Zapi ZAPIMOS H2 96V 400A User Manual Download Page 1

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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

USER'S MANU

USER'S MANUA L

A L

Summary of Contents for ZAPIMOS H2 96V 400A

Page 1: ...AMICHE INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 0522...

Page 2: ...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 27 Variants for braking soft 27 5 1 5...

Page 3: ...th weakening 55 6 1 7 Connection diagram for H2B with power unit bypass contactor and main contactor 56 6 1 8 H2B power unit standard connection diagram 56 6 2 H2B lifting 3rd motor 57 6 2 1 Input con...

Page 4: ...e IN Backward IND Weakening MA Forward speed microswitch MCL Horn microswitch MD Descent microswitch MEF Electric brake switch MI Backward microswitch MS Rise microswitch MT Handle microswitch MUM Dea...

Page 5: ...fied by the final user Various chopper functional configurations can be selected by the user without the need for hardware modifications Any future technological updates are made clear to the user Th...

Page 6: ...d serie 4 cables Operating ambient temperature 30 to 40 C Maximum allowable temperature for chopper body 85 C Drop voltage with I 200 A SYSTEM VOLTAGE H2 400 SHORT H2 600 LONG H2 601 24V 250mV 200mV 4...

Page 7: ...but you should state its ohmic value since a resistor on the logic boars must be installed accordingly Correspondence between the voltage signal to pin C1 and motor voltage The procedure for automatic...

Page 8: ...cquisition procedure is invalidated by the machine if the difference between the maximum value and the mini mum value is less than 2V This acquisition procedure makes it possible to use reversed poten...

Page 9: ...eed 85 C Low battery charge When the battery charge is low the maximum current is reduced by 50 and in the lifting version all functions except hydrodrive and descent are blocked This feature may be e...

Page 10: ...high accelerator test 2 Standby diagnosis which includes watchdog test VMN test contactor pilot test current sensor test 3 Diagnosis while running which includes watchdog test VMN test current test c...

Page 11: ...rters or power suppliers For special applications please consult the nearest ZAPI service centre Start the machine the first time with the wheels raised to ensure that connection errors do not create...

Page 12: ...afety 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 T...

Page 13: ...1 CONNECTION CABLES For the auxiliary circuits use cables of 0 5mm section For power connections to the motor and to the battery use cables having sections of 35 50mm For the best chopper performance...

Page 14: ...maximum speed C2 NPOT Potentiometer negative a battery negative C3 PPOT Potentiometer positive a 12 V output Do not short circuit this terminal toward the battery negative or apply a resistive load o...

Page 15: ...IGNAL LEVEL HIGH LOW 24 10K 10V 50V 48 27K 20V 10V 80 47K 35V 18V 3 5 H2B POWER CONNECTORS SH Output current sense B Battery positive VMN Connected to the power mosfet drain it supplies a negative to...

Page 16: ...ntactor coil NTIND Negative field weakening contactor coil NTIND 4 blue black 2 Negative backward contactor coil NTI Negative main contactor coil NTG 5 red green 6 Negative braking contactor coil NTFR...

Page 17: ...Page 16 3 7 H2B CHOPPER MECHANICAL DRAWING H2B general description...

Page 18: ...2 ACCELERATOR DELAY 2 2ND SPEED 3 BRAKING 3 3RD SPEED 4 CUT BACK SPEED 1 4 HYDRO SPEED 5 CUT BACK SPEED 2 5 HYDRO COMP 0 NOT CONNECTED 0 NOT CONNECTED The adjustments are possible within 10 intermedi...

Page 19: ...48V 60 72 80V 96V fine adjustment AUX FUNCTION CURRENT GAIN HYDRO CONTACTOR BIMOTOR CONTACT traction pump PROGRAM ACCELERATION DELAY ACCELERATION DELAY INVERS BRAKING EV ACCELER DELAY RELEASE BRAKING...

Page 20: ...T HANDLE E4 BATTERY BATTERY MOTOR VOLTAGE MOTOR VOLTAGE SAVE Chopper parameters are stored in the console memory 10 different memories are available for each chopper model RESTORE Transfer of paramete...

Page 21: ...eck activated BATTERY Free No low battery charge alarm Check Low charge alarm with 50 max current if less than 10 of charge ARB Free No Anti rollback Check Anti rollback handled RELEASE Free No regene...

Page 22: ...aking The turning OFF delay is programmable at AUXILIARY TIME Jumper setting 1 2 3 4 3 BIMOT CONTACTOR AUX G7 output is activated when turning from off status to running status and at the beginning of...

Page 23: ...ress ENTER to go into the General Menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 Tthe Display will show 6 Press ENTER to go into the PROGR...

Page 24: ...est 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...

Page 25: ...ITCH E3 RV1 Input for 1st speed reduction request which is active when pin is opened The activation of this reduction is combined with an intensity braking and programmable length curve braking It is...

Page 26: ...current 80 Imax output current 90 Imax activation delay 800 msec weak The contactor connected to connector G3 is handled as weakening with activation current 50 of the pro grammable output current WEA...

Page 27: ...E1 8 PIN E4 seat The input of running enable by the seat microswitch is associated to connector E4 the seat microswitch running microswitch temporal sequence is requested Delay of 2 seconds on deacti...

Page 28: ...oltage on the basis of the current when the speed reductions are active 10 BRAKING MODULATION defines the maximum current in inversion braking with the acelerator pedal pressed When the accelerator is...

Page 29: ...44 266 289 311 333 355 378 400 MAX SPEED FORW BACK VBatt 20 29 38 47 56 64 73 82 91 100 CREEP SPEED VBatt 0 1 9 3 9 5 9 7 8 9 8 11 7 13 7 16 6 17 6 WEAK DROPOUT IMax 10 20 30 40 50 60 70 80 90 100 CUR...

Page 30: ...Page 28 5 1 5 Wiring diagram for H2B regenerative model with pedal 5 1 6 Wiring diagram for H2B regenrative model with handle H2B regenerative traction...

Page 31: ...Page 29 H2B regenerative traction...

Page 32: ...Page 30 H2B regenerative traction...

Page 33: ...Page 31 H2B regenerative traction...

Page 34: ...Page 32 H2B regenerative traction...

Page 35: ...Page 33 H2B regenerative traction...

Page 36: ...Page 34 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 regenerative traction...

Page 37: ...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 s...

Page 38: ...4 but active low N B A detailed description of these pins is given on point 5 1 1 5 2 2 Programmable functions OPTIONS The options can be programmed from the console using the SEL OPTIONS menu Functio...

Page 39: ...rve braking time 16 BACKING TIME Time delay to activate the back request 9 continuous A detailed description of these parameters is given on point 5 1 3 5 2 4 Adjustment chart PARAMETER PROGRAMMED LEV...

Page 40: ...Page 38 5 2 5 Wiring diagram for H2B standard traction with pedal 5 2 6 Wiring diagram for H2B standard traction with handle H2B standard traction...

Page 41: ...Page 39 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 42: ...el 0 With the machine stopped press the pedal lightly in order to trip the running microswitch leaving the potentiometer at the minimum value and then raise the level of the CREEP until the machine be...

Page 43: ...N LOW 4 BLINKS Accelerator high in standby this error inhibits operation VACC NOT OK 5 BLINKS Error in reading current this error inhibits operation I HIGH AT STAND I 0 EVER 6 BLINKS Malfunctioning of...

Page 44: ...running request running contactor closure is verified by checking that the VMN signal is consistent Possible causes a For finding out the causes follows the diagnosis procedure herefollowing CONDITIO...

Page 45: ...on is that the normally closed contact of the braking contactor doesn t make a good contact towards the battery negative for dust dirt or because the contact doesn t lean completely for a mechanical d...

Page 46: ...NTA C2 Supply don t come up to TI please check cabling and connections from TI coil to connectors PT and NTI C3 Supply don t come up to TA and TI please check cabling and connections from the coils to...

Page 47: ...tive cable on the braking contactor B4 Replace the contactor coil or the complete contactor B5 Contactor mechanically locked unlock it and replace it B6 Contactor with working nominal voltage bigger t...

Page 48: ...LIED YES B7 NO B8 NO D1 D2 D3 RUNNING WITH CONTACTORS ON RUNNING POSITIONS C5 AS SOON AS THE ACCELERATOR PEDAL IS COMPLETLY RELEASED FOR DOING A RELEASE BRAKING IS IT PRESENT THE BYPASS OR THE WEAKENI...

Page 49: ...Short circuit between BATT and VMN please check if there are any metallic parts causing short circuit in the contactor board c Logic failure probably the braking diode are broken replace the power 7 N...

Page 50: ...it is generated an alarm because the logic don t find the load on the pin C2 b The potentiometer is not correctly calibrated c The potentiometer is defective interrupted 13 I HIGH AT STAND Test carrie...

Page 51: ...6 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 16 EEPROM CONF KO 20 WATCHDOG...

Page 52: ...ire potentiometer 4 speeds with separately adjustable compensation 1 speed with associated delay for hydrodrive and adjustable compensation Main contactor handling Weakening or bypass contactor handli...

Page 53: ...e pin is high connected to Batt E6 DOWN Only input DOWN function descent with proportional EV con nected to connectors PT and NEVP Input DOWN Hydro both functions are activated Input Down ABP function...

Page 54: ...e active only in running key on Hour metre active with key PIN G5 status The output relative to pin G5 is active when the chopper is carrying out any function except descent main c The output relative...

Page 55: ...DRO 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...

Page 56: ...433 467 500 533 567 600 I MAX H2 500 Amp 250 278 306 333 361 388 416 444 472 500 I MAX H2 400 Amp 200 222 244 266 289 311 333 355 378 400 SPEED COARSE ALL VBatt 0 11 22 33 44 55 66 77 88 100 SPEED FIN...

Page 57: ...Page 55 6 1 5 H2B electrical connection diagram standard lifting 6 1 6 Connection diagram for H2B pump unit with weakening H2B standard lifting...

Page 58: ...Page 56 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 standard lifting...

Page 59: ...4 speeds with separately adjustable compensation Contactor handling with programmable delay 3rd hydrodrive motor and adjustable compensation Main contactor handling Weakening or bypass contactor handl...

Page 60: ...enoid valve connected to connectors G1 and G4 E7 UP Input for speed request handled by potentiometer active high E8 HYD S Same function as E4 but active when forced to BATT E9 HYD S Like pin E8 6 2 2...

Page 61: ...Page 59 6 2 4 H2B electrical connection diagrams pump hydro 6 2 5 H2B power unit wiring lifting hydroguide weakening H2B lifting 3rd motor...

Page 62: ...hen apply a load and set the compensation until it reaches the desired speed As the adjustments of speed and compensation are interdependent further adjust ments must be made before reaching the optim...

Page 63: ...32 BLINKS Low battery charge battery with 10 of residual charge BATTERY 6 5 1 Decoding the alarms displayed on console H2B LIFTING 1 STAND BY VMN LOW The test is carried out in standby If the VMN volt...

Page 64: ...ibits machine operation If the defect persists when the key is switched off and on again replace the logic If the alarm disappears remember that the parameters stored previously have been cancelled an...

Page 65: ...utput Possible causes a The coils of the contactors are in short circuit or they absorb more than 6A con tinue b Short circuit with batt of the cabling which cores out from the contactor connec tor Th...

Page 66: ...onnector C12767 Female connector for male lock C29508 Contactor SW 180 24V C29524 Contactor SW 181 24V C29528 Contactor SW 182 24V C29548 Contactor SW 80 24V C29521 Contactor SW 180 36V C29525 Contact...

Page 67: ...ical movements They should be frictionfree and not stick Mechanical movements of the contactors should be checked every 3 months Checks should be done by skilled personnel only and all spare parts sho...

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