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H2B USER'S MANUAL - 550145G

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LEGEND

1^V

= 1st lift speed request

= Forward

= Key

= Brake diode

= Flywheel diode

= Backward

IND

= 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

= Speed reduction

VMN = Negative motor voltage

Содержание ZAPIMOS H2B

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 52: ...dcontrolbypotentiometer 4 speeds with separately adjustable compensation Contactor handling with programmable delay 3rd hydrodrive motor and adjustable compensation Maincontactorhandling Weakening or...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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