Zapi ZAPIMOS H2 96V 400A User Manual
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Zapi ZAPIMOS H2 96V 400A User Manual

Zapi ZAPIMOS H2 96V 400A User Manual

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COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI
42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA
Tel. (0522) 960050 (r.a.) - Tlx. 530021 AINDRE I - Fax (0522) 960259
ZAPIMOS H2B
ZAPIMOS H2B
ZAPIMOS H2B
ZAPIMOS H2B
ZAPIMOS H2B
USER'S
USER'S
USER'S
USER'S
USER'S
MANU
MANU A L
MANU
A L
A L
A L
MANU
MANU
A L

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Summary of Contents for Zapi ZAPIMOS H2 96V 400A

  • Page 1 COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE - OLEODINAMICHE - INDUSTRIALI 42028 - POVIGLIO - (R.E.) - Via Parma, 59 - ITALIA Tel.

  • Page 2: 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 3 Page 5.2.5 Wiring diagram for H2B standard traction with pedal ....38 5.2.6 Wiring diagram for H2B standard traction with handle ....38 5.2.7 Wiring diagram for H2B power unit standard traction with weakening ................39 5.2.8 Wiring diagram for H2B power standard with 5 cables motor ... 39 Sequence of settings for regenerative / standard traction ....

  • Page 4: 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 5: 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 6: 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 7: 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 8 fig. 8a fig. 8b The two graphs show the output voltage from an uncalibrated potentiometer with re- spect 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 rota- tion).

  • Page 9: 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 10: 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 tem- perature that can be displayed on the console.

  • Page 11: 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...
  • Page 12 2.8 GENERAL CONTACTORS AND SAFETY SWITCH FOR REGENERATIVE MODEL - The connection of eventual interruption systems of the battery must be executed scrupulously 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 13: 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 corro- sive substances may cause the connector contacts to oxidise, thus jeopardising good functioning.

  • Page 14: 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 15: 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 16: Contactors Connector

    3.6 CONTACTORS CONNECTOR 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 17: H2B Chopper Mechanical Drawing

    3.7 H2B CHOPPER MECHANICAL DRAWING Page 16 H2B general description...

  • Page 18: Parameter Modifications

    4 . PARAMETER MODIFICATIONS Modification of the parameters, in addition to the configuration of the inputs, is made directly by ZAPI on customer specifications, or the customer may make adjustments himself using the programming console or the mini-console, (with the later only certain parameters can be modified).

  • Page 19: Modifying Parameters Using The Digital-Console

    4.2 MODIFYING PARAMETERS USING THE DIGITAL-CONSOLE The digital console displays the model type and its built-in hourmeter. SEL MODEL REGENER STANDARD TR. STANDARD PUMP PUMP + HYDRO SEL OPTION: PIN G3 bypass / weak SPEED free / check BATTERY free / check free / check RELEASE free / braking...
  • Page 20 traction pump TESTER: VMN 30% VMN 30% VMN 80% VMN 80% DIRECTION E7/E6 DIRECTION E7/E6 ACCELERATOR ACCELERATOR CURRENT CURRENT TEMPERATURE TEMPERATURE CUTBACK E1/E2/E3 SPEED E5/E3/E2 BRAKE E5 SPEED E1/E4 SEAT / HANDLE BATTERY BATTERY MOTOR VOLTAGE MOTOR VOLTAGE SAVE : Chopper parameters are stored in the console memory.

  • Page 21: Chopper Configuration And Connections Description

    4.3 CHOPPER CONFIGURATION AND CONNECTIONS DESCRIPTION The choices made regarding power connections must be communicated to the chop- per. In order to supply this information, you have to connect the chopper to the program- ming console and access the set model, set options, and set battery menus (see spe- cific configuration descriptions).
  • Page 22 - AUXILIARY FUNCTION: It allows the aux output of the connector G7 to be active under certain conditions. We can set it in the following way: 1) CURRENT GAIN: It is the logic board standard way of working. The output AUX G7 is not used.

  • Page 24: 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 25: 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 programmed as input for rapid inversion signal, the safety is active when pin is opened.

  • Page 26: Programmable Functions (Options)

    B4 STATE REC. During the energy recovery phase the output is acti- vated (that's to say that the output is taken to a low level). It is used for the control of the state of the bat- tery charge level of the instrument "ZILB 93". B7 SPEED SIGNAL* Input for the speed signal caming from a trasducer speed / voltage.
  • Page 27 4) ARB free No anti-rollback. check Anti-rollback. 5) RELEASE free No regenerative braking at release. check Braking active at the moment of pedal release with increment of the braking current by means of the brake pedal. 6) HOURS running Hour-metre only active when running. key on Hour-metre active with the key on.

  • Page 28: Parameter Modification

    5.1.3 Parameter modification (PROGRAM MENU) The parameters can be modified with the chopper in standby or running. In the latter case, you must return to standby before switching off the chopper so that the modifications are stored in the nonvolatile memory. Regenerative traction parameters.

  • Page 29: Variants For Braking Soft

    5.1.4 Adjustments chart PROGRAMMED LEVEL UNIT PARAMETER ACCELERATION DELAY Sec. 0.41 0.82 INVERS 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 30: 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 Page 28 H2B regenerative traction...
  • Page 31 H2B regenerative traction Page 29...
  • Page 32 Page 30 H2B regenerative traction...
  • Page 33 H2B regenerative traction Page 31...
  • Page 34 Page 32 H2B regenerative traction...
  • Page 35 H2B regenerative traction Page 33...

  • Page 36: 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 Page 34 H2B regenerative traction...
  • Page 37 5.2 H2B STANDARD TRACTION - Input for speed controlled by 3-wire potentiometer - N. 3 reduction speeds. - Handle or seat (2 sec. delayed) switches input. - Quick inversion input. - Bypass or weakening contactor handling. H2B standard traction Page 35...

  • Page 38: H2B Standard Traction

    5.2.1 Input connectors Pin Function Description E1 RV3 Input for 3rd speed reduction or rapid inversion request. QUICK I Rapid inversion request. E2 RV2 Input for 2nd speed reduction request. BACKING Back request. E3 RV1 Input for 1st speed reduction request with curve braking combined. E4 MSEAT Input for seat microswitch signal (delayed 2 sec.) or handle signal.

  • Page 39: Parameter Modification (Traction)

    5.2.3 Parameter modifications (TRACTION) The parameters can be modified with the chopper standby or running. In the latter case, you must return to standby before switching off the chopper so that the modifica- tions are stored in the chopper’s nonvolatile memory. ACCELER.DELAY Acceleration time BRAKING...

  • Page 40: Wiring Diagram For H2B Standard Traction With Pedal

    5.2.5 Wiring diagram for H2B standard traction with pedal 5.2.6 Wiring diagram for H2B standard traction with handle Page 38 H2B standard traction...

  • Page 41: Wiring Diagram For H2B Power Unit Standard Traction With Weakening

    5.2.7 Wiring diagram for H2B power unit standard traction with weakeening 5.2.8 Wiring diagram for H2B power standard with 5 cables motor H2B standard traction Page 39...

  • Page 42: Sequence Of Settings For Regenerative / Standard Traction

    5.3 TABLE OF MODIFICATIONS SEQUENCE OF SETTINGS FOR REGENERATIVE / STANDARD TRACTION - 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 manu- facturer’s name, programme release, configuration, and hour-metre value.

  • Page 43: H2B Traction Diagnosis

    5.4 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 44: Decoding Console Displayed Alarms

    5.5 DECODING CONSOLE DISPLAYED ALARMS 1) BRAKE CON CLOSED (only regenerative version) 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.
  • Page 45 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 apply- ing a soft abrasive movement.
  • Page 46 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 47 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? OHMMETER OF THE TFR RUNNING REQUEST, IS THERE A VOLTAGE AT PIN COIL IS INTERRUPTED BTFR FOR A TIME OF 0.3sec?
  • Page 48 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 UNDER FAULT WHICH FAULTS IS...
  • Page 49 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 50 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 51 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. Otherwise, keep in mind that the chopper configuration has been reset to the default values (regeneration version, etc.);...

  • Page 52: 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 50 H2B standard lifting...

  • Page 53: H2B Standard Lifting

    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 54: Programmable Functions (Options)

    6.1.2 Programmable functions (OPTIONS) These options can be programmed from the console with the “SEL OPTIONS” menu pin/function option description PIN G3 bypass The contactor connected to connector G3 is handled as bypass. Activation current = <80% IMAX. Output current = <90% IMAX. Activation delay = 800 ms.
  • Page 55 8) HYD SPEED FINE = Fine hydrodrive speed (a value from 0 to 10% Vbatt is added to the coarse speed value). The speed is given by: motor voltage = [(coarse speed) x 10 + (fine speed)] x Vbatt /100 The interval of values ranges from 0 to total conduction.

  • Page 56: Adjustment Chart

    6.1.4 ADJUSTMENT CHART PROGRAMMED LEVEL UNIT PARAMETER ACCELERATION DELAY* Sec. 0.15 0.24 0.39 0.50 0.63 0.74 0.86 0.97 1.09 1.22 EV. ACCELER DELAY Sec. 0.39 0.63 0.71 0.81 0.97 1.05 1.27 1.36 1.46 1.54 DECELER DELAY Sec. 0.06 0.13 0.19 0.25 0.31 0.38 0.44 0.50 0.56 0.62 EV.

  • Page 57: Connection Diagram For H2B Pump Unit With Weakening

    6.1.5 H2B electrical connection diagram standard lifting 6.1.6 Connection diagram for H2B pump unit with weakening H2B standard lifting Page 55...

  • Page 58: H2B Power Unit Standard Connection Diagram

    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 Page 56 H2B standard lifting...

  • Page 59: 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 H2B lifting + 3rd motor Page 57...

  • Page 60: 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 61: H2B Electrical Connection Diagrams Pump + Hydro

    6.2.4 H2B electrical connection diagrams pump + hydro 6.2.5 H2B power unit wiring lifting + hydroguide + weakening H2B lifting + 3rd motor Page 59...

  • Page 62: Sequence Of Settings For Lifting

    6.3 SEQUENCE OF SETTINGS 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 manu- facturer’s name, programme release, configuration, and hour-metre value. If the module has already been configured, the procedure passes directly to step four.

  • Page 63: H2B Lifting Diagnosis

    6.5 H2B LIFTING 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”. 1 BLINK = Logic anomaly (EEPROM DATA KO, EEPROM PAR. KO, EEPROM CONF.
  • Page 64 4) BATTERY The battery charge is low. The alarm is signalled only if the BATTERY CHECK option has been selected. All functions except hydrodrive are inhibited. 5 ) INCORRECT START A running request is present on key startup. Possible causes: a) Operator error.
  • Page 65 12) CHOP. NO CONF. An alarm similar to no.9, except that here, even though the data is correct, it does not correspond to a hardware configuration recognised by the H2B. The considera- tions are the same as for alarm 9 “EEPROM CONF.KO”. 13) WATCHDOG The test is made in both running and standby.
  • Page 66 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 67 Any cause which is visible or realizable by an ordinary technician who periodically checks the equipment, that can create damages or defects to the device should be transmitted to the ZAPI's technician or to the technical commercial net. They will take the responsibility for possible decisions regarding the functioning safety of the electric vehicle.

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