Table of Contents
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.............................................................................................................. 3
1
Introduction to the ZAPIMOS family ............................................................. 4
2
General H2B characteristics ......................................................................... 5
2.1
Technical specifications ......................................................................... 5
2.2
Control unit ............................................................................................. 6
2.2a Microswitches ............................................................................... 6
2.2b Potentiometer ................................................................................ 6
2.3
Protection features ................................................................................. 8
2.4
Performance features ............................................................................. 9
2.5
H2B chopper diagnosis.......................................................................... 9
2.6
Thermal considerations .......................................................................... 9
2.7
2.8
3
Installation .................................................................................................... 12
3.1
Choosing connection cables ................................................................ 12
3.2
Contactors ........................................................................................... 12
3.3
Fuses ................................................................................................... 12
3.4
H2B connectors ................................................................................... 13
3.5
H2B power connectors ......................................................................... 14
3.6
Contactors connector ........................................................................... 15
3.7
H2B chopper mechanical drawing ........................................................ 16
4
Parameter modifications ............................................................................. 17
4.1
Modifying parameters using the digital-console .................................... 17
4.2
Chopper configuration and connections description ............................. 20
5
Traction ........................................................................................................ 22
5.1
H2B regenerative traction ..................................................................... 22
5.1.1 Input connectors description ....................................................... 23
5.1.2 Programmable functions (options) .............................................. 24
5.1.3 Parameter modification .............................................................. 26
5.1.4 Adjustment chart ......................................................................... 28
Variants for braking soft .............................................................. 28
5.1.5 Wiring diagram for H2B regenerative model with pedal .............. 29
5.1.6 Wiring diagram for H2B regenerative model with handle ............. 29
speed check and pick-up ........................................................... 30
and tacho-generator .................................................................... 31
check and backing ...................................................................... 32
5.1.10 Wiring diagram for H2B regenerative model power unit ............ 33
with weakening .......................................................................... 34
weakening ................................................................................. 35
5.2
Sequence of settings for regenerative .................................................. 36
5.3
H2B traction diagnosis ......................................................................... 37
5.4
Decoding console displayed alarms ..................................................... 38
CONTENTS
H2B USER'S MANUAL - 550145G
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Page
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Summary of Contents for Zapi ZAPIMOS H2B
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Page 1: Table Of Contents
CONTENTS Page Legend ......................3 Introduction to the ZAPIMOS family ............. 4 General H2B characteristics ................. 5 Technical specifications ................. 5 Control unit ..................... 6 2.2a Microswitches ................6 2.2b Potentiometer ................6 Protection features ................. 8 Performance features ................9 H2B chopper diagnosis................ - Page 2 Page Pump ......................46 H2B standard lifting ................46 6.1.1 Input connectors ................47 6.1.2 Programmable functions (options) ..........47 6.1.3 Parameter modification .............. 47 6.1.4 Adjustment chart ................. 49 6.1.5 Connection diagram for H2B standard lifting ....... 50 6.1.6 Connection diagram for H2B pump unit with weakening ....50 6.1.7 Connection diagram for H2B, with power unit bypass contactor and main contactor............
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Page 3: Legend
LEGEND = 1st lift speed request = Forward = Key = Brake diode = Flywheel diode = Backward = Weakening = Forward speed microswitch MCL = Horn microswitch = Descent microswitch MEF = Electric brake switch = Backward microswitch = Rise microswitch = Handle microswitch MUM = Dead man microswitch = Contactor negative... -
Page 4: Introduction To The Zapimos Family
1 INTRODUCTION TO THE ZAPIMOS FAMILY The ZAPIMOS chopper family is ZAPI’s answer to the needs of users of the ’90s. To ensure that the product stays on the market without running the risk of becoming technologically obsolete, ZAPI has designed the ZAPIMOS family to offer the following... -
Page 5: General H2B Characteristics
2 GENERAL H2B CHARACTERISTICS 2.1 TECHNICAL SPECIFICATIONS Voltage: ..................24V (14 ÷ 32V) ................36 / 40 / 48V (22 ÷ 55V) ................60 / 72 / 80V (36 ÷ 90V) ..................96V (57 ÷ 120V) Maximum current: ................short size = 400 A ............. -
Page 6: Control Unit
2.2 CONTROL UNIT 2.2a Microswitches Microswitches send a voltage signal when the request for startup or desired function is made. Microswitches for forward, backward, and rapid inversion (if present) are dimen- sioned for carrying the current of one contactor (3 amp). 2.2b Potentiometer In the 3-wire configuration, the CPOT (C1) useful input signal goes from 0V to 10V. - Page 7 fig. 8a fig. 8b The two graphs show the output voltage from an uncalibrated potentiometer with respect to the mechanical “zero” of the knob of one handle (MI and MA indicate the point at which the speed microswitches close, 0 is the mechanical zero of the handle rotation). The first graph (Fig.
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Page 8: Protection Features
2.3 PROTECTION FEATURES Battery inversions: It is necessary to respect the connections indicated in the diagrams in order to avoid damage to the power unit. In the lifting versions, a general contactor may be connected which is handled by the logic against any polarity inversions. The logic is intrinsically protected against polarity inversions. -
Page 9: Performance Features
2.4 PERFORMANCE FEATURES - Optimum sensitivity to low speeds. - Self-diagnosis with indication of the type of anomaly by an optional LED. - Configurable from the console (traction or lifting). - Modification of parameters from the console. - Internal hour-meter with values that can be displayed on the console. - Memorisation of the last 5 alarms tripped, with relative hour-meter value and tempera- ture that can be displayed on the console. -
Page 10: General Notes And Precautions
Take particular care of the length, of the electrical connections and of the braided wires. Therefore ZAPI declines any responsibility for badrunnings that can be attributed to the above mentioned circumstances, above all if the manufacturer of the machine doesn't... -
Page 11: General Contactors And Safety Switch For Regenerative Model
2.8 GENERAL CONTACTORS AND SAFETY SWITCH FOR REGENERATIVE MODEL - The connection of eventual interruption systems of the battery must be executed scrupu- lously respecting one of the following wirings. - With safety switch - With switch and general contactor - These circuital solutions are necessary to avoid the chopper fail when the connection to the battery is opened during the phase of regenerative braking. -
Page 12: Installation
3 INSTALLATION Install the chopper with the base-plate on a flat metallic surface that is clean and unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to permit better heat dissipation. Despite the protection provided against external agents, the continuous attack of corrosive substances may cause the connector contacts to oxidise, thus jeopardising good function- ing. -
Page 13: H2B Connectors
3.4 H2B CONNECTORS function description -LED Alarm LED negative: to be connected to the cathode +LED Alarm LED positive: to be connected to the anode Output current 12mA, for standard type LED PCLRXD Serial reception positive NCLRXD Serial reception negative PCLTXD Serial transmission positive NCLTXD... -
Page 14: H2B Power Connectors
ELECTRICAL CIRCUIT OF INPUT PINS Pin C1 Pins E1, E2, E3, E4, E5, E6, E7 INPUT SIGNAL SYSTEM LEVEL VOLTAGE HIGH >10V <50V >20V <10V >35V <18V 3.5 H2B POWER CONNECTORS Output current sense Battery positive VMN Connected to the power mosfet drain, it supplies a negative to the motor with variable duty cycle Battery negative +SH Input current sense... -
Page 15: Contactors Connector
3.6 CONTACTORS CONNECTORS CONN. WIRE CONN. TRACTION FUNCTION PUMP FUNCTION COLOUR white-green Positive of braking contactor PTFR red-black Contactors positive PT Contactors positive PT Negative field weakening contactor Negative field weakening contactor grey-black coil NTIND coil NTIND blue-black Negative backward contactor coil NTI Negative main contactor coil NTG Negative proportional electrovalve coil red-green... -
Page 16: H2B Chopper Mechanical Drawing
3.7 H2B CHOPPER MECHANICAL DRAWING Page 16/60 H2B USER'S MANUAL - 550145G... -
Page 17: Parameter Modifications
Modification of the parameters, in addition to the configuration of the inputs, is made di- rectly by ZAPI on customer specifications, or the customer may make adjustments himself using the programming console. The console can remain connected to the chopper when running and the parameters can also be varied in real time during operation. - Page 18 ADJUSTMENTS: SET BATTERY TYPE 12V, 24V, 36V, 40V, 48V, 60V, 72V, 80V, 96V, 120V ADJUST BATTERY ..V traction pump PARAMETER CHANGE: ACCELERATION DELAY ACCELERATION DELAY INVERS. BRAKING EV. ACCELER DELAY BRAKING (*) DECELER. DELAY RELEASE BRAKING EV. DECELER DELAY PEDAL BRAKING MAXIMUM CURRENT CUTBACK SPEED 1 HYD SPEED COARSE...
- Page 19 HANDLE / SEAT SW. 2ND SPEED SWITCH BATTERY VOLTAGE 3RD SPEED SWITCH FORWARD SWITCH 4TH SPEED SWITCH BACKWARD SWITCH HYDRO SPEED REQ BATTERY CHARGE (*) BATTERY CHARGE (*) BACKING ENABLE (*) QUICK INVERSION (*) SPEED REFERENCE (*) SPEED VALUE (*) SAVE: Chopper parameters are stored in the console memory.
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Page 20: Chopper Configuration And Connections Description
4.2 CHOPPER CONFIGURATION AND CONNECTIONS DESCRIPTION The choices made regarding power connections must be communicated to the chopper. In order to supply this information, you have to connect the chopper to the programming console and access the set model, set options, and adjustment menus (see specific con- figuration descriptions). - Page 21 ing time parameter. SOFT BRAKING No Soft braking. Soft braking activated. AUX FUNCTION none No Aux function. bimotor contactor AUX G7 output is activated when turning from off status to running status and at the beginning of regenerative braking, and it is switched off when PWM is greater than 20%, both statuses.
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Page 22: Traction
5 TRACTION 5.1 H2B REGENERATIVE TRACTION - Input for 3-wire potentiometer (optional 2-wire on request) - 3 speed reductions - Input for handle microswitch or seat microswitch (delayed 2 sec) - Input for rapid inversion signal - Input for brake pedal microswitch - Weakening or bypass contactor handling - Maximum speed control - Backing request with associated speed and programmable timing... -
Page 23: Input Connectors Description
5.1.1 Input connector description E1 RV3 / QUICK I Input for 3rd speed reduction request. The request is active when the pin is disconnected. To disconnect link to +CH or adjust to level 9 the corresponding speed. This pin can be pro- grammed as input for rapid inversion signal, the safety is active when pin is opened. -
Page 24: Programmable Functions (Options)
B4 STATE REC. During the energy recovery phase the output is activated (that's to say that the output is taken to a low level). It is used for the control of the state of the battery charge level of the instrument "ZILB 93". B7 SPEED SIGNAL* Input for the speed signal caming from a trasducer speed / voltage. - Page 25 4) ANTIROLLBACK No anti-rollback. Anti-rollback. 5) RELEASE BRAKING No regenerative braking at release. Braking active at the moment of pedal release with incre- ment of the braking current by means of the brake pedal. 6) HOUR COUNTER running Hour-meter only active when running. key on Hour-meter active with the key on.
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Page 26: Parameter Modification
10) SOFT BRAKING Every braking current is handled at normal values as showed on the adjustments chart. Every braking current is reduced by 25% when the soft way is selected it is necessary that the jumpers in the card are configured 1-3 and 2-4, and that the maximum current level (IMax) is programmed to a value not inferior to Six. - Page 27 8) CUTBACK SPEED 3 = reduction of speed no.3 associated to input E1. 9) AUXILIARY TIME = Auxiliary contactor activating time connected to the G7 output (request option or hardware modifications are necessary, see p.18) 10) COMPENSATION = compensation of the speed (motor voltage) on the basis of the current when the speed reductions are active.
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Page 28: Variants For Braking Soft
5.1.4 Adjustments chart PARAMETER PROGRAMMED LEVEL UNIT ACCELERATION DELAY Sec. 0.41 0.82 INVERS BRAKING % IMax. BRAKING % IMax. RELEASE BRAKING % IMax. PEDAL BRAKING % IMax. CUTBACK SP. (1-2-3) % VBatt. COMPENSATION K (I) BRAKING MODUL % IMax. I MAX. (H2 600) Amp. -
Page 29: Wiring Diagram For H2B Regenerative Model With Pedal
5.1.5 Wiring diagram for H2B regenerative model with pedal 5.1.6 Wiring diagram for H2B regenrative model with handle H2B USER'S MANUAL - 550145G Page 29/60... -
Page 30: Wiring Diagram For H2B Regenerative Model With Speed Check And Pick-Up
5.1.7 Wiring diagram for H2B regenrative model with speed check and pick-up Page 30/60 H2B USER'S MANUAL - 550145G... -
Page 31: Wiring Diagram For H2B Regenerative Model With Speed Check And Tacho-Generator
5.1.8 Wiring diagram for H2B regenrative model with speed check and tacho- generator H2B USER'S MANUAL - 550145G Page 31/60... -
Page 32: Wiring Diagram For H2B Regenerative Model With Speed Check And Backing
5.1.9 Wiring diagram for H2B regenrative model with speed check and backing Page 32/60 H2B USER'S MANUAL - 550145G... -
Page 33: Wiring Diagram For H2B Regenerative Model Power Unit
5.1.10 Wiring diagram for H2B regenrative model H2B USER'S MANUAL - 550145G Page 33/60... -
Page 34: Wiring Diagram For H2B Regenerative Model Power Unit With Weakening
5.1.11 Wiring diagram for H2B regenrative model with weakening Page 34/60 H2B USER'S MANUAL - 550145G... -
Page 35: Wiring Diagram For H2B Power Unit Regenerative With Bypass
5.1.12 Wiring diagram for H2B power unit regenerative with by-pass 5.1.13 Wiring diagram for H2B power unit regenerative with weakening H2B USER'S MANUAL - 550145G Page 35/60... -
Page 36: Sequence Of Settings For Regenerative
5.2 SEQUENCE OF SETTINGS FOR REGENERATIVE - With the machine switched off, connect the programming console and then switch on. If no wiring errors or component defects are found, the display shows the manufacturer’s name, programme release, configuration, and hour-metre value. If the module has already been configured, the procedure passes directly to step four. -
Page 37: H2B Traction Diagnosis
5.3 H2B TRACTION DIAGNOSIS Description of the alarms signalled by the diagnostic LED. The alarm code is shown in parentheses. A detailed description is given in the section “DECODING THE ALARMS DISPLAYED ON CONSOLE” on point 5.5. 1 BLINK = Logic anomaly (EEPROM DATA KO, EEPROM PAR. -
Page 38: Decoding Console Displayed Alarms
5.4 DECODING CONSOLE DISPLAY ALARMS 1) BRAKE CON CLOSED Test carried out in the passage from running to initial regenerative braking. If, on running contactor closure, the VMN is > 2/3 VBATT, an alarm is issued. Possible causes: a) The normally open contact of the braking contactor is stuck. Unlock the contact and clean it;... - Page 39 It could be necessary changing both contactors. A2) There is not a good contact either on TI NA or on TA NC, due to dust, dirt or any particles which prevent a valid contact. Clean contacts by means of compressed air; if necessary remove dirt applying a soft abrasive movement.
- Page 40 B1) Forward contactor (TA) is supplied with a correct voltage but it doesn’t close. Possible causes: Contactor coil is interrupted, verify its resistance using an ohmmeter. Contact can’t move due to mechanic block. Nominal working coil voltage is greater than battery one. B2) Backward contactor (TI) is supplied with a correct voltage but it doesn’t close;...
- Page 41 FAULT TEST RESULT 2° TEST RESULT 3° TEST RESULT DESCRIPTION AT POINT → → → → AT RUNNING REQUEST THE TFR CLOSES FOR WHEN THERE'S THE CHECK WITH AN 0.3sec? RUNNING REQUEST, IS OHMMETER OF THE TFR THERE A VOLTAGE AT PIN COIL IS INTERRUPTED BTFR FOR A TIME OF 0.3sec?
- Page 42 5) VMN LOW The test is carried out at standby and in running up to 80% of PWM. If the VMN voltage is lower than 1/3 of the battery voltage, an alarm is shown. For finding out the causes follows the diagnosis procedure herefollowing: CONDITIONS FAULT UNDER WHICH...
- Page 43 D2) There is a current dispersion in the motor between the stator winding and the armature one otherwise there are some electric parts of these windings that makes a contact inside the motor. D3) Check that there are not metallic parts inside the contactor board that cause a short towards the negative in the points connected to SH- and SH+.
- Page 44 10) INCORRECT START An incorrect starting sequence. The machine only starts if the sequence is followed: key-handle (or seat) - running. Possible causes: a) Running microswitch or handle microswitch stuck. b) Error in sequence made by the operator, pedal pressed at the key on. c) Incorrect wiring if there is not any defects externally is necessary to replace the logic..
- Page 45 16) EEPROM CONF.KO Fault in the area of memory in which the special chopper configuration data is stored. If the defect persists when the key is switched off and on again, replace the logic. Other- wise, keep in mind that the chopper configuration has been reset to the default values (regeneration version, etc.);...
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Page 46: Pump
6 PUMP 6.1 H2B STANDARD LIFTING - Input for speed controlled by 3-wire potentiometer - 4 speeds with separately adjustable compensation - 1 speed with associated delay (for hydrodrive) and adjustable compensation - Main contactor handling - Weakening or bypass contactor handling - Proportional solenoid valve handling for descent Page 46/60 H2B USER'S MANUAL - 550145G... -
Page 47: Input Connectors
6.1.1 Input connectors pin function description 4TH S. Input for 4th speed request. The speed is active when the pin is high, connected to +Batt. 3RD S. Input for 3rd speed request. The speed is active when the pin is high, connected to +Batt. 2ND S. -
Page 48: Parameter Modification
2) BYPASS CONTACTOR bypass The contactor connected to connector G3 is handled as bypass, with activation current =<80%Imax., output current =<90%Imax., activation delay= 800 msec. weakening cont. The contactor connected to connector G3 is handled as weakening, with activation current = 50% of the pro- grammable output current (WEAK DROP OUT) from 10% to 100% Imax. -
Page 49: Adjustment Chart
12) HYDRO TIME = Hydrodrive delay time. If set at 0, there is no delay; thus the hydrodrive input can be handled as a 5th speed. 13) 1ST SPEED COARSE = Speed no. 1, coarse adjustment. 14) 1ST SPEED FINE = Speed no. 1, fine adjustment. 15) 1ST SPEED COMP. -
Page 50: Connection Diagram For H2B Standard Lifting
6.1.5 H2B electrical connection diagram standard lifting 6.1.6 Connection diagram for H2B pump unit with weakening Page 50/60 H2B USER'S MANUAL - 550145G... -
Page 51: Connection Diagram For H2B, With Power Unit Bypass Contactor And Main Contactor
6.1.7 Connection diagram for H2B pump unit, with by-pass contactor and main contactor 6.1.8 H2B power unit standard connection diagram H2B USER'S MANUAL - 550145G Page 51/60... -
Page 52: H2B Lifting + 3Rd Motor
6.2 H2B LIFTING + 3RD MOTOR - Input for speed control by potentiometer - 4 speeds with separately adjustable compensation - Contactor handling with programmable delay (3rd hydrodrive motor) and adjustable compensation - Main contactor handling - Weakening or bypass contactor handling - Proportional solenoid valve handling for descent Page 52/60 H2B USER'S MANUAL - 550145G... -
Page 53: Input Connectors
6.2.1 Input connectors pin function description E1 4TH S. Input for 4th speed request. The speed is active when the pin is connected to +Batt. E2 3RD S. Input for 3rd speed request. The speed is active when the pin is connected to +Batt. E3 2ND S. -
Page 54: Parameter Modification
4) MAIN CONTACTOR present The output G5 handles a main contactor. running status The output G5 is active when the chopper is carrying out any function (except descent). A detailed description of the meanings is given on point 6.1.2 as per the H2B standard lifting model. -
Page 55: H2B Power Unit Wiring Lifting + Hydrodrive + Weakening
6.2.5 H2B power unit wiring lifting + hydrodrive + weakening 6.3 SEQUENCE OF SETTING FOR LIFTING - With the machine switched off, connect the programming console and then switch on. If no wiring errors or component defects are found, the display shows the manufacturer’s name, programme release, configuration, and hour-metre value. -
Page 56: Setting The Proportional Solenoid Valve
6.4 SETTING THE PROPORTIONAL SOLENOID VALVE - For handling the solenoid valve, it is necessary to fit the potentiometer and the descent request microswitch. 1) Carry out the potentiometer signal acquisition using the “PROGRAM VACC” function. 2) With the lever in minimum speed position, set the “MIN VALUE VOLT” parameter by incrementing the level until it begins to descend. - Page 57 2) NO FULL COND. The test is carried out in full conduction. If, in this condition, the VMN is found to be greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, and thus machine operation is inhibited. If the defect persists, replace the logic.
- Page 58 9) EEPROM CONF.KO Fault in the area of memory in which the special chopper configuration data is stored. If the defect persists when the key is switched off and on again, replace the logic. Other- wise, keep in mind that the chopper configuration has been reset to the default values (regeneration voltage, etc.);...
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Page 59: Recommended Spare Parts For H2B
7 RECOMMENDED SPARE PARTS ARTICLE CODE NO. DESCRIPTION E07008 Potentiometer 5 kohm 330 C22000 Microswitch 10A 250V 1-way C16506 Protected power fuse 425A C16507 Protected power fuse 500A C12373 9-way molex female connector C12371 3-way molex female connector C12370 2-way molex female connector. C12769 Female connector (molex) C12203... -
Page 60: Periodic Maintenance To Be Regulary Repeated
The disposal and recycling of this controller has to follow the local laws for these types of waste materials. Zapi commits itself to update its technology in order to reduce the presence of polluting substances in its product. Page 60/60... - Page 61 ELECTRONIC INDUSTRIAL DEVICES 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel. +39 0522 960050 (r.a.) - Fax +39 0522 960259 - e-mail: zapi@zapispa.it ZAPIMOS H2B USER'S MANUAL...
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