Zapi ZAPIMOS H2B User Manual Download Page 59

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H2B USER'S MANUAL - 550145G

Page 59/60

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

6-way female lok connector

C12768

Male connector (for female lock)

C12229

6-way male lok connector.

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

Contactor SW 181 36V

C29529

Contactor SW 182 36V

C29504

Contactor SW 80 36V

C29522

Contactor SW 180 48V

C29526

Contactor SW 181 48V

C29530

Contactor SW 182 48V

C29506

Contactor SW 80 48V

C29523

Contactor SW 180 80V

C29527

Contactor SW 181 80V

C29531

Contactor SW 182 80V

C29514

Contactor SW 80 80V

P00085

Logic Board ZP321C (24V)

P00086

Logic Board ZP321C (36/40/48V)

P00087

Logic Board ZP321C (60/72/80V)

Logic Board ZP321C (96V)

Summary of Contents for ZAPIMOS H2B

Page 1: ...ction 22 5 1 H2Bregenerativetraction 22 5 1 1 Inputconnectorsdescription 23 5 1 2 Programmable functions options 24 5 1 3 Parameter modification 26 5 1 4 Adjustmentchart 28 Variants for braking soft 2...

Page 2: ...connectors 53 6 2 2 Programmable functions options 53 6 2 3 Parameter modification 54 6 2 4 H2B electrical connection diagrams pump hydro 54 6 2 5 H2B power unit wiring lifting hydrodrive weakening 55...

Page 3: ...iode DV Flywheeldiode IN Backward IND Weakening MA Forward speed microswitch MCL Hornmicroswitch MD Descentmicroswitch MEF Electric brake switch MI Backwardmicroswitch MS Rise microswitch MT Handlemic...

Page 4: ...can also be modified by thefinaluser Various chopper functional configurations can be selected by the user without the need for hardware modifications Any future technological updates are made clear t...

Page 5: ...otors characteristics DC wire wound serie 4 cables Operatingambienttemperature 30 to 40 C Maximumallowabletemperatureforchopperbody 85 C Drop voltage with I 200 A SYSTEM VOLTAGE H2 400 SHORT H2 600 LO...

Page 6: ...in the 2 wire configuration 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...

Page 7: ...n by the potentiometer The acquisition procedure is invalidated by the machine if the difference between the maximum value and the minimum value is less than 2V This acquisition procedure makes it pos...

Page 8: ...Thetemperaturemayneverexceed85 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 bloc...

Page 9: ...ing request present high accelerator test 2 Standby diagnosis which includes watchdog test VMN test contactor pilot test cur rentsensortest 3 Diagnosis while running which includes watchdog test VMN t...

Page 10: ...t use outputs of converters or power suppliers For special applications please consult the nearest ZAPIservicecentre Start the machine the first time with the wheels raised to ensure that connection e...

Page 11: ...ollowing wirings Withsafetyswitch 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 r...

Page 12: ...ed by the chopper itself 3 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 th...

Page 13: ...lt minimum speed to 10 V maximum speed C2 NPOT Potentiometernegative abatterynegative C3 PPOT Potentiometer positive a 12 V output Do not short circuit this terminal toward the battery nega tive or ap...

Page 14: ...E7 SYSTEM VOLTAGE RIN INPUT SIGNAL LEVEL HIGH LOW 24 10K 10V 50V 48 27K 20V 10V 80 47K 35V 18V 3 5 H2B POWER CONNECTORS SH Outputcurrentsense B Batterypositive VMN Connected to the power mosfet drain...

Page 15: ...Negative field weakening contactor 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...

Page 16: ...Page 16 60 H2B USER S MANUAL 550145G 3 7 H2B CHOPPER MECHANICAL DRAWING...

Page 17: ...ameters modification and PROGRAM VACC function are locked by default To enable them special adj PARAM CHANGE EN must be set to ON Pay special attention to the polarity of the console connector when it...

Page 18: ...K DROPOUT BRAKINGMODUL HYDROTIME MAXIMUMCURRENT 1ST SPEED COARSE MAX SPEED FORW 1ST SPEED FINE MAX SPEED BACK 1ST SPEED COMP CREEP SPEED 2ND SPEED COARSE WEAK DROPOUT 2ND SPEED FINE CURVEBRAKING 2ND S...

Page 19: ...NG ENABLE QUICKINVERSION SPEED REFERENCE SPEED VALUE SAVE Chopper parameters are stored in the console memory 10 different memories are available for each chopper model RESTORE Transfer of parameters...

Page 20: ...NFIGURATIONOFOPTIONS SETOPTIONSMENU function option meaning BYPASS CONTACTOR Bypass Bypasscontactor Weakening cont Weakeningcontactor SPEED CONTROL On No speed check Off Speed check activated BATTERY...

Page 21: ...TACTOR present Main contact present on G5 running status G5 is ON during functions exceptdescent SELECTION OF BATTERY VOLTAGE ADJUSTMENT MENU Makes it possible to set the nominal voltage of the batter...

Page 22: ...meter 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 bypas...

Page 23: ...to active the pin E4 SEAT MICROSWITCH E3 RV1 Input for 1st speed reduction request which is active when pin is opened The activation of this reduction is combined with an inten sity braking and progra...

Page 24: ...ypass withactivationcurrent 80 Imax output current 90 Imax activationdelay 800msec weakening cont The contactor connected to connector G3 ishandled as weakening with activation current 50 of the pro g...

Page 25: ...I function is active if the request of motion in the direction opposite to the forks is present and if the safetybuttonpushesontheoperator Associates the function for rapid inversion to connector E1 8...

Page 26: ...e disable at key on 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 t...

Page 27: ...level 0 to 100 level 9 13 MAX SPEED FORW Max speed wit forward direction on This speed reduction goesunderadjustablecompensationwiththeCOMPENSATIONparameter 14 MAX SPEED BACK Max speed wit backward d...

Page 28: ...361 388 416 444 472 500 I MAX H2 400 Amp 200 222 244 266 289 311 333 355 378 400 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 WE...

Page 29: ...H2B USER S MANUAL 550145G Page 29 60 5 1 5 Wiring diagram for H2B regenerative model with pedal 5 1 6 Wiring diagram for H2B regenrative model with handle...

Page 30: ...Page 30 60 H2B USER S MANUAL 550145G 5 1 7 Wiring diagram for H2B regenrative model with speed check and pick up...

Page 31: ...H2B USER S MANUAL 550145G Page 31 60 5 1 8 Wiring diagram for H2B regenrative model with speed check and tacho generator...

Page 32: ...Page 32 60 H2B USER S MANUAL 550145G 5 1 9 Wiring diagram for H2B regenrative model with speed check and backing...

Page 33: ...H2B USER S MANUAL 550145G Page 33 60 5 1 10 Wiring diagram for H2B regenrative model...

Page 34: ...Page 34 60 H2B USER S MANUAL 550145G 5 1 11 Wiring diagram for H2B regenrative model with weakening...

Page 35: ...H2B USER S MANUAL 550145G Page 35 60 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 36: ...th 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 begins to...

Page 37: ...CORRECTSTART 3 BLINKS Error on VMN test NO FULL CONDUCTION VMN LOW 4 BLINKS Accelerator high in standby this error inhibits operation VACC NOT OK 5 BLINKS Error in reading current this error inhibits...

Page 38: ...rried out at 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 herefollow...

Page 39: ...e most probably reason 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 completel...

Page 40: ...ons from TA coil to connectors PT and NTA C2 Supply don t come up to TI please check cabling and connections from TI coil toconnectorsPTandNTI C3 Supply don t come up to TA and TI please check cabling...

Page 41: ...actor A5 Missing the positive 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...

Page 42: ...STUCK CONTACTOR COIL IS SUPPLIED 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 PRES...

Page 43: ...tandardtraction b 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 rep...

Page 44: ...e logic board In this case 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 Thepotentiometerisdefective interrupted 13 STB...

Page 45: ...NF An alarm similar to no 16 except that here even though the data is correct it does not correspond to a hardware configuration recognised by the H2B The considerations are the same as for alarm 16 E...

Page 46: ...or speed controlled by 3 wire potentiometer 4 speeds with separately adjustable compensation 1 speed with associated delay for hydrodrive and adjustable compensation Maincontactorhandling Weakening or...

Page 47: ...ated Input Down ABP function slow lifting The value of parameter is reduced in function of the parameter VMN VALVE VOLTAGE that in this case has the following values Prog 0 1 2 3 4 5 6 7 8 9 pwmmax 2...

Page 48: ...e 2 EV ACCELER DELAY Acceleration time relative to descent proportional solenoid valve 3 DECELER DELAY Deceleration time i e to annul the voltage on the motor upon release 4 EV DECELER DELAY Decelerat...

Page 49: ...lve 27 MAX VALVE VOLT Maximum voltage applied on the proportional solenoid valve 6 1 4 Adjustment chart PARAMETER PROGRAMMED LEVEL UNIT 0 1 2 3 4 5 6 7 8 9 ACCELERATION DELAY Sec 0 15 0 24 0 39 0 50 0...

Page 50: ...Page 50 60 H2B USER S MANUAL 550145G 6 1 5 H2B electrical connection diagram standard lifting 6 1 6 Connection diagram for H2B pump unit with weakening...

Page 51: ...H2B USER S MANUAL 550145G Page 51 60 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 52: ...dcontrolbypotentiometer 4 speeds with separately adjustable compensation Contactor handling with programmable delay 3rd hydrodrive motor and adjustable compensation Maincontactorhandling Weakening or...

Page 53: ...ected 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 Programmable fun...

Page 54: ...outanyfunction exceptdescent A detailed description of the meanings is given on point 6 1 2 as per the H2B standard liftingmodel 6 2 3 Parameter modifications h2b configuration pump 3rd motor The para...

Page 55: ...nctioning of all the wired inputs including the potentiometer by means of thetesterfunctionsontheconsole 5 Carry out accelerator signal acquisition on the PROGRAM VACC menu 6 Set the maximum current b...

Page 56: ...etailed description is given in the section DECODING THE ALARMS DISPLAYED ON CONSOLE 1 BLINK Logic anomaly EEPROM DATA KO EEPROM PAR KO EEPROM CONF KO EEPROM OFF LINE CHOPPER NO CONF WATCHDOG 2 BLINKS...

Page 57: ...driveareinhibited 5 INCORRECT START A running request is present on key startup Possible causes a Operatorerror b Requestmicroswitchstuck 6 STBY I HIGH Test carried out in standby checks that the curr...

Page 58: ...except that here even though the data is correct it does not correspond to a hardware configuration recognised by the H2B The considerations are the same as for alarm 9 EEPROM CONF KO 13 WATCHDOG The...

Page 59: ...waymalelokconnector 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 C2...

Page 60: ...ion of this electronic controller should be done according to the diagrams included in this manual and any variation should be done accordingly with the supplier The supplier is not responsible for an...

Page 61: ...ZAPIMOSH2B USER S MANUAL ELECTRONICINDUSTRIALDEVICES 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it...

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