MHYRIO CB - Zapi Inc USA
Contents
1. A B T D E F G H I K CMM 0 cee LE_ 1 LOWERING VALVI TH gt 0 z LMM B6 LA l A DI yA 1 UP VALVE 2 la a aUx IN VALVE lt T gt 1 JAUX DUT VALVE R 6 L cg eo PP 1 TILT UP VALVE Z 3 CR as 1 TILT DOWN VALVE la C13 e ii TT 11 SHIFT RIGHT VALVE 4 ea SHIFT LEFT VALVE O A C16 1 LOAD HOLD VALVE gt 5 lt e 1 SPARE VALVE 5 1516 310 C10 5 l F x 2 RSS M 7 2S B12 L 5 1 SPARE VALVE 8 C11 SN 7 AUX PROP VALVE COIL 7 C20 0 20 mA c19 0 5 Vv 0 10 V a MH 7 A gt gt SI IEJ EJ BICI CUNSULE IP TILINA 8 ATRO CB CONNECTORS CONN A MOLEX SPUX 8 POLES CONN B AMPSEAL 14 PULES 5 CUNN C AMPSEAL 23 PULES THIS DRAWING IS A ZAPI 5 PROPERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE TO THE REPAIRS OF ZAPI PRODUCTS MHYRIO CB FUNCTIONAL DRAWING 7 IA Data Date Tecnico Technician AF File File Serie Series Disegno n Drawing Pa2. gt Es aat 82 n 5 inf gt la 39 5 3 amp x lt ag ua Be a lt Y LN y Ae Ta 0 E we J pmi M li EN 5 EN A Y NJI N C Ze ee LA D A l 5 Z WY H alle 3 TS x lt Ey sS q gt D T OQ i m 5 D z Sagn 5 m a T Co 3 a Oo a Co D ps ki A E Y 2 p ax i B D Lh 2 gt NY IF 2 7 A 7 mi ES 55 T T I AEGZPOAD MHYRIO CB User Manual Page 17 36 6 2 Functional drawing
3. 20 74 Description of programmable functions OPTIONS 21 7 5 Description of parameters that may be programmed parameter change 23 7 6 Adjustments KANE Aaaa 25 7 7 Special Adjustment MENU cccssccccceececceeeecceueeecsececceeeeeeeeeessueeecsueeessueeesseeessaes 27 TO INCI 27 7 9 Description of the console SAVE 29 7 10 Description of the console restore fUNCTION ccccececceeeeceeeeceeeeeeeeeeaeeeeeeeeeneneensaess 29 7 11 Description of the set model FUNCTION cccceeccececeeeeeeeeeseeeeeseaeeeeeeeeeesaeeeeeeaeeeeas 30 7 12 Description of alarms 32 8 CONIROLLER DIAGNOSTIC 99 8 1 Analysis of alarms displayed on the console cccccseeceeceeeeeeeeeeeeseeeeesaeeesseeeesaaes 33 9 RECOMMENDED SPARE PARTS FOR CONTROLLER ccccccssssseeeeeeeseeeeeeeseeeeeeennees 35 10 PERIODIC MAINTENANCE BE REPEATED AT 5 36 AEGZPOAD MHYRIO CB User
4. VI mape ELECTRONIC INDUSTRIAL EQUIPMENTS CONSTRUCTIO Via Parma 59 42028 RE ITALY Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it User Manual MHYRIO CB MULTIFUNCTIONAL HYDRAULIC REMOTE FOR COUNTER BALANCED TRUCK Copyright 1975 2006 Zapi S p A All rights reserved The contents of this publication is a ZAPI 5 property all related authorizations are covered by Copyright Any partial or total reproduction is prohibited Under no circumstances will Zapi S p A be held responsible to third parties for damage caused by the improper use of the present publication and of the device devices described in it Zapi spa reserves the right to make changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the characteristics of the product as a result of updating VA MAP is a registered trademark property of Zapi S p A NOTES LEGEND EY The symbol aboard is used inside this publication to indicate an annotation or a Suggestion you should pay attention The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page
5. 2 36 AEGZPOAD MHYRIO CB User Manual Contents 1 INTRODUCTION TO 5 2 GENERAL lg Po oa oe NI Aa 6 2 1 Functional characteristics swianinsensrsicdexcniwmacovmsndensnantsuaninsnntrsauesagiaeaieusoesnaneemnnianniasenens 6 NOE A NTE E E EAA 6 o INOTACEATION FIN IIIA 7 3 1 7 3 1 1 Connection cables wwwwwmwmewamanwanzamwnana muna nunununu unanunua nu nuna naku nana 7 eM waa wa mnane Mae 7 3 2 Installation Of the wanakaa 7 9 2 1 Wirings CAN connections and possible interferences 8 3 2 2 Wirings I O CONNECTIONS cccceeeccceeeececeseeeceececceueeeesueeeseueeesaeeessaneeesags 10 3 2 3 Insulation 10 3 3 Protection and Safety 10 3 3 1 Protection nanu ninani na nikanawa
6. 4 5 6 7 8 9 MIN EVP This parameter adjusts the minimum current of the SINGLE valve if it is set as proportional see set option menu MAX EVP This parameter adjusts the MAXIMUM current of the SINGLE valve if it is set as proportional see set option menu MIN EVP1 This parameter adjusts the minimum current of valve 1 if it is set as proportional see set option menu MAX EVP1 This parameter adjusts the maximum current of valve 1 if it is set as proportional see set option menu MIN EVP2 This parameter adjusts the minimum current of valve 2 if it is set as proportional see set option menu MAX EVP2 This parameter adjusts the maximum current of valve 2 if it is set as proportional see set option menu MIN EVP3 This parameter adjusts the minimum current of valve 3 if it is set as proportional see set option menu MAX EVP3 This parameter adjusts the maximum current of valve 3 if it is set as proportional see set option menu MIN EVP4 This parameter adjusts the minimum current of valve 4 if it is set as proportional see set option menu 10 MAX EVP4 This parameter adjusts the maximum current of valve 4 if it is set as proportional see set option menu 11 MIN EVP5 This parameter adjusts the minimum current of valve 5 if it is set as proportional see set option menu 12 MAX EVP5 This parameter adjusts the maximum current of valve 5 if it is
7. ANALOG DIGITAL ANALOG DIGITAL ANALOG DIGITAL ANALOG DIGITAL ANALOG DIGITAL ANALOG DIGITAL ANALOG Meaning This parameter sets the battery nominal voltage that is the key input voltage MHYRIO supply This parameter sets the on off valves coil nominal voltage This parameter sets the voltage of the valve s coil positive supply lt sets EVP single to ON OFF valve type It sets EVP single to PROPORTIONAL valve type It sets EVP1 to ON OFF valve type lt sets EVP1 to PROPORTIONAL valve type It sets EVP2 to ON OFF valve type lt sets EVP2 to PROPORTIONAL valve type It sets EVP3 to ON OFF valve type lt sets EVP3 to PROPORTIONAL valve type It sets EVP4 to ON OFF valve type lt sets EVP4 to PROPORTIONAL valve type It sets EVP5 to ON OFF valve type lt sets EVP5 to PROPORTIONAL valve type It sets EVP6 to ON OFF valve type lt sets EVP6 to PROPORTIONAL valve type It sets EVP7 to ON OFF valve type lt sets EVP7 to PROPORTIONAL valve type It sets EVP8 to ON OFF valve type lt sets EVP8 to PROPORTIONAL valve type Page 21 36 Flow chart showing how to make changes to Option Menu MHYRIO CB ZAP VO O 48v DA 00000 1 Opening Zapi Menu 2 Press ROLL UP amp SET UP buttons together to enter the SET MENU CONFIG MENU SET MODEL 3 The Display will show SET MODEL 4 Press ROLL UP or ROLL DOWN buttons until SET OPTIONS Menu appears CONFIG MENU SET OPTIONS 5 SET OPTIONS appears on the display 6 Press ENTER to
8. INPUT 1 Level of DIGITAL INPUT 1 ON VB input active switch closed OFF COND input not active switch open 10 INPUT 2 Level of DIGITAL INPUT 2 ON VB input active switch closed AEGZPOAD MHYRIO CB User Manual Page 27 36 OFF COND input not active switch open 11 ANALOG INPUT 1 Voltage of the analog input Page 28 36 AEGZPOAD MHYRIO CB User Manual Flow Chart showing how to use the TESTER function of the Digital Console 1 Opening Zapi Menu 2 Press ENTER to go into the GENERAL MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until TESTER menu appears on the display 5 The Display shows TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the Display 8 Press either ROLL UP or ROLL DOWN buttons 9 Next variable for measurement appears 10 When you have finished Press OUT 11 The Display shows TESTER 12 Press OUT again and return to Opening Zapi Menu MHYRIO CB ZAP VO O 48v DA 00000 Omg do OO dQ MAIN MENU PARAMETER GHANGE MAIN MENU TESTER 00 BATTERY VOLTAGE 50 3V E O0 O Mod VALVES SUPPLY 50 1V MAIN MENU TESTER Remember it is not possible to make any changes using TESTER All you can do is measure as if you were using a pre connected multimeter 7 9 Description of the
9. with Eprom CK ULTRA MHYRIO CB VO O 48v 0A 00000 1 Opening Zapi Menu 2 Press ENTER to go into the GENERAL MENU 3 The Display will show PARAMETER CHANGE ee PARAMETER GHANGE 4 Press ENTER to go into the PARAMETER CHANGE menu 5 The Display will show the first parameter 6 Press ROLL UP and ROLL DOWN buttons until desired parameter appears 7 The names of the Parameters appear on the MAX EVP2 Display 88 8 When the desired Parameter appears the Display will show a Level Number that will be between 0 and 9 Press either SET UP or SET DOWN buttons to change the Level value 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made Press OUT 11 The Display asks ARE YOU SURE o YESF ENTER NO gt DUT 12 Press ENTER to accept the changes or press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters 13 The Display will show PARAMETER MAIN MENU CHANGE PARAMETER CHANGE Page 26 36 AEGZPOAD MHYRIO CB User Manual 7 7 Special Adjustment menu In the Special Adjustments menu which is a submenu of the Alarm menu it is possible to adjust the following parameters 1 2 3 SYNC FREQ It is the carrier frequency of the proportional valve coils drivers The default value is 1000 Hz it can be adjusted in the 10 to 2000 Hz The resolution is 10 Hz
10. connected to the positive The sensor switch has to be supplied at battery voltage Analog inputs Mhyrio provides 1 analog input The analog device can be supplied at 5 V or 12 V It is necessary to specify in the order the voltage selected The supply output is able to deliver max 100 mA ON OFF valves drivers programmable They can drive the coil in full conduction or in PWM mode in order to supply the coil at the nominal programmed voltage independently by the battery voltage See related parameter in Set Option menu Proportional valves are driven in current mode with programmable frequency The valves voltage supply is the same used for ON OFF valves and the current range have to be defined Via handset it is adjustable in a big range but the shunts can be adapted to every types of valves minimum current 200 mA maximum current up to 2 A Page 6 36 AEGZPOAD MHYRIO CB User Manual 3 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours they mean EY These are information useful for anyone is working on the installation or 8 deeper examination of the content These are Warning boxes they describe operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator tems which are important to guarantee system performance and safety 3 1 Material overview Before to start it is necessary to have the requi
11. console save function The SAVE PARAM function is allowed in the MHYRIO controller but it s useless because console cannot save all parameters correctly Use of this function don t create problems to the console functionality and to the others ZAPI device functionality In order to perform SAVE FUNCTION use ZAPI PC Win console 7 10 Description of the console restore function The RESTORE PARAM function is allowed in MHYRIO controller but ZAPI recommend don t use this because should make several problems to the AEGZPOAD MHYRIO CB User Manual Page 29 36 controller As a result of using this function all parameters will be overwritten with incorrectly values and MHYRIO controller will not work correctly In order to perform RESTORE FUNCTION use ZAPI PC Win console 7 11 Description of the set model Function Page 30 36 The only parameter present in SET MODEL function is CONNECTED TO By setting this parameter operator can connect ZAPI Console to every ZAPI product connected to CAN BUS line This functionality allow completely control of every ZAPI product without changing the position of the Console connector 1 Opening Zapi Menu 2 Press ROLL UP amp SET UP buttons together to enter SET MENU 3 The Display will show SET MODEL lf another menu is displayed press ROLL UP or ROLL DOWN until SET MODEL appears 4 Press ENTER to go into the SET MODEL Menu 5 The display will shows the first opt
12. go into the SET OPTIONS Menu SET BATTERY TYPE 7 The display will shows the first option 48V 8 Press ROLL UP or ROLL DOWN buttons until desired option appears EVPZ TYPE 9 Desired option appears SETA 10 Press SET UP or SET DOWN buttons in order to modify the value for selected option EVP2 TYPE 11 New value for selected option appears ANALOG 12 Press OUT to exit the Menu 3 5 z ARE YOU SURE YESSENTER NO gt DUT 19 Confirmation reguest appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes CONFIG MENU SET OPTIONS 15 SET OPTIONS Menu appears 16 Press OUT again Display now shows the Opening Zapi Menu Page 22 36 AEGZPOAD MHYRIO CB User Manual 7 5 Description of parameters that may be programmed parameter change In addition to the Configuration Parameter settings can be factory set Zapi default parameters or the customer can make changes according to the application using a Digital Console During the setting up procedure on the machine the Console can remain connected to the controller during travel The Parameters can be modified in real time during operation Pay attention to the polarity of the Console Connector Refer to chapter 7 1 and 7 2 of this Manual for connection details CONNECTION OF THE CONSOLE TO THE CONTROLLER MUST BE MADE WITH THE KEY SWITCH TURNED OFF The following Parameters can be modified 1 2 3
13. study of the immunity can be divided in two main branches protection from electromagnetic fields and from electrostatic discharge The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device There are well defined tests which the machine has to be exposed to These tests are carried out at determined levels of electromagnetic fields to simulate external undesired disturbances and verify the electronic devices response 3 The second type of immunity ESD concerns the prevention of the effects of electric current due to excessive electric charge stored in an object In fact when a charge Is created on a material and it remains there it becomes an electrostatic charge ESD happens when there Is a rapid transfer from a charged object to another This rapid transfer has in turn two important effects A this rapid charge transfer can determine by induction disturbs on the signal wiring and thus create malfunctions this effect is particularly critical in modern machines with serial communications canbus which are spread everywhere on the truck and which carry critical information B inthe worst case and when the amount of charge is very high the discharge process can determine failures in the electronic devices the type of failure can vary from an intermittently malfunction to a completely failure of the electr
14. the others are connected in a decreasing order of power Otherwise if two controllers are similar in power for example a traction and a pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration Correct Layout Module 2 Center of the Ground connection Module 3 Note Module 1 power Module 2 power gt Module 3 power In this case the power cables starting from the two similar controllers must be as short as possible Of course also the diameter of the cable concurs in the voltage drops described before higher diameter means lower impedance so in this last example the cable between the minus of the Battery and the common ground point pointed by the arrow in the image must be dimensioned taking into account thermal and voltage drop problems AEGZPOAD MHYRIO CB User Manual Page 9 36 EY Can advantages The complexity of today systems needs more and more data signal and information must flow from a node to another CAN is the solution to different problems that arise from this complexity simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability fewer connections analysis of problems improved easy connection with a pc to read the data flowing through the cable 3 2 2 Wirings connections After crimping the cable verif
15. 10 332 aetpoacaeeneecbaegec vies boc aseeasicenunosncowesaecn 10 11 4 OPERATIONAL FEATURES 14 5 DESCRIPTION OF THE CONNECTORS sssssmsssmaasaanan ananuna nanu na anazaa 15 5 1 Connector CNA 15 5 2 Connector CNB AMP Ampseal 14 poles 15 5 3 Connector CNC AMP Ampseal 29 0 685 15 E 17 6 1 Mechanical drawing ccccccccsssecceeeeeeeeeceeeeeseeeeeeeeeeseeeeseeeseeeeseueesseeeeseeeeseeeetseeesseeeens 17 62 FUNGUONG AEA ONERE 18 7 PROGRAMMING ADJUSTMENTS USING DIGITAL 19 7 1 Adjustments via console 19 7 2 Description Of console and CONNECTION 19 7 3 Description of Standard console MENU
16. 6 proportional valve current ramping up time this parameter sets the EVP6 valve current ramp to change from 0 A to operating current 32 EVP6 CLOSE DELAY EVP6 proportional valve current ramping down time this parameter sets the EVP6 valve closing ramp to change the coil current from operating current to OA 33 EVP7 OPEN DELAY EVP7 proportional valve current ramping up time this parameter sets the EVP7 valve current ramp to change from 0 A to operating current 34 EVP7 CLOSE DELAY EVP7 proportional valve current ramping down time this parameter sets the EVP7 valve closing ramp to change the coil current from operating current to OA 35 EVP8 OPEN DELAY EVP8 proportional valve current ramping up time this parameter sets the EVP8 valve current ramp to change from 0 A to operating current 36 EVP8 CLOSE DELAY EVP8 proportional valve current ramping down time this parameter sets the EVP8 valve closing ramp to change the coil current from operating current to OA 7 6 Adjustments range MIN EVP EVP1 EVP8 range 0 100 250 steps MAX EVP EVP1 EVP8 range 0 100 250 steps 7 EVP EVP1 EVP8 OPEN DELAY range 0 20 sec EVP EVP1 EVP8 CLOSE DELAY range 0 20 sec NOTE with the standard shunt resistances of the proportional valves circuits the coil current range corresponding to 0 100 is 0 1 A AEGZPOAD MHYRIO CB User Manual Page 25 36 Flow Chart showing how to make Program changes using Digital Console fitted
17. D MHYRIO CB User Manual Page 19 36 7 3 Description of standard console menu PA CHA AMETER GE SAVE PA AME eS ORE PA AME ALARMS VACC Page 20 36 HEADING MAIN MENU EVP 100 CONFIG MENU EV 021700 EVP 1 0 100 AX EVP1 U2 100 EVP 2 0 100 EYP 0100 SET MODEL CONNECTED TO EVP 3 O 100 EV O 100 EVP4 O 100 AX EVP4 O 100 EVPS 0 100 AX EVP5 0 100 SET BATTERY TYPE 12 24 36 EVP6 0 100 48 72 80V AX EVP6 0100 SET OPTIONS V VALVES COIL 12 24 36 EVP 0 100 48 72 80V EVP7 0 100 VALVES SUPPLY FETE T EVP8 0 100 48 2 80 AX EVP8 100 EVP TYPE Analog Digita EVP OPEN DELAY 0 20 Sec EVP 1 PE Analog Digite EVP C
18. LEX SPOX A1 A2 A3 A4 A5 A6 A7 A8 PCLRXD NCLRXD PCLTXD NCLTXD GND 12 Serial communication interface Serial communication interface Serial communication interface Serial communication interface Negative supply 12 V supply 5 2 Connector CNB AMP Ampseal 14 poles B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 KEY PAUX BATT CANL CANL OUT CMM DIT DI2 CANT PPOS ANIN GND CANH CANH OUT Mhyrio CB positive power supply Input of valves positive power supply Mhyrio CB negative supply CAN low signal in CAN low signal out Positive supply of digital input devices Digital Input N 1 Digital Input N 2 CAN termination connect to CANH OUT to insert a 120 ohm termination resistance Positive supply of analog devices 12 V or 5 V Analog input range 0 5 V or 0 12 V Negative supply of analog devices Can high signal in Can high signal out 5 3 Connector CNC AMP Ampseal 23 poles C1 C2 C3 C4 C5 C6 C7 NEVP1 PEVP1 2 NEVP2 NEVP3 PEVP3 4 NEVP4 NEVP5 AEGZPOAD MHYRIO CB User Manual Negative of the proportional electrovalve N 1 Positive of the proportional electrovalves N 1 and N 2 Negative of the proportional electrovalve N 2 Negative of the proportional electrovalve N 3 Positive of the proportional electrovalves N 3 and N 4 Negative of the proportional electrovalve N 4 Negative of the proportional electrovalve N 5 Page 15 36 C8 PEVP5 6 Positiv
19. LOSE DELAY 0 20 Sec EVP DE Analog Digita EVP1 OPEN DELAY 0 20 Sec a8 Gee EVP1 CLOSE DELAY 20 Sec EVP4 PE Analog Digita EVP OPEN DELAY 0 20 Sec FVP5 SE Analog Digita VP2 CLOSE DELAY 0 20 Sec vee Ta kataa Atoa FVP3 OPEN DELAY 0 20 Sec mine Gee EVP3 CLOSE DELAY 0 20 Sec EVP4 OPE DELA 0 20 Sec EVP4 CLOSE DELAY O 20 Sec EVPS OPE DELA U 20 Sec EVPS CLOSE DELAY 0 20 Sec FVP6 OPEN DELAY 0 20 Sec FVPG CLOSE DELAY 0 20 Sec ADJUSTMENTS ADJUST BATTERY uaa V EVP 7 OPE DELA 0 20 Sec EVP CLOSE DELAY 0 20 Sec EVPS OPE DELA 0 20 Sec EVP8 CLOSE DELAY 0 20 Sec BATTERY VOLTAGE V VALVES SUPPLY V CAN POT EV Zo CAN POT GROUP 1 YA CAN POT GROUP 2 Zo CAN POT GROUP 3 CAN POT GROUP 4 yA INPUT ON OFF INPUT 1 ON OFF INPUT 2 ON OFF ANALOG INPUT 1 0 256 CODE h Jee C SPECIAL ADJUSTMENTS SYNC FREQ 10 2000 Hz DITTER AMPLITUDE Zo DITTER FREQUENCY 071 2 AEGZPOAD MHYRIO CB User Manual 7 4 Description of programmable functions options The options can be set on the SET OPTIONS Menu Function SET Battery Type V VALVES COIL VALVES SUPPLY EVP TYPE EVP1 TYPE EVP2 TYPE EVP3 TYPE EVP4 TYPE EVP5 TYPE EVP6 TYPE EVP7 TYPE EVP8 TYPE AEGZPOAD MHYRIO CB User Manual Option 12 24 36 48 72 80V 12 24 36 48 72 80V 12 24 36 48 72 80V DIGITAL ANALOG DIGITAL ANALOG DIGITAL
20. Manual Page 3 36 SIGNS COMPANY FUNCTION INITIALS GRAPHIC AND LAYOUT TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N AEGZPOAD Edition October 2006 eto Page 4 36 AEGZPOAD MHYRIO CB User Manual 1 INTRODUCTION ZAPI CAN SYSTEM Distributed intelligent systems are not new in Zapi the first one has gone in production in the 95 with a serial communication link RS232 Today we use a more sophisticated and safe communication protocol CAN BUS In this way it is possible to reduce the harness allocating the modules exactly near the sensor or the actuators and connecting the modules with only 4 wires CAN and supply Mhyrio CB is one of this modules designed to drive the hydraulic electrovalves and connect some inputs which normally are in the actuators proximity but with complete independent functions AEGZPOAD MHYRIO CB User Manual Page 5 36 2 GENERAL CHARACTERISTIC 2 1 Functional characteristics WA 12 24 36 48 72 80 V Output Tor ON OFF valves N aectdccpcecnceceensiecetvintrrendestiectaiwinaceuidssentaieieeceudseomedeune 3 Output for proportional valves NJJ w wwwamamwna namuna wa mwnama ni 9 ICICI MOUS IAI ia 3 Analog inputs 1 Fe AI 1 CANIN IA 1 POSA IP65 2 2 Input Digital inputs they accept PNP type sensor or switches
21. are the code of the alarm the number of times the particular Alarm occurred the Hour Meter count and the controller temperature This function permits deeper diagnosis of problems as the recent history can now be accessed Flow Chart showing how to use the ALARMS function via the Digital Console MHYRIO CB ZAP VO O 48v 0A 00000 1 Opening Zapi Display 0 E O g 2 Press ENTER to go into the General menu MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display MAIN MENU ALARMS 5 The Display will show 6 Press ENTER to go into the ALARMS function Sod CODE 7 The Display will show the most recent Alarm nodes fue 8 Each press of the ROLL UP button brings up following Alarms Pressing ROLL DOWN returns to the most recent 9 If an Alarm has not occurred the Display will CODE show ALARM NULL 00007 03 18 C 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK YES ENTER NO gt DUT 12 Press ENTER for Yes or OUT for NO a E E 13 Press OUT to return to the Opening Zapi Display AEGZPOAD MHYRIO CB User Manual 8 CONTROLLER DIAGNOSTIC 8 1 Analysis of alarms displayed on the console 1 EEPROM Fault in the area of memory where the adjustment parameters are stored This Alarm does not inhibi
22. ation length layout and screening of electrical connections have to be carefully designed ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions Furthermore ZAPI is available to develop new SW or HW solutions to improve the safety of the machine according to customer requirements Machine manufacturer holds the responsibility for the truck safety features and related approval The positive of EVs coils outputs C16 C17 C18 for ON OFF VALVES outputs C20 C2 C5 C8 C13 for proportional valves comes from the valve positive voltage supply input B2 being controlled by an electronic high side switch In this way Mhyrio CB is able to open not only the negative side of the valve coil but also the positive side The positive for valves input B2 can be independent from the Mhyrio CB power supply It is strongly suggested that valve positive is cut by a device controller by another intelligent module which is thus able to open the valves positive in case of Mhyrio failures or malfunctioning Thus the more safe solution is PEV supplied to B2 controlled by another intelligent module Positive of the valves taken from the PEV 1 2 3 and PEVP 1 2 3 4 5 6 7 8 9 outputs 3 4 EMC A and ESD performances of an electronic system are strongly influenced by the installation Special attention must be given to the lengths and the paths of the electric
23. connections and the shields This situation is beyond ZAPI s control Zapi can offer assistance and suggestions based on its years experience on EMC related items However ZAPI declines any responsibility for non compliance malfunctions and failures if correct testing is not made The machine manufacturer holds the responsibility to carry out machine validation based on existing norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetic energy generated or received by an electrical device So the analysis works in two directions 1 The study of the emission problems the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy we talk about conduction issues when guiding structures such as wires and cables are involved radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space In our AEGZPOAD MHYRIO CB User Manual Page 11 96 case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy but wires and cables have the key role to propagate the disturbs because they works as antennas so a good layout of the cables and their shielding can solve the majority of the emission problems 2 The
24. e of the proportional electrovalves N 5 and N 6 C9 NEV1 Negative of the on off electrovalve N 1 C10 NEV2 Negative of the on off electrovalve N 2 C11 NEV3 Negative of the on off electrovalve N 3 C12 7 Negative of the proportional electrovalve N 7 C13 PEVP 7 8 Positive of the proportional electrovalves N 7 and N 8 C14 NEVP8 Negative of the proportional electrovalve N 8 C15 NEVP6 Negative of the proportional electrovalve N 6 C16 PEV1 Positive of the on off electrovalve N 1 C17 PEV2 Positive of the on off electrovalve N 2 C18 PEV3 Positive of the on off electrovalve N 3 C19 NEVP Negative of the single proportional electrovalve 020 Positive of the single proportional electrovalve C21 CMM Positive supply of digital input devices C22 DIO Digital input 0 C23 BATT Mhyrio CB negative supply Page 16 36 AEGZPOAD MHYRIO CB User Manual 6 DRAWINGS 6 1 Mechanical drawing eA
25. ferring ESD sensitive material C GROUNDING when a complete isolation cannot be achieved a good grounding can divert the discharge current trough a safe path the frame of a truck can works like a local earth ground absorbing excess charge So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator who is most of the time the source of ESD AEGZPOAD MHYRIO CB User Manual Page 13 36 4 OPERATIONAL FEATURES Mhyrio CB has been designed to work on CANBUS system So it follows the commands received by CAN communication and broadcasts the input status on the CAN 8 of the 9 proportional valves are separated in 4 groups used for 4 different functions Only one valve of the group can be active It is possible to activate more function at the same time FUNCTION1 is related to EVP1 and 2 outputs C1 C3 typically this function is lowering lifting FUNCTION2 is related to EVP3 and 4 outputs C4 C6 typically this function is an auxiliary function FUNCTIONS is related to EVP5 and 6 outputs C7 C15 typically this function is tilting fw rev FUNCTION4 is related to EVP7 and 8 outputs C12 C14 typically this function is shifting right left The 9th proportional valve is single and can be driven in parallel to the others proportional valves Page 14 36 AEGZPOAD MHYRIO CB User Manual 5 DESCRIPTION OF CONNECTORS 5 1 Connector CNA MO
26. ge the coil current from operating current to OA 23 EVP2 OPEN DELAY EVP2 proportional valve current ramping up time this parameter sets the EVP2 valve current ramp to change from 0 A to operating current 24 EVP2 CLOSE DELAY EVP2 proportional valve current ramping down time this parameter sets the EVP2 valve closing ramp to change the coil current from operating current to OA 25 EVP3 OPEN DELAY EVP3 proportional valve current ramping up time this parameter sets the EVP3 valve current ramp to change from 0 A to operating current 26 EVP3 CLOSE DELAY EVP3 proportional valve current ramping down time this parameter sets the EVP3 valve closing ramp to change the coil current from operating current to OA 27 EVP4 OPEN DELAY EVP4 proportional valve current ramping up time this parameter sets the EVP4 valve current ramp to change from 0 A to operating current 28 EVP4 CLOSE DELAY EVP4 proportional valve current ramping down time this parameter sets the EVP4 valve closing ramp to change the coil current from operating current to OA 29 EVP5 OPEN DELAY EVP5 proportional valve current ramping up time this parameter sets the EVP5 valve current ramp to change from 0 A to operating current AEGZPOAD MHYRIO CB User Manual 30 EVP5 CLOSE DELAY EVP5 proportional valve current ramping down time this parameter sets the EVP5 valve closing ramp to change the coil current from operating current to OA 31 EVP6 OPEN DELAY EVP
27. gina Page Z 2 BOVICLIOITALY Visto ina AEGZP1AA 1 1 Page 18 36 AEGZPOAD MHYRIO CB User Manual 7 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 7 1 Adjustments via console Adjustment of Parameters and changes to the controller s configuration are made using the Digital Console Zapi console can be connected directly to Mhyrio CB connector A or it can be physically connected to another controller in the CANBUS net then virtually connected to Mhyrio CB which is node 9 of the net 7 2 Description of console and connection CONSOLE CONNECTOR ase Bae as OF ZAPI PRODUCT CONSOLE CONNECTOR A Somme WU DISPLAY 1 PARAM MAY B REVERSE BRAKING COMPENS ACCEL R BRAKE 29 TRESTE i eee AX SP SPEED I S P SPEED 3 SAVE S P I SPEED 1 BYPASS FIELD WEAK RESTORE MOT TEMP BATT ALARMS V MOT 1 8W TEST 6 ACCELERATOR 7 MOTOR DATA 1 1 3 5 1 ROLL ENTER SE BUTTONS A ROLL OUT SET ite 1 fle VA zar _ Digital consoles used to communicate with MHYRIO controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 06 AEGZPOA
28. ion only CONNECTED TO option is present in this menu 6 Press SET UP or SET DOWN buttons in order to select the desired value for selected option 7 New desired value appears 8 Press OUT to exit the Menu 9 Confirmation request appears 10 Press ENTER to accept the changes or press OUT if you do not accept the changes 11 SET MODEL Menu appears 12 Press OUT again Console now disconnects and reconnects 13 Display now shows the Opening Zapi Menu of the ZAPI product corresponding to option selected at point 7 MHYRIO CB ZAP VO O 48v DA 00000 CONFIG MENU SET MODEL CONNECTED TO 9 CONNECTED TO 2 o0 g YOU SURE YES ENTER CONFIG MENU SET MODEL 2 48V OA 00000 AEGZPOAD MHYRIO CB User Manual The table below indicates which parameter can be set to connect ZAPI products to Console PARAMETER CONNECTED PRODUCT 9005 EPS 6 EPS II AA MHYRIO The range for this parameter is 0 32 but only above number are enabled If operator selects a not specified value ZAPI Console reconnects the product physically connected to Console To have a confirmation of the product connected see the console headline AEGZPOAD MHYRIO CB User Manual Page 31 36 7 12 Description of alarms menu Page 32 36 The microprocessor in the controller records the last five Alarms that have occurred Items remembered relative to each Alarm
29. it can be adjusted in steps of 10 Hz DITTER AMPLITUDE It is the dither signal amplitude The dither signal is a square wave which is superposed to the proportional valves set point In this way the proportional valves response to set point variations is optimized This parameter is a percentage of the valves maximum current It can be adjusted in the 0 to 20 3 by nine levels Setting the parameter to 0 means the dither isn t used DITTER FREQUENCY lt is the dither signal frequency It can be used one of three 0 the dither signal frequency is 62 5 Hz 1 the dither signal frequency is 83 Hz 2 the dither signal frequency is 125 Hz 7 8 Tester menu Following parameters can be measured in real time in the TESTER menu 1 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch 2 VALVES SUPPLY Level of voltage at the positive valve supply input 82 3 CAN POT EVP Single proportional valve current set point received by canbus 4 CAN POT GROUP 1 Group 1 proportional valves current set point received by canbus 5 CAN POT GROUP 2 Group 2 proportional valves current set point received by canbus 6 CAN POT GROUP 3 Group 3 proportional valves current set point received by canbus 7 CAN POT GROUP 4 Group 4 proportional valves current set point received by canbus 8 INPUT O Level of DIGITAL INPUT 0 ON VB input active switch closed OFF COND input not active switch open 9
30. nded by the microcontroller 20 SIDEDRIVER KO The high side driver which supply the valves coils positive is shorted or open 21 WAITING FOR PEV There isn t the valves positive power supply Check B2 input then verify the VALVES SUPPLY parameter is correctly set Page 34 36 AEGZPOAD MHYRIO CB User Manual 9 RECOMMENDED SPARE PARTS FOR CONTROLLER Part Number eee C12531 Ampseal Connector 23 pins Female C12530 Ampseal Connector 14 pins Female C12796 Female ampseal pin harness side AEGZPOAD MHYRIO CB User Manual Page 35 36 10 PERIODIC MAINTENANCE BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors moving and fixed contacts Electrical Contacts should be checked 3 MONTHS Check the Foot pedal or Tiller microswitch Using a suitable test meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound Microswitches should be Checked 3 MONTHS Check the Battery cables cables to the controller and cables to the motor Ensure the insulation is sound and the connections are tight Cables should be CV CMY 3 MONTHS Check the mechanical operation of the pedal or tiller Are the return springs Do the
31. onic device IMPORTANT NOTE it is always much easier and cheaper to avoid ESD from being generated than to increase the level of immunity of the electronic devices There are different solutions for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 1 EMISSIONS Three ways can be followed to reduce the emissions A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using shielded cables C LAYOUT a good layout of the cables can minimize the antenna effect cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level 2 ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and bypass capacitors 3 ELECTROSTATIC IMMUNITY Three ways can be followed to prevent Page 12 36 AEGZPOAD MHYRIO CB User Manual damages from ESD A PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase B ISOLATION use anti static containers when trans
32. potentiometers wind up to their full or programmed level Check every PPE EEDE A E E EE E E E T 3 MONTHS Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check 6 3 MONTHS Checks should be carried out by gualified personnel only and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special reguirements should be made after consulting a Zapi Agent The supplier is not responsible for any problem that arises from wiring methods that differs from information included in this Manual During periodic checks if a technician finds any situation that could cause damage or compromise safety the matter should be bought to the attention of a Zapi Agent immediately The Agent will then take the decision regarding operational safety of the machine Remember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER Page 36 36 AEGZPOAD MHYRIO CB User Manual
33. red material for a correct installation Otherwise a wrong choice of cables or other parts could lead to failures misbehaviour bad performances 3 1 1 Connection cables For the auxiliary connections use cables of 0 5 mm section For the valves connections use cables of 0 75 mm section 3 1 2 Fuses Use a 6 3 A Fuse for protection of the auxiliary circuits For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow 3 2 Installation of the hardware Before doing any operation ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not compromise safety Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause valves driver section failure A lower voltage may prevent the logic operating AEGZPOAD MHYRIO CB User Manual Page 7 36 3 2 1 Wirings CAN connections and possible interferences EY Page 8 36 CAN stands for Controller Area Network It is a communication protocol for real time control applications CAN operates at data rate of up to 1 Megabits per second It was invented by the German company Bosch to be used in the car industry to permit communication among the various electronic module
34. s of a vehicle connected as illustrated in this image CAN Controller The best cable for can connections is the twisted pair if it is necessary to increase the immunity of the system to disturbances a good choice would be to use a Cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded Ina system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted through the can wires In the following figures there is an overview of wrong and right layouts of the cables routing Wrong Layout Module 1 Module 2 Module 3 The red lines are can wires The black boxes are different modules for example traction controller pump controller and display connected by canbus The black lines are the power cables AEGZPOAD MHYRIO CB User Manual This is apparently 4 good layout but can bring to errors in the can line The best solution depends on the type of nodes modules connected in the network If the modules are very different in terms of power then the preferable connection is the daisy chain Correct Layout Module 1 Note Module 1 power gt Module 2 power gt Module 3 power The chain starts from the BATT post of the controller that works with the highest current and
35. set as proportional see set option menu AEGZPOAD MHYRIO CB User Manual Page 23 36 Page 24 36 13 MIN EVP6 This parameter adjusts the minimum current of valve 6 if it is set as proportional see set option menu 14 MAX EVP6 This parameter adjusts the maximum current of valve 6 if it is set as proportional see set option menu 15 MIN EVP7 This parameter adjusts the minimum current of valve 7 if it is set as proportional see set option menu 16 MAX EVP7 This parameter adjusts the maximum current of valve 7 if it is set as proportional see set option menu 17 MIN EVP8 This parameter adjusts the minimum current of valve 8 if it is set as proportional see set option menu 18 MAX EVP8 This parameter adjusts the maximum current of valve 8 if it is set as proportional see set option menu 19 EVP OPEN DELAY Single proportional valve current ramping up time this parameter sets the single valve current ramp to change from 0 A to operating current 20 EVP CLOSE DELAY Single proportional valve current ramping down time this parameter sets the single valve closing ramp to change from operating current to 0 A 21 EVP1 OPEN DELAY EVP1 proportional valve current ramping up time this parameter sets the EVP1 valve current ramp to change from 0 A to operating current 22 EVP1 CLOSE DELAY EVP1 proportional valve current ramping down time this parameter sets the EVP1 valve closing ramp to chan
36. t machine operation but operation goes on with default values if fault is still present when the Key Switch is re cycled replace the logic If the fault disappears the previously stored Parameters will have been replaced by the default parameters 2 CAN BUS KO There is a problem related to the CAN BUS line The error is signalled if the MHYRIO controller does not receive any message from the CAN BUS line First of all check the wiring If it is ok the problem is on the logic board which must be replaced 3 WATCHDOG The test is made in both running and standby It is a self diagnosing test within the logic If an alarm should occur replace the logic 4 WRONG SET BATTERY This fault is signalled if the battery voltage is non consistent with the set battery programmed in the set option menu 5 UNDERVOLTAGE This fault is signalled if an undervoltage condition is detected in the MHYRIO power supply 6 FF VALVES Flip flop circuit that manages on off valve drivers short circuit protection does not reset in the correct way The problem is probably in the hardware circuit 7 COIL SHORTED ON OFF valves drivers are protected against coil short circuit if a short is present across the coil the flip flop circuit is set and the alarm is signalled 8 EV DRIVER SHORT One of the on off valves driver is shorted check the external connection if it is ok the driver is probably damaged 9 EVP DRIVER SHORT The single proportional valve dri
37. ver is shorted check the external connection if it is ok the driver is probably damaged 10 EVPG1 DRIVER SHORT One of the Group 1 valves drivers is shorted check the external connection if it is ok the driver is probably damaged 11 EVPG2 DRIVER SHORT One of the Group 2 valves drivers is shorted check the external connection if it is ok the driver is probably damaged 12 EVPG3 DRIVER SHORT One of the Group 3 valves drivers is shorted check the external connection if it is ok the driver is probably damaged 13 EVPG4 DRIVER SHORT One of the Group 4 valves drivers is shorted check the external connection if it is ok the driver is probably damaged 14 EV DRIVER KO One of the On Off valves drivers is open it does not close when it is commanded by the microcontroller AEGZPOAD MHYRIO CB User Manual Page 33 96 15 The single proportional valve driver is open it does not close when it is commanded by the microcontroller 16 EVPG1 DRIVER KO One of the Group 1 valves drivers is open it does not close when it is commanded by the microcontroller 17 EVPG2 DRIVER KO One of the Group 2 valves drivers is open it does not close when it is commanded by the microcontroller 18 EVPG3 DRIVER KO One of the Group 3 valves drivers is open it does not close when it is commanded by the microcontroller 19 EVPG4 DRIVER KO One of the Group 4 valves drivers is open it does not close when it is comma
38. y that all strands are entrapped in the wire barrel Verify that all the crimped contacts are completely inserted on the connector cavities A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire For information about the mating connector pin assignment see the paragraph description of the connectors 3 2 0 Insulation of truck frame As stated by EN 1175 Safety of machinery Industrial truck chapter 5 7 there shall be no electrical connection to the truck frame So the truck frame has to be isolated from any electrical potential of the truck power line 033 Protection and safety features 3 3 1 Protection features Battery polarity inversion lt is necessary to fita MAIN CONTACTOR to protect the MHYRIO against reverse battery polarity and for safety reasons Connection Errors All inputs are protected against connection errors External agents The controller is protected against dust and the spray of liquid to a degree of protection meeting IP65 3 3 2 Safety Features controllers are designed according to the prEN954 1 specifications for Page 10 36 AEGZPOAD MHYRIO 68 User Manual safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to install
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