handset functions Six buttons provide the capability...

Page 11: ...________________________________________ ____________________________________________________________ ____________________________________________________________ _____________________________________...

Page 12: ...Programming 2200 YRM 1067 8...

Page 13: ...2200 YRM 1067 Programming Figure 4 ZAPI Handset Instructions 9...

Page 14: ...essage displayed on Handset or PC CORRESPONDING SCHEMATIC SHOWING CIRCUITS TO BE CHECKED OR AFFECTED COMPONENT S CONDITION TRUCK RESPONSE POSSIBLE CAUSES AND TEST PROCEDURES LOGIC Brief description of...

Page 15: ...rify continuity between battery positive at bat tery and B 1 and B 12 connection at controller If no continuity check Fuse 2 for open Key switch continuity in ON position Wiring battery to main contac...

Page 16: ...rify continuity between battery positive at bat tery and B 1 and B 12 connection at controller If no continuity check Fuse 2 for open Key switch continuity in ON position Wiring battery to main contac...

Page 17: ...confirm commu nication to handset If handset operates correctly replace MDI Defective LED Disconnect LED and connect handset If handset works replace LED LOGIC Occurs when the MDI or LED receives no...

Page 18: ...go to test menu Check brake switch it should be off If steer handle is in vertical position and reading is not OFF check brake switch for damage interference or shorts Check accelerator Should be 0 v...

Page 19: ...ND TEST PROCEDURES Control card throttle calibration is out of range Install handset Go to tester function of handset If accelerator output is 1V 20 and the enable switch is open recalibrate control c...

Page 20: ...lift ing control and EVP voltage Check on off switches and proportional switches for smooth linear opera tion Replace damaged switches Control card lift lower switch calibration is out of range Instal...

Page 21: ...PONSE Traction and hoist functions disabled POSSIBLE CAUSES AND TEST PROCEDURES Control card throttle device may be damaged or Cam Magnetic Holder may not be properly aligned with Alignment Window Che...

Page 22: ...Verify connection at controller Verify wire harness connection at base of steer han dle Verify connection at control card Damaged or defective control card Measure voltage at pin 5 connector C on the...

Page 23: ...IC Control card is not sending digital signal for the traction reversing switch Dash Display Controller LED Handset or PC AL01 1 Flash INPUT ERROR 2 CONDITION Connection communication error between co...

Page 24: ...connected Dash Display Controller LED Handset or PC 12V AL02 2 Flashes CONTACTOR CLOSED CONDITION Main contactor circuit is damaged TRUCK RESPONSE Traction and hydraulic functions disabled POSSIBLE CA...

Page 25: ...ts and components LOGIC Occurs when the controller detects a short in the main contactor circuit Dash Display Controller LED Handset or PC AL4 4 Flashes EVP NOT OK CONDITION Lowering valve will not op...

Page 26: ...ect coil resistance Disconnect brake Measure brake coil resistance in both directions Coil resistance should be between 28 32 ohms Damaged fly back diode at brake Check coil resistance Short circuit m...

Page 27: ...ault occurs when the voltage measured at the field connections is not the expected value Dash Display Controller LED Handset or PC AL6 6 Flashes I 0 EVER CONDITION Motor current levels do not exceed a...

Page 28: ...oller LOGIC Measured field current is too high Dash Display Controller LED Handset or PC AL6 6 Flashes NO FIELD CURR CONDITION Low field current values measured by controller TRUCK RESPONSE Traction f...

Page 29: ...cts motor currents during standby mode Dash Display Controller LED Handset or PC AL7 7 Flashes THERMAL PROTECTION CONDITION Controller temperature is out of operating range TRUCK RESPONSE Traction fun...

Page 30: ...ance should be between 27 36 and 30 24 ohms Check the electric valve coils for correct resistance of 15 to 20 ohms Value should be within 10 at room temperature Refer to the section Electrical System...

Page 31: ...ircuit in component coil Disconnect battery Disconnect all drive motor pump motor solenoid brake and coil connections at the component end of the harness Tape or secure the wire ends to prevent shorts...

Page 32: ...OSSIBLE CAUSES AND TEST PROCEDURES Loose or damaged cable connections to motor Verify motor armature cables and connections Ground between motor windings and chassis Check for grounds between motor ch...

Page 33: ...OSSIBLE CAUSES AND TEST PROCEDURES Loose or damaged cable connections to motor Verify motor armature cables and connections Ground between motor windings and chassis Check for grounds between motor ch...

Page 34: ...troller Motor field winding is shorted to chassis Check motor field for shorts to chassis LOGIC This fault occurs when the voltage measured at the field connections is not the expected value Dash Dis...

Page 35: ...s Refer to the section Electrical System 2200 YRM 1007 for more information on troubleshooting electrical system circuits and components LOGIC This fault occurs when the voltage measured at the field...

Page 36: ...y if controller has been replaced TRUCK RESPONSE Traction and hydraulic functions disabled for 1 minute POSSIBLE CAUSES AND TEST PROCEDURES No fault is occurring Controller will send hourmeter data to...

Page 37: ...or extremely discharged battery Disconnect battery and check voltage at connector Inspect battery for correct water level and damage Repair or replace battery Defective or damaged connection to batte...

Page 38: ...ted swap the pro portional switch with other proportional switch available within tiller head to verify if problem follow the switch 6 If handset test are not passed open tiller head and verify connec...

Page 39: ...he Electrical System 2200 YRM 1007 section 7 If speed is other than desired refer to Programming in this section NOTE ENSURE THAT THE CAM MAGNETIC HOLDER IS ALIGNED WITH THE ALIGNMENT WINDOW OTHER WIS...

Page 40: ...artment cover to ac cess the controller 3 Locate the communications port on the controller The port will have either a diagnostic LED as in Figure 6 or a connector for the display as in Fig ure 7 Figu...

Page 41: ...7 ZAPI PC Interface 6 You should now see a screen as shown in Fig ure 11 Figure 11 ZAPI Software Screen 7 Click on the START button first and then turn the key switch to ON See Figure 12 Figure 12 Sta...

Page 42: ...1 This tells the current software revision Nominal Voltage 24V Voltage of the controller installed Nominal Current 180A Maximum operating current of the controller Hour 0h Internal hourmeter of the co...

Page 43: ...067 ZAPI PC Interface FILE MENU Open File When you select this function you will be able to open a previously saved file that contains parameter settings for the controller See Figure 14 Figure 14 Fil...

Page 44: ...en sion and observe how the file name was used See the Save File section of this manual for proper file sav ing techniques See Figure 15 Figure 15 Look In TX From File This selection in the file menu...

Page 45: ...2200 YRM 1067 ZAPI PC Interface Notice the CONNECTION STATUS while the file is downloaded into the controller See Figure 17 Figure 17 Connection Status 41...

Page 46: ...le The ZAPI PC software can save configurations for up to 500 controllers When saving a configuration to the PC the following steps should be followed to help track which file goes with each controlle...

Page 47: ...ter a Comment box you can either describe what is different with the settings or enter a customer name Here is what a saved parameter file looks like Info Chopper_Name MPB NA V1 01 User_Comment modifi...

Page 48: ...ZAPI PC Interface 2200 YRM 1067 Print Settings This selection allows you to print out your current pa rameter settings in the controller See Figure 21 Figure 21 File Print 44...

Page 49: ...2200 YRM 1067 ZAPI PC Interface Exit This selection will exit the ZAPI PC console software See Figure 22 Figure 22 File Exit 45...

Page 50: ...the display screen See Figure 23 Figure 23 Connection Menu FUNCTION MENU There are seven selections under this menu 1 Parameter Allows the performance and configu ration of the controller to be adjust...

Page 51: ...controller you have to download them to the PC This can be done by 1 of 2 ways 1 Receive menu This will only download the current selected tab 2 Receive This will download all parameters and configura...

Page 52: ...covered in Set Options in this section Adjustments can be made by first highlighting the pa rameter to be modified and then using the scroll bar on the right side of the screen to adjust it You will a...

Page 53: ...eration curve to a lower speed coasting Level 9 Short deceleration curve to a lower speed aggressive 3 RELEASE BRAKING Amount of braking when the accelerator is released Level 0 Minimum braking coasti...

Page 54: ...s they are being adjusted The lift truck will react to the setting Once the lift truck is performing as wanted the Store button is pressed to save the settings into the controller See Figure 28 Figure...

Page 55: ...he Memory menu to see the screen in Figure 29 Figure 29 Memory Menu This menu has three selections 1 Receive Same as Receive menu and Receive but ton 2 Store Same as Store button 3 Restore Will revert...

Page 56: ...PC Interface 2200 YRM 1067 Set Options This selection will allow Mode 4 to be activated so that the performance parameters can be adjusted for a cus tom configuration See Figure 30 Figure 30 Set Optio...

Page 57: ...ne 1 Press the Store button to save the change into the controller 2 Press the Close button to go to the main screen of the ZAPI PC software 3 Press the Stop button to disconnect the communi cation be...

Page 58: ...on allows the technician to monitor up to four items at a time to help troubleshoot problems See Fig ure 32 Figure 32 Tester The Tester function also features a data logging capa bility to further ass...

Page 59: ...ent of throw from the traction thumbwheel 7 Lifting Control 8 Tiller Switch position of tiller handle 9 Forward Switch directional input 10 Backward Switch directional input 11 Lifting Switch refers t...

Page 60: ...Stop Rec Stops the data logger 4 Save Rec Saves the log to a file The Advanced button allows the user to initiate a series of samples to be taken for the 4 items you have selected in the tester menu...

Page 61: ...er is running the screen will look like what is shown in Figure 36 During the logging process you will still be able to see the values changing in the display menu Once the data logger is done you can...

Page 62: ...ile looks like this see Figure 38 Info Chopper_Name CS P20 V1 00 Save_Date Thu Apr 04 13 32 24 2002 TIME MOTOR CURRENT ACCELERATOR BATTERY CHARGE FIELD CURRENT 0 0 0 00 0 80 0 0 10 0 0 00 0 80 0 0 20...

Page 63: ...2200 YRM 1067 ZAPI PC Interface Alarm Logbook The ZAPI controller can record up to five unique alarms and store them in a logbook that the PC can access See Figure 39 Figure 39 Alarm Logbook 59...

Page 64: ...arm occurred The user can check for new alarms by pressing the Up date key or clear out the alarm log by pressing the Clear key The following list consists of possible alarms Alarms 1 EVP NOT OK 2 BRA...

Page 65: ...Enter Password a Enter the password ZAPI in all capital letters The password can only be entered if the Com Configuration was properly connected in the previous steps b Click OK 4 On the drop down men...

Page 66: ...ntroller BRASS STUD REPLACEMENT Remove 1 Remove M8 nut lockwasher flat washer brass washer power fuse and brass washer from brass stud 2 Remove brass stud from controller Install The stud must be inst...

Page 67: ......

Page 68: ...Yale Materials Handling Corp 1400 Sullivan Dr Greenville NC 27834 2011 2200 YRM 1067 8 10 11 07 8 05 7 03 Printed in U S A...

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