Index

Page
1 Features ......................................................................................................... 2
1.1 Specification .......................................................................................... 2
1.2 Functional Description ............................................................................ 3
1.2.a LED function .................................................................................. 3
1.2.b DISPLAY function .......................................................................... 3
2 Installation ...................................................................................................... 5
2.1 Connection Drawing ............................................................................... 5
2.2 Dimensions ............................................................................................ 6
3 Programmation and adjustments ................................................................. 7
3.1 Battery Discharge algorithm ................................................................... 7
3.2 Maintenance / Service .......................................................................... 10
3.3 Hour-meter Memory service ................................................................. 11
4 Alarms ........................................................................................................... 12
4.1 Decoding of the Alarms displayed ........................................................ 12

SIGNED IN APPROVAL

COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE

ENGINEERING SECTION EXECUTIVE

EXPORT MANAGER

Pubblication n.: AD2ZP0CB

Edition: March 2003
Page 1
 1 FEATURES
1.1 SPECIFICATIONS

- ZAPI MDI is an indicator suitable for every type of battery powered vehicle equipped
with a high frequency traction controller from Zapimos family.
- This Unit is supplied directly from the chopper and not by the battery. In this way the
same device can be used on systems with different battery voltages.
- The battery's state of charge is obtained with an advanced algorithm made by the mi-
croprocessor. This algoritm considers the condition of braking or large acceleration
current demands from the drive motor.
- Using the Zapi PROGRAMMING CONSOLE, it is possible to make a selection from
100 different types of discharge curves.
- ZAPI MDI is a microprocessor- based system that allows high precision, reliability and
adaptability in the measurement of the battery's state of charge, and the calculation of
the hours worked.
- The ZAPI MDI indicator has three internal functions.
- Indication of the battery's state of charge
- Operating hour meter
- Indication of the system Alarms.
- As this unit is not connected directly to the battery, the ZAPI MDI does not require the
complex auxiliary wiring associated with traditional indicators.The wiring is "point-to-
point"(from the indicator directly to the chopper). In this way, the wiring of the machine is
simpler, with reduced costs and installation time.

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 1.2 FUNCTIONAL DESCRIPTIONS
1.2.a LED function

Battery State of charge.

Five LEDs, show the battery's State of Charge. Four Green, and one Red. With a fully
charged battery, all the Green LEDs are illuminated. As the battery becomes discharged,
the Green LEDs turn off progrssively, one after the other, in proportion to the residual
charge of the battery,until value of residual charge is reached. At this time the Red Led
illuminates indicating a discharged battery.

1.2.b DISPLAY function

Hour meter
An alpha-numeric liquid crystal display is fitted in the centre of the unit that shows the Hours
Worked.

Alarms
The same display can also indicate the Alarm state, showing a Code corresponding to the
type of Alarm. To attract attention, the Red LED will start flashing when an Alarm is gener-
ated.

Software version
When the Key Switch is initially closed, the display shows the Eprom Version for a few
seconds. (EPXXX where XXX represents the version). Simultaneously the symbol of a
Shifting Spanner appears.

Page 3
Other information
Three symbols inform the operator as follows:

Turtle Symbol
Shows activation of the “soft” mode of the truck, Maximum speed and acceleration are
reduced.

Shifting Spanner Symbol

Shows the request of programmed maintenance or the state of Alarm. In this case the
relative code will be displayed. The information supplied by the MDI can be extremely
useful. Failures can be quickly identified by the Operator or Service Technician thereby the
fastest solution to the problem;

Sand Glass Symbol

This Symbol flashses when the Hour Meter is working.

Page 4
 2 INSTALLATION
2.1 CONNECTION SCHEME

Page 5
 2.2 DIMENSIONS

Page 6
 3 PROGRAMMING AND ADJUSTMENTS

Using the Zapi console, it is possible to configure the following options:

- The battery discharge algorithm
- The service maintenance
- The hour meter memory service.

3.1 BATTERY DISCHARGE ALGORITHM

The Battery Discharge algorithm is adjustable. The limits of the discharge curve can be
programmed.
Parameters allowing this adjustement are:

- ADJUSTMENT #1 = This modifies the voltage limit which reduces the 100% charge to
90% charge.
- ADJUSTMENT #2 = This modifies the voltage limit which reduces the 20% from the
charge 10%
Any other limit (80%, 70%, 60%,…..) is modified linearly.

Note :

- The parameter set at 0 represents a decrease of the limit of 3.21%

- The parameter set to 9 represents an increase of the limit of 2.75%
Default values are at level 5 (there is no correction of the limits).

The following chart shows the values of the battery limits with the default parameters.
Remember that the values are relative to readings taken with battery currents between
15% and 27% of the maximum (armature) current.

% IN THE N UMBER O F
CO N DITIO N O F THE BATTERY VO LTAGE
CO N SO LE TESTER LEDs O N MDI
V BATT > 99.54% V N O M 100% 4 LED GREEN
V BATT ≤ 99.54% V N O M 90% 3 LED GREEN
V BATT ≤ 98.62% V N O M 80% 3 LED GREEN
V BATT ≤ 97.25% V N O M 70% 3 LED GREEN
V BATT ≤ 96.33% V N O M 60% 2 LED GREEN
V BATT ≤ 95.41% V N O M 50% 2 LED GREEN
V BATT ≤ 94.50% V N O M 40% 2 LED GREEN
V BATT ≤ 93.57% V N O M 30% 1 LED GREEN
V BATT ≤ 92.20% V N O M 20% 1 LED GREEN
V BATT ≤ 91.28% V N O M 10% 1 LED RED

Page 7
It has to be considered that:-

Once the controller is turned on, the charge can decrease

- It is possible to reach the 100% charge only at turning on after a re-charge, except in the
case in which the preceding turn off, the charge was over 70%. When this happens, the
displayed percentage (ex. 80%) is reteined longer than normal.This is because the true
voltage is higher than the dispalyed value. It becomes necessary to wait until the true
voltage decreases until it reaches the limit of the displayed percentage
- It is advised to charge batteries when low charge percentages are reached (example
10%, 20%, 30%).This will extend the life of the battery. .

Using the ZAPI Console, it is possible to modify the limits of the algorithm for battery dis-
charge, as follows:

1) Zapi Opening Menu.

2) Press ENTER to access to Menus

3) The PARAMETER CHANGE Menu appears

4) Press ROLL UP until the “ALARMS” Menu

is displayed.

5) Press ENTER to access the Menu

6) The First / last alarm memorised in the

logbook appears

7) Press ROLL UP and ROLL DOWN together to find the

"Zapi Protected Menù"

8) The heading of the Menu appears, together

with the first Sub-Menù item.
9) Press ROLL UP or ROLL DOWN to find the
HARDWARE SETTING Menu

Page 8
10) The heading HARDWARE SETTING appears

11) Press ENTER to access the Menu

12) Now Press buttons ROLL UP or ROLL DOWN to the

desired option to be changed.

13) When found, the option (ex. Adjustment #1) is

displayed with its value, previously set or with
the default value
14) Now press buttons PARAM or SET to modify
the dispalyed value.

15) The new value is displayed

16) Press OUT button to leave Menu

17) Finally press ENTER to confirm modification.

Follow the procedure from point 5 to point 12 to make other adjustments (ex adjustment
#2).

IMPORTANT:
Before making tests on a discharged battery, it is reccomended to check (with a cali-
brated digital multimeter), that the value Battery Voltage dispalyed in the “Tester" Menu of
the Zapi Console, is the same as the same as the true battery voltage.
If the two voltages are not the same, it is necessary to make a calibration. This can be
made using the "Adjust Battery" facility located in the "Adjustement" Menu. For further
information, see the Manual applicable to the controller to wich the MDI is connected.

Page 9
 3.2 MAINTENANCE SERVICE

- The MDI indicator may display the Alarm “AL 99” corresponds to “CHECK UP
NEEDED” on the Zapi console, and informs the operator that it is necessary for the
machine to receive some service.
- The display of this Alarm depends on how the operation “CHECK UP TYPE” is set in
the Zapi Console.
- The performance of the machine also depends on this parameter (reduction or disabling
of the traction function).

In the following chart, the type of behaviour is shown according to how the parameter
“CHECK UP TYPE” has been set.

STATE OF THE DISPLAYED

380 HOURS SPEED 380 HOURS STOP
OPTION CHECK ALARM 340
REDUCTION OF THE MACHINE
UP TYPE HOURS

NONE NO NO NO

OPTION 1 YES NO NO

OPTION 2 YES YES NO

OPTION 3 YES YES YES

Note:

- the state of the option “CHECK UP TYPE” on default is NONE. Therefore in this configu-
ration the Alarm is not shown and does not cause any speed reduction or disabling of
the traction motor.
- To cancel the Alarm it is necessary to set option " CHECK UP DONE" to ON.This can
be found in the HARDWARE SETTING Menu (Zapi Protected Menu) of the
Console.When this change has been made, esxit all Menus so that Zapi Opening
Dispaly is seen. The Key switch should be turned off and after 10 seconds turned on
again.
- If it is required to activate the maintenance function, after the machine has done some
hours of work, it is necessary to set option "CHECK UP DONE" to ON. This permits a
reset of the maintenance hour-meter. As above, when this change has been made, exit
all Menus so that the Zapi Opening Display is seen. The key switch should be turned off
and after 10 seconds turned on again.
- In case you wish to activate the maintenance function also after the machine has done
some hours of work, you have to set ON the option “CHECK UP DONE” which permits
to reset the maintenance hour-meter. Turning off and on again the key, the function will
self-reset to OFF.

Page 10
 3.3 HOUR-METER MEMORY SERVICE

The MDI indicator retains the Hour Meter value in its own memory (EEPROM). It is possi-
ble to transfer the Hour Meter values into other controllers, should a raplacement be
rquired. In this way there is no loss of the Hour Meter record for a particular machine.

This can achieved as follows:

- With the key Switch open, connect the ZAPI Console. (Midi NOT connected).
- Close the key Switch. Set the function "LOAD HM FROM MDI"to ON.This can be
found in the HARDWARE SETTING Menu (Zapi Protected menu). In some ver
sions, this function may be called "AUX FUNCTION1".
- Open the key switch. Disconnected the Zapi Console. Connect the MDI and then
close the key Switch.

The repalcement controller will now receive and retain the Hour Meter value of the previous
controller.

It has to be considered that:

- On default, the parameter "LOAD HM FROM MDI" is set to OFF. Therefore if this type of
function is not activated as described above, at turn on the memory of the hour-meter
will be lost.
- To avoid this situation (at present only in some versions of Dual-Sem or Asyncronous
controllers) should the operator forget to set parameter, the MDI signals the alarm " AL
98" for 1 minute (during this time traction is disabled). This warms the operator of the
imminent cancellation of the Hour Meter Memory.After 1 minute, if the operator has not
intervened, theHour Meter of the MDI will be re-written, with the Hour Meter value of the
new controller (Zero Hours if the controller is new).

Page 11
 4 ALARMS

The ZAPI MDI gives indication of the Alarm of the controller to which it is connected, with a
corresponding code..
When an Alarm is generated, the Red LED flashes to attract the attention of the operator.
The symbol of Shifting Spanner also appears.

4.1 DECODING OF THE ALARMS DISPLAYED ON THE MDI

Using the indication given by the MDI and after reference to the following chart, the opera-
tor can solve the problem, if the failure is not serious. It will also be necessary to refer to the
paragraph describing the Alarms in the Manual of the relevant controller.
If the Alarm information suggests or indicates a serious problem,the operator will be able
to give useful information to the Service Centre, thereby reducing down time with relative
costs savings.

AL 00 NONE
AL 01 CHOPPER RUNNING
AL 02 NO COMUNICATION
AL 03 UNKNOWN CHOPPER
AL 04 CONSOLE EEPROM
AL 05 SERIAL ERROR 2
AL 06 SERIAL ERROR 1
AL 07 CHOPPER NOT CONFIG
AL 08 WATCHDOG
AL 09 FIELD FF FAILURE

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AL 10 EEPROM DATA KO
AL 11 EEPROM PAR KO
AL 12 EEPROM CONF KO
AL 13 EEPROM KO
AL 14 EEPROM OFFLINE
AL 15 LOGIC FAILURE 5
AL 16 LOGIC FAILURE 4
AL 17 LOGIC FAILURE 3
AL 18 LOGIC FAILURE 2
AL 19 LOGIC FAILURE 1
AL 20 FORW VMN LOW
AL 21 FORW VMN HIGH
AL 22 BACK VMN LOW
AL 23 BACK VMN HIGH
AL 24 LEFT VMN LOW
AL 25 LEFT VMN HIGH
AL 26 RIGHT VMN LOW
AL 27 RIGHT VMN HIGH
AL 28 PUMP VMN LOW
AL 29 PUMP VMN HIGH
AL 30 VMN LOW
AL 31 VMN HIGH
AL 32 VMN NOT OK
AL 33 NO FULL COND
AL 34 RGT NO FULL COND
AL 35 LFT NO FULL COND
AL 36 PU NO FULL COND
AL 37 CONTACTOR CLOSED
AL 38 CONTACTOR OPEN
AL 39 BRAKE DON' T CLOSED
AL 40 BRAKE CONT OPEN

Page 13
 AL 41 DIR CONT CLOSED
AL 42 DIR CONT OPEN
AL 43 RIGHT CONT CLOSED
AL 44 RIGHT CONT OPEN
AL 45 LEFT CONT CLOSED
AL 46 LEFT CONT OPEN
AL 47 MAIN CONT CLOSED
AL 48 MAIN CONT OPEN
AL 49 I=0 EVER
AL 50 LEFT I=0 EVER
AL 51 RIGHT I=0 EVER
AL 52 PUMP I=0 EVER
AL 53 STBY I HIGH
AL 54 LEFT STBY I HIGH
AL 55 RGT STBY I HIGH
AL 56 PUMP STBY I HIGH
AL 57 HIGH FIELD CURR
AL 58 NO FIELD CURR
AL 59 HIGH BRAKING I
AL 60 CAPACITOR CHARGE
AL 61 HIGH TEMPERATURE
AL 62 TH PROTECTION
AL 63 THERMIC LEVEL 2
AL 64 PUMP TEMPERATURE
AL 65 MOTOR TEMPERATURE
AL 66 BATTERY LOW
AL 67 BATTERY LEVEL 2
AL 68 BATTERY LEVEL 1
AL 69 CURRENT SENS KO
AL 70 POWER FAILURE 4
AL 71 POWER FAILURE 3

Page 14
AL 72 POWER FAILURE 2
AL 73 POWER FAILURE 1
AL 74 DRIVER SHORTED
AL 75 CONTACTOR DRIVER
AL 76 COIL SHORTED
AL 77 COIL INTERRUPTED
AL 78 VACC NOT OK
AL 79 INCORRECT START
AL 80 FORW + BACK
AL 81 BAD STEER 0 SET
AL 82 ENCODER ERROR
AL 83 BAD ENCODER SIGN
AL 84 STEER SENS KO
AL 85 STEER HAZARD
AL 86 PEDAL WIRE KO
AL 87 PEDAL FAILURE
AL 88 TRACTION BRUSHES
AL 89 PUMP BRUSHES
AL 90 DRIVER 1 KO
AL 91 DRIVER 2 KO
AL 92 DRIVER 1 SIC KO
AL 93 DRIVER 2 SIC KO
AL 94 INPUT ERROR 6
AL 95 INPUT ERROR 5
AL 96 INVERSION
AL 97 POSITION HANDLE
AL 98 INPUT ERROR 2
AL 99 INPUT ERROR 1

Page 15
Important:
The alarms reported in the previous tables are refered to Zapi standard coding.
Customized software or special products can have same changements in the alarms
indications.
Following you can find same example:

COD. MDI ALARM CHOPPER

AL 15 V FIELD NOT OK SEM-0 / SEM-1C
AL 15 R VMN NOT OK DUAL-SEM
AL 16 SYSTEM CHECK KO SEM-2 / SEM-3 / COMBI-SEM
AL 16 L VMN NOT OK DUAL-SEM
AL 17 PUMP MOTOR TEMP. SEM-2 / SEM-3 / COMBI-SEM
AL 17 R V FIELD NOT OK DUAL-SEM
AL 18 BRAKE DRIVER KO SEM-2 / SEM-3 / COMBI-SEM
AL 18 L V FIELD NOT OK DUAL-SEM
AL 70 PUMP VACC NOT OK SEM-2 / SEM-3 / COMBI-SEM
AL 70 R FIELD I LOW DUAL-SEM
AL 71 HANDBRAKE SEM-2 / SEM-3 / COMBI-SEM
AL 71 L FIELD I LOW DUAL-SEM
AL 72 R FIELD I HIGH DUAL-SEM
AL 73 L FIELD I HIGH DUAL-SEM
AL 94 MICRO CHECK KO DUAL-SEM
AL 95 OPERATOR ABSENT DUAL-SEM
AL 96 BRAKE DRIVER KO DUAL-SEM
AL 97 HANDBRAKE DUAL-SEM
AL 98 CLEARING MDI HM DUAL-SEM
AL 99 CHECK UP NEEDED SEM-0 / SEM-1C

Page 16
 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]

INSTALLATION AND
USER MANUAL
MDI
( Multifunction Digital Indicator )