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ZAPIMOS H2B USER'S MANU USER'S MANUAL

1. 150 11 EEN 107 ett nnnnunnnnn 1 D D 2 TY EP Ey a py in oO HH 1 e 2 we ES n E IN SU 1 1 iD 10 16 5 13 15 10 15 10 15 13 16 5 10 mt 43i ol ol 4 142 4 m 1 1 l i 10 1 CN 5 i i P E ES 1 WY ISP S 8 t _ mi m RE E i Ee QU ed a ee as T T d X cM 5 o o c WE m v 2 EE E st Pe Gy L 22 WEL s l 00 T n _ _ 7 1 amp Co ES 27 16 2 general description 4 MODIFICATIONS Modification of the parameters 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 The console can remain connected to the chopper when running and the parameters can also be varied in real time during operation To confirm data press ENTER when requested by the message on the console The parameters thus modifi
2. Saa SN 12 oM peel 12 9 4 2 45452255 54248 58555245 0052 50652225 13 2 55 H2B power COMME GIONS 14 3 6 Contactors COMMS CLO etree cee Tb Db pa id 15 3 7 chopper mechanical 16 4 Parameter modifications ct Dra dad eccl b dw ex eibi edd 17 4 1 Modifying parameters using the mini console 17 4 2 Modifying parameters using the digital console 18 43 Chopper configuration and connections description 20 5 TRACTION Mc M 22 5 1 H2Bregenerative 22 5 1 1 Input connectors description 23 5 1 2 Programmable functions options 24 5 1 3 Parameter modification 26 5 1 4 Adj stment chart uu u u UD 27 Variants for brakimg soft 27 5 1 5 Wiring diagram for H2B regenerative model with pedal 28 5 1 6 Wiring diagram for H2B regenerative model with handle 28 5 1 7 Wiring diagram for H2B regenerative model with speed check and 29 5 1 8 Wiring diagram for H2B regenerative mo
3. 60 65 H B lifting diagnosis oca aA 61 6 5 1 Decoding the alarms displayed on console 61 7 Recommended spare parts for H2B 64 8 Maintenance storne te aaeei Ca Re uds us ama EVE 65 A The informations included into the marked paragraphs by this symbol are essential for the safety APPROVAL SIGNATURES MANAGEMENT EXECUTIVE Pubblication 5501450 Edition September 1995 Page 2 H2B 14V AV CH DF DV IND MA MCL MD MEF MI MS MT MUM NT RV VMN LEGEND 1st lift speed request Forward Key Brake diode Flywheel diode Backward Weakening Forward speed microswitch Horn microswitch Descent microswitch Electric brake switch Backward microswitch Rise microswitch Handle microswitch Dead man microswitch Contactor negative Speed reduction Negative motor voltage H2B Page 3 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 has designed the ZAPIMOS family to offer the following features Advanced technology and economical costs Maximum safety Maximum flexibility Open to future technological innovations Optimum le
4. 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 Tthe Display will show MENU AM VACC MAI PROGI 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions shown 8 Press ENTER to clear these values Display will show 0 0 oz lt gt 9 Select Forward Direction close any interlock switches that may be in the system 10 Slowly depress the accelerator pedal or tiller butterfly to S its maximum value minimum maximum voltages will displayed Console plus bz arrow indicating the direction MIN VACC MAX 4 4 YOU SURE YES ENTER NO OUT 5 TRACTION 5 1 2 REGENERATIVE TRACTION Input for 3 wire potentiometer optional 2 wire 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 contac
5. 5 358 WA IN ED 7 7 A09 ind f 7 1 es H2 q N 10444 gt H 18 11 P I I ANDI I I I wi Y pg l d rd 5 21604 21 8 4 Nd 4 se 9 L 4 XA L SSA 10444 10d0 LOdN gt Pe 22 HST g NW HSS AN A 4 1 IILSONIVITC 4 J 9 2 1 12 1 26 6978 12 lt lia 1265 e 9 7 V g 2 4 P 2 Uu CU AAA ZT ze i IT ASST gt gt Og zg x 11 a e 2 2 AJ T LT deleol Seg 6 8 4 9 S y 0 H2B regenerative traction Page 30 6EG2 0 2 NV 03395 13014 3ATIVH3N3938 03 Nas ToS a Vas ouGasi 31 ozon la Wa 51200084 1497 JU 5519438 381 138 IVHI SI 380 Q3ADU112 IND 3HI NUILVZISOHIOV NJILISA 9 903 1d30X3 SI NOILOnGUSd3H Sll AlNddUNd 095 1497 9 SI SIHI 15300384 ONIMOVE DENYA NGOLING LI 1124 2 CA 6 xnv y g
6. 7 4 L 70 12V 6 d r 60 5 4 50 O C1 4 4 Z 40 7 34 a 30 OV 2 4 WA 20 O C2 14 L10 PEDAL VACC accelerator signal voltage to C1 O 30 40 50 60 70 80 90100 STROKE VMOT percentage of batt voltage on the motor Central zero signal VACC i volt 104 100 9 4 60 ad SN L C C3 PPOT 7 70 12V MAX AV 6 60 S VACC 5 E 50 5V MIN C1 CPOT 4 L 40 IN 5 20 ov 2 20 CQ C2 1 Lio 0 100 80 60 40 20 0 20 40 60 80100 2 HANDLE BACKWARD FORWARD SIROKE H2B general description Page 7 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 Connection errors All the inputs are protected against connection errors The contactors do not accept loads greater than 3 amp and are in any case pro tected against overloads and short circuits Thermal protection If the temperature exceeds 80 C the maximum current is reduced in proportion to the thermal increase The temperature may never exceed 85 C Low battery charge When the battery charge is low the maximum current is reduced by 50 and i
7. 41 5 5 Decoding console displayed 42 MM Ut m 50 6 1 H2B standard Illico eet OE eine oae 50 JINDUT GOMMECIONS 3 cuoi oh ER eH n eine 51 6 1 2 Programmable functions options 52 6 1 3 Parameter modification 52 6 1 4 Adjustment chart 54 6 1 5 Connection diagram for H2B standard lifting 55 6 1 6 Connection diagram for H2B pump unit with 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 62 HB B lifting 3rd motor ose eoe rre od eene quete tene 57 6 2 110 01 18 01311 10 16 beet 58 6 2 2 Programmable functions options 58 6 2 3 Parameter modification 58 6 2 4 2 electrical connection diagrams pump hydro 59 6 2 5 H2B power unit wiring lifting hydrodrive weakening 59 63 Sequence of settings for lifting 60 6 4 Setting the proportional solenoid valve
8. LADI COSTRUZIONE ELETTRONICHE OLEODINAMICHE INDUSTRIALI 42028 POVIGLIO R E Via Pama 59 ITALIA Tel 0522 960050 r a Tlx 530021 AINDRE I Fax 0522 960259 ZAPIMOS 2 USER S MANUAL CONTENTS LOO uu RE Re D M ME ED 3 1 Introduction to the ZAPIMOS family J 4 2 General H2B characteristics 5 2 1 Technical specifications ette reb rr dera roter ideae oH rein Pera es 5 OOo Ulla 5 y ET 251208 6 2 23 MIGIOSWIICDOS orn iE e oc Ux UR PR E na eR RE ue MEUS 6 2 2b Polehtlotmmblel or abe reb eodd 6 2 35 Protection feallifBs u uuu u unu ep odia 8 2 4 Performance TeatUres uo E Ep ecd dua 9 25 chopper CAG OSIS sisa arasa 9 26 Thermal considerations AA ate ake Sentence ed 9 2 7 General notes and precautions N cM e EAE 10 2 8 General contactors and safety switch for regenerative model A 11 3 Ins tallati9 n 12 3 1 Choosing connection cables 12 22 WOMACIONS
9. Bypass or weakening contactor handling 211321 CONSOLE CHIAVE RV3 TI RV1 Om SEAT MS E URVARD M S BACKWARD MS QO V nN L DIAGNOSTIC LED FUSE 10A H2B standard traction Page 35 5 2 1 Input connectors Pin Function 1 RV3 QUICK E2 RV2 BACKING E3 RV1 E4 MSEAT E5 MF 7 E8 E9 Description Input for 3rd speed reduction or rapid inversion request Rapid inversion request Input for 2nd speed reduction request Back request Input for 1st speed reduction request with curve braking combined Input for seat microswitch signal delayed 2 sec or handle signal Input for brake pedal microswitch when the pin is taken VB the speed No 2 reduction is actived and the maximum current halved Input for backward request Input for forward request Like pin E4 but active low Like pin E4 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 Function PIN G3 BATTERY ARB HOURS PIN E1 PIN E4 PIN E2 option description by pass Contactor with bypass weak Contactor with weakening free No low battery charge alarm check Low charge alarm wi
10. C q VoL m 10444 10424 LON ININ24 V4 AJ E 212604 Pri X0 1 602604 AZ T 0 9947 3 SSA 4 lt 1 x A H lie SSM S 10444 10494 l1OdN4 WIND 441 I O MO INO DO MO MO NGO NO QXMION 10d OXLTON 11 8 1 3445 033495 1043 10 1044 N 100 HO SAH Q3SN IN YN gt d4ddOH TEH Page 31 H2B regenerative traction 8S50v2 0 1140 82H 3AILVN3N3O38 04 ONISIA 915 26 60 81 111 ws vuj8og u 0462510 O3lu3 1 Sii ucu Si19nd 3d 1492 40 5419439 FHL 01 3 119134 LYH SI 350 03 11 AIND 3H ILYZIXOHLNY N M 9 X04 SI 1 095 1497 V SID N 88 IIN lt ld P 5 N 9 e uu 49 T 9 1 2
11. 2 electrical connection diagram standard lifting H2B CHOPPER 5 ii 2 oS 55 2 EE 8 555 28 5 5558 YENING gt gt gt gt Z0 Z E D 382823880 BEN 828838860 Bl TT Wd A E 1 SH THE CONSOLE 2 MRIDR MRIDR MS g Q g T MRIDR TMV4 CH THE RUNNING CONTACTORS OF THE TRACTIONS CHOPPER CAN BE NEGATIVE 6 1 6 Connection diagram for H2B pump unit with weakening CONNECTOR CONNECTIONS EIN FUNCTION COLOUR RR N 2 nre PTFR 5 NTIDR G N 6 V RR H2B CHOPPER H2B standard lifting Page 55 6 1 7 Connection diagram for H2B pump unit with by pass contactor and contactor H2B CHOPPER 6 1 8 H2B power unit standard connection diagram H2B CHOPPER 1 56 H2B standard lifting 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 BATT CONSOLE FUSE 10A Wo DISCENT APP H2B lifting
12. 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 considera tions are the same as for alarm 16 EEPROM CONF KO 20 WATCHDOG The test is made in both running and standby It is a self diagnosis test within the logic If an alarm should occur replace the logic 21 SHORTED COIL An overload or a short circuit toward BATT on the contactor negative driver out puts Possible causes a The contactor coils are short circuited or absorb more than 6 A continuous b Short circuit with BATT of the wiring that comes from the contactor connector The alarm indicates the occurrence of an overload not the breakdown of a chopper component Once the external cause is removed the chopper can be restarted 22 DRIVER SHORTED The test is carried out in standby and checks that the voltage of the drivers that control the contactors is consistent with the preset value Possible causes a Logic failure b Driver breakdown caused by overvoltage in the contactor negative wiring Replace the logic after having removed the cause H2B diagnosis traction Page 49 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 han
13. COLOUR H2B CHOPPER RR N BB N GG B V B G N V RR STATOR TQ 1 6 PT 5 2 8 Wiring diagram for H2B power standard with 5 cables motor CONNECTOR CONNECTIONSI PIN JFUNCTION COLOUR PT RR N BB N H2B CHOPPER 1 NTIND GG B NTFR V RR MATE IN LHCK CHNN FE 6PIN a PIN H2B standard traction Page 39 5 3 TABLE 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 If the module has already been configured the procedure passes directly to step four Otherwise proceed in order as follows Consult the console manual for further procedure details 1 2 3 4 5 6 7 8 9 Configure the model Select the desired options Select and set battery voltage Check the functioning of all the wired inputs including the potentiometer by means of the tester functions on the console Carry out accelerator signal acquisition on the PROGRAM VACC menu Set the maximum current by selecting the level corresponding to the desired value shown on the table of modifications point 5 1 4 and 5 2 4 Set accleration by moving the machine for
14. comes off the slow lift microswitch must be cable in series with the ABP microswitch E6 4 SLOW E7 ABP Input for speed request handled by potentiometer active high Same function as E4 but active when forced to BATT Like pin E8 H2B standard lifting Page 51 6 1 2 Programmable functions OPTIONS These options can 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 lt 80 IMAX Output current lt 90 IMAX Activation delay 800 ms weak The contactor connected to connector G3 is handled as weakening Activation current 50 of the output current Output current is programmable WEAK DROP OUT from 10 to 100 IMAX BATTERY No low battery charge alarm check Activates the test that reads the battery charge in standby at intervals of 1 second This value constitutes the level of residual battery charge and is compared with a table in memory When the charge is less than 10 all functions are blocked except for the hydrodrive and the LED signals this condition by blinking continuously HOURS running Hour metre 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 to pin G5 handles a main contactor 6 1 3 Parame
15. proceed in order as follows Consult the console manual for further procedure details 1 2 3 4 5 6 7 8 9 1 2 3 4 Configure the model Select the desired options Select and set battery voltage Check the functioning of all the wired inputs including the potentiometer by means of the tester functions on the console Carry out accelerator signal acquisition on the PROGRAM VACC menu Set the maximum current by selecting the level corresponding to the desired value Set the speed of the respective functions with the machine in standby and the level of compensation set at 0 Then 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 optimum condition Set the hydrodrive speed in the same way as the others with the only difference being that the speed is set with the steering in standby while the compensation is set with the steering under load Set acceleration deceleration and creep as necessary 6 4 SETTING THE PROPORTIONAL SOLENOID VALVE For handling the solenoid valve it is necessary to fit the potentiometer and the de scent request microswitch Carry out the potentiometer signal acquisition using the PROGRAM func tion With the lever in minimum speed position set the MIN VALUE VOLT paramete
16. 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 11 FORW BACK The test is carried out continuously An alarm is signalled when two requests for running are made simultaneously Possible causes a Defective wiring b Running microswitch stuck Incorrect manoeuvre d If there is not external defects replace the logic 12 VACC NOT OK The test is made in standby The alarm indicates that the accelerator voltage is greater than 1V with respect to the minimum value stored Possible causes a A potentiometer wire is interrupted or the potentiometer negative has not been connected to the PIN C2 of the 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 The potentiometer is defective interrupted 13 I HIGH AT STAND Test carried out in standby Checks that the current is nil If this is not verified an alarm is signalled This alarm inhibits machine operation Possible causes a Current sensor broken and logic failure First replace the logic and if the defect persists replace the power unit 14 1 0 EVER Test carried out in running Checks that the current during running is greater than a minimum value If not an alarm is
17. 3rd motor Page 57 6 2 1 Input connectors function E1 4THS E2 3RDS E3 2ND S E4 HYD R E5 1STS E6 DOWN E7 UP E8 HYD S E9 description Input for 4th speed request The speed is active when the pin is connected to Batt Input for 3rd speed request The speed is active when the pin is connected to Batt Input for 2nd speed request The speed is active when the pin is connected to Batt Input for hydrodrive request When the request is active a contactor for controlling the hydrodrive pump motor with programmable delay is handled Hydr time function is actived by this pin Input for 1st speed request The speed is active when the pin is connected to Batt Input for descent request When this input is active it is possible for the potentiometer to handle a proportional solenoid valve connected to connectors G1 and G4 Input for speed request handled by potentiometer active high Same function as E4 but active when forced to BATT Like pin E8 6 2 2 Programmable functions OPTIONS The options can be programmed from the console with the SEL OPTIONS menu function pin PIN G3 BATTERY HOURS PIN G5 option meaning Bypass Bypass contactor Weak Weakening contactor Free No low battery charge alarm Check Low battery charge alarm which blocks all functions except hydrodrive Running Hour metre active only in running Key on Hour metre active for the entire chopper star
18. 42 49 HHA 9 177 TOLTO T um EZH CN ENG wi 2 I S 8 1 9 2 5 2 I 0 H2B regenerative traction Page 32 g0yvs u ou 1492 30 SNIvd33 3 GV 0 82H FAI SN DI 1IDIADd 82020 UH3N3O38 A04 AlN3d Nd 945 1492 v S 99 33 2 14 ND LON mq 0 218 1 2 02 M 5 4 gt LI PENES 9 c D Qu x 8 5 Ho o nh um I gt Jg H2B regenerative traction 5 1 12 Wiring diagram for H2B power unit regenerative with by pass CONNECTOR CONNECTIONS PIN FUNCTION COLOUR I H2B CHOPPER 3 NTB GG B 4 PTFR V B 5 NTA G N 6 V R NTFR V RR PTFR V B 5 1 13 Wiring diagram for H2B power unit regenerative with weakening CONNECTOR CONNECTIONS PIN JFUNCTION COLOUR 1 PT RR N H2B CHOPPER NTIND 4 PTFR 5 NTA G N 6 NTFR V RR GG B NTFR V RR PTFR V B NTI BB N Page 34 H2B regenerative traction 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
19. 7 lt 602604 OLE dZ 2 YOSNAS JHL 40 1 3AVS 3HL 30 38 LSNN 31915335 30 NOISN3NIQ HLOOL 133HM JHL x I 0 MO INO No o MC wc Id 1 5 93395 day 43445 HO LOdN 1044 1 HO ZAY 1049 dOHO 921 AN 29 H2B regenerative traction BES2 0 JHD 3D1933N3D DH391 NV 03348 HLIM 82H X04 DNISIA Sun NOE MIET sige 31 ior lll NV 74 51200044 1492 30 59194384 SHI 3AILVT3N 19 SI 350 Q3AUTIV AND 3HI NDILVZINOHIDV N3IIISA Y 303 1d329X3 SI 112000 434 SII ALN3dUNd 5 14927 9 SI SIHI
20. arc suppres sors For contactors with magnetic suppressors make sure you respect the polarity indi cated on the cap 3 3 FUSES Use a 10 amp fuse for auxiliary circuit protection For protecting the power unit see the diagrams The value shown is the maximum allowable For special applications or requirements this value can be reduced For safety reasons we recommend that you use protected fuses in order to prevent the spread of fused particles in the event of blowout Page 12 H2B general description 1 2 1 2 4 5 B6 B7 B8 C1 C2 C3 D1 D2 E9 E8 E7 E6 E5 E4 E3 E2 3 4 H2B CONNECTORS 0201 030201 8 7 6 5 4 5 2 1 A2A1 LOW LOW c c function LED LED INPUT PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FUNCTION SELECT UP DOWN CPOT NPOT PPOT CH IN CH OUT INPUT 5 20 z O Q KEK x x X x aa II SOG EE TE 2 jt 4 azo G Z description Alarm LED negative to be connected to the cathode Alarm LED positive to be connected to the anode Output current 12mA for standard type LED Serial reception positive Serial reception negative Serial transmission positive Serial transmission negative Console supply negative Console supply positive Channel for mini console speed signal Channel for mini console
21. as such and not as bypass in which case the output threshold is fixed and not programmable 12 HYDRO 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 adjustment 15 1ST SPEED COMP Compensation speed no 1 16 2ND SPEED COARSE Speed no 2 coarse adjustment 17 2ND SPEED FINE Speed no 2 fine adjustment 18 2ND SPEED COMP Compensation speed no 2 19 3RD SPEED COARSE Speed no 3 coarse adjustment 20 3RD SPEED FINE Speed 3 fine adjustment 21 3RD SPEED COMP Compensation speed no 3 22 4TH SPEED COARSE Speed no 4 coarse adjustment 23 4TH SPEED FINE Speed no 4 fine adjustment 24 4TH SPEED COMP Compensation speed no 4 25 MIN VALVE VOLT Minimum voltage applied on the proportional solenoid valve 26 MAX VALVE VOLT Maximum voltage applied on the proportional solenoid valve H2B standard lifting Page 53 6 1 4 ADUUSTMENT CHART PROGRAMMED LEVEL 39 0 63 0 74 1 09 1 22 H 1 46 1 54 19 0 56 0 62 0 70 1 43 1 53 367 400 600 250 278 306 472 500 100 os 1 9 3 9 59 7 8 9 8 117 137 16 6 17 6 oo oo 5 17 20 11 3 15 2 39 43 64 5 92 5 97 5 54 H2B standard lifting 6 1 5
22. azo 1 D 2828534885 Gen 82933360 BD DIAGNOSTIC LED 5 1 6 Wiring diagram for H2B regenrative model with handle 2 CHOPPER 56 82 ere 85 n ooo Zoax 4 E E lt u gt gt Ir aaa a5 M7O0000 oo azo 1 D B A 9463543805 0 26 n 2854380 BN LT L 2 1 TAN N 4 M B SH qH B TO THE CONSOLE PE ES B RV1 HANDLE _ Page 28 H B regenerative traction 1662 0 06551 EPEN 40 3214 ANY 24 2 04445 13 0 903 WVSDVIG DNISIA OSIA 31 1 56 01 90 1911 D IDIAUd 82029 79 al 51910044 1497 40 5 19 3 3H1 OL 3AI197323 19 SI JASN 03 111 AINO AHL NOILYZIJOHLNAY N31113A Y 304 1d32X3 31I8IHU2d SI NLILOn0GU23d39 511 0 945 1497 V SI ONIAVAC SIHI LAVHS YOLOW NO 133HM 9 10444 NOLON 7 m ae lt D 10 g CONE VOL lt lt KON HJ 104324 4 TAS
23. 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 regenerative brak ing and it is switched off when PWM is greater than 20 both statuses NOTE It is necessary to adjust the jumper configuration on the chopper electronic board depending upon previous program set Mismatchings cause the power section of the chopper to be damaged as well as mis functioning For each setting we should set the jumpers J 1 2 3 4 configuration on the logic board RESISTOR SUPPLY 100 1W R29 JUMPER EPROM PONTICELLI 3 1 4692 G CONNECTOR AP oe i H2B general description Page 21 DESCRIPTION OF CONSOLE PROGRAM VACC FUNCTION This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function Flow Chart showing how to use the PROGRAM VACC function of the Digital Console i i Di ZAPI 0 0 Opening Zapi Display DISPLAY P dA gt 2 Press ENTER to go into the General Menu KEYBOARD amp 3 The Display will show AIN MENU M J PARAMETER CHANGE
24. the programming console manual Page 6 H2B general description Vmot Vacc Vacc Vmot Vmot Vacc Vacc Vmot A A A 5V 100 4 5V 100 100 4V 100 0 100 100 100 MA 100 MECHANICAL HANDLE ANGLE MECHANICAL HANDLE ANGLE 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 The first graph Fig 8a shows the correspondence of the motor voltage without having made the acquisition while the second graph Fig 8b shows the same corre spondence after signal acquisition by the potentiometer The acquisition 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 potentiometric signals i e those which are carried from a high initial value to a low final value to use anormal potentiometer instead of one with central zero For the correct functioning of signal acquisition it is absolutely necessary that the run ning microswitches be activated by the same shaft that moves the potentiometer VACC Application examples volt AMOT Signal overturn s gt p 3 WIRE PEDAL 2 WIRE PEDAL Le
25. to 5V Input for the reference speed signal On this pin it is fixed the voltage corresponding to the relative speed which must not be exceeded on the pin B7 range admitted from OV to 5V This function is active when the option speed is programmed in the check way 5 1 2 Programmable functions OPTIONS The options can be programmed from the console using the sel options menu function pin option 1 PING3 bypass weak 2 SPEED free check 3 BATTERY _ free check description The contactor connected to connector G3 is handled as a bypass with activation current 809elmax output current 90 lmax activation delay 800 msec The contactor connected to connector G3 is handled as weakening with activation current 50 of the pro grammable output current WEAK DROP OUT from 10 to 100 Imax Activation delay 800 msec Speed check not active The mini console can be used with this option Speed check active At input B8 a reference potential between 1 and 5 V is applied at B7 an analogue signal proportional to the speed is applied When the signal on connector B7 exceeds that of reference on B8 the machine begins to reduce the motor voltage or brakes if the difference persists This braking state remains until the signal on B7 becomes less than that of B8 Sampling is made once every 60 msec Note when the speed check option is active the mini console cannot be used No low battery c
26. A detailed description of these parameters is given on point 5 1 3 Q 5 5 2 4 Adjustment chart PROGRAMMED LEVEL B 0 oo N BRAKING IMax CUTBACK SP 1 2 3 VBatt wj o en H N 3 500 95 95 Ww o nN 5 1235 SP a vear w vsa s AUXILIARY TIME EB BACKING TIME 2 B e w gt g x 5 5 2 5 Wiring diagram for 2 standard traction with pedal H2B CHOPPER 7 LL asd 5 82 ccc 86 S wean 244441 0 lt 0 gt gt gt oo azo 1 D 2828534885 Gen 82933360 BD DIAGNOSTIC LED 5 2 6 Wiring diagram for H2B standard traction with handle 2 CHOPPER 82884855 BH x DIAGNOSTIC b LED qH B SH TO THE CONSOLE i RVI Page 38 H2B standard traction 5 2 7 Wiring diagram for H2B power unit standard traction with weakeening CONNECTOR CONNECTIONS PIN FUNCTION
27. ACTERISTICS 2 1 TECHNICAL SPECIFICATIONS VONAGE susu a 24V 14 32V 36 40 48V 22 55V 60 72 80V 36 90V 96V 57 120V Maxim m eerte Ra ra Ea e EK SLE ots short size 400 long size 600 80 V model 500 SYSTEM H2 400 H2 600 VOLTAGE SHORT LONG 24V 400A 600A 48V 400A 600A 80V 400A 500A 600A 96V 400A 500A 600A po 16 kHz Motors DC wire wound serie 4 cables Operating ambient temperature 30 to 40 Maximum allowable temperature for chopper body 85 C Drop voltage with 200 A SYSTEM H2 400 H2 600 VOLTAGE SHORT LONG 24V 250mV 200mV 80V 1 00V 550mV 550mV Microprocessor logic unit 4 different configurations that can be set from the console 1 traction control and energy regeneration 2 5 speed pump control 3 4 pump control hydrodrive contactor handling There are two H2B models based on the maximum current 400 A and 600 A which also differ in size H2B general description Page 5 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 dime
28. ICLE 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 8 PERIODIC MAINTENANCE TO REGULARLY REPEATED Check outwear of electric contacts they should be replaced when matchboard is too strong and worn out Electric contacts should be checked every 3 months Check pedal microswitch verify with a tester that there is no electric resistance be tween the contacts by measuring the voltage drop between its terminals Also the re lease should have a firm sound The ped
29. ING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0 3 sec gt WHEN REQUESTING BACKWARD RUNNING YOU FIND ANY VOLTAGE AT COIL CONTACTS FOR 0 3sec gt WHEN REQUESTING FORWARD RUNNING YOU FIND ANY VOLTAGE AT TA COIL S CONTACTS OR AT BACKWARD CONTACTOR COIL S CONTACTS FOR 0 3sec A1 There is not a good contact either on TA forward contactor NA normally open or on TI backward contactor NC normally closed 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 42 H B diagnosis traction CLEAN FORWARD RUNNING CONTACTOR NORMALY OPEN CONTACTS CLEAN BACKWARD RUNNING CONTACTOR NORMALY CLOSED CONTACTS 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 CLEAN BACKWARD RUNNING CONTACTOR NORMALY OPEN CLEAN FORWARD CONTACTS RUNNING CONTACTOR NORMALY CLOSED CONTACTS TI It could be changing both contactors A3 The most probably reason is that the normally closed contact of the braking contactor doesn t make a good contact towar
30. a fixed increment every second 3 RELEASE BRAKING release braking current should have the lowest value 4 PEDAL BRAKING release braking current with brake pedal pressed 5 CUTBACK SP 1 reduction of speed no 1 relative to input E3 A braking is also associated curve braking the accelerator is reduced 6 CUTBACK SP 2 reduction of speed no 2 associated to input E2 If the pin E2 input option is configured in the backing way this parameter defines the backing speed whose adjustment values are defined at the point BACKING SPEED of the adjustment chart 7 CUTBACK SP 3 reduction of speed no 3 associated to input E1 8 AUXILIARY TIME Auxiliary contactor activating time connected to the G7 output request option or hardware modifications are necessary see p 18 9 COMPENSATION compensation of the speed motor voltage 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 pressed all the way down in inversion braking becomes more brusque the higher the value of the parameter 11 IMAX defines the maximum current of the chopper both when running and in braking All the current adjustments are expressed as a percentage of this value The adjustment interval is from 50 level 0 to 100 level 9 12 MAX SPEED FORW Max speed wit forward direction on This speed reduction go
31. active when pin is opened The activation of this reduction is combined with an intensity braking and programmable length curve braking It is possible to eliminate the braking in curve program ming curve time as 0 Input for seat microswitch signal delayed 2 sec if the pin is taken to a high potential the running is active the delay isn t executed if the pin is programmed as tiller handle Input for brake pedal microswitch when the pin is taken high VB during a release braking phase the braking current is the one programmed at the parameter PEDAL BRAKING plus a value that is proportional to the accelerator signal and to the parameter BRAKING MODUL If the brake is pressed during the usual running the current is reduced by 50 and the speed No 2 reduc tion is activated Input for backward request signal The request is active when the signal is high VB Input for forward request signal The request is active when the signal is high VB Same as pin E4 but active when signal is low Same as E8 H2B regenerative traction Page 23 4 STATE 7 SPEED SIGNAL B8 SPEED REF 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 Input for the speed signal caming from a trasducer speed voltage The range admitted by the signal is from OV
32. ain it supplies a negative to the motor with variable duty cycle B Battery negative SH Input current sense Page 14 H2B general description 3 6 CONTACTORS CONNECTOR 1 G PRINTED CIRCUIT ZP3e1C 0 CONN WIRE COLOUR CONN TRACTION FUNCTION PUMP FUNCTION es Positive of braking contactor PTFR of Positive of braking contactor PTFR contactor PTFR E red black Contactors positive PT Contactors positive PT PT Contactors positive PT PT raviblabk 22 field weakening contactor Negative field weakening contactor grey coil NTIND coil NTIND blue black 2 2 Negative backward contactor NTI Negative backward contactor NTI contactor coil NTI Negative main contactor coil NTG main contactor Negative main contactor coil NTG NTG Negative braking contactor coil NTFR Negative a eon black 5 5 Negative forward contactor coil NTA Negative forward contactor coil NTA contactor coil NTA Negative hydro contactor coil NTIDR optional Negative of auxiliary contactor AUX G7 H2B general description Page 15 3 7 2 CHOPPER MECHANICAL DRAWING
33. al microswitch should be checked every 3 months Check motor battery power links they should be in excellent shae as well as the wires claddings Wires should be checked every 3 months Control of the pedal and contactors springs They should be able to extend to its full extention and checked every 3 months Check contactors mechanical 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 should be original Installation of this electronic controller should be done according to the diagrams in cluded in this manual and any variation should be done accordingly with the supplier The supplier is not responsible for any problem that rises from using wiring solutions different from the ones suggested on this manual 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 DO NOT USE A VEHICLE WITH FAULTY ELECTRONIC CONTROLLER H2B
34. ated 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 regenerative braking at release Braking Release braking HOURS Running Hour metre active only when running Key on Hour metre active with key on PIN E1 Cut b 3 E1 Reduction of speed no 3 Quick 1 E1 Rapid inversion input PIN E4 Seat 4 Seat microswitch Handle E4 Handle microswitch PIN E2 Cut b 2 E2 Speed reduction no 2 Backing E2 Back request with speed relative to cutback speed 2 and timing of backing time parameter SELECTION OF BATTERY VOLTAGE SEL BATTERY MENU Makes it possible to set the nominal voltage of the battery for handling the charge status and tester functions With ROLL UP ROLL DOWN buttons it is possible to select battery nominal voltage With SET UP SET DOWN buttons it is possible to make fine adjustments of battery voltage Page 20 H2B general description 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 Jumper setting 1 3 2 4 2 HYDRO CONTACTOR The output AUX G7 commands the hydrodrive contactor It should be active during both forward and backward directions and during release braking The turning OFF delay is
35. auses a Contactor stuck only standard traction 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 replace the power NO FULL COND The test is carried out in full conduction If in this condition the VMN is found to be greater than 1 3 VBATT the diagnostic circuit is faulty causing a safety risk and thus machine operation is inhibited If the defect persists replace the logic THERMAL PROTECTION An indication that the controller temperature has exceeded 80 C The maximum current is gradually reduced reaching 0 at a temperature of 85 C If the alarms occurs while cold the most probably reason is the failure of the thermic diagnosis circuit on the power or on the logic board replace on of the two parts or replace the complete controller b If the alarm often occurs after short time the machine is working probably it is due to inadequate heat sink check the fixing nuts tightening and the correct installation BATTERY The battery charge is low The alarm is signalled only if the battery check option has been selected from the serial console default When this alarm occurs the maximum current is reduced to 50 2 diagnosis traction Page 47 10 INCORRECT START An incorrect starting sequence The machine only starts if the sequence is followed key handle or seat
36. automatically stored by the control logic without the need for confirmation before switching off or disconnecting the console Important note the console does not function if connected when the motor is running Switch the machine off and on again for activating the console functions H2B general description Page 17 4 2 MODIFYING PARAMETERS USING THE DIGITAL CONSOLE The digital console displays the model type and its built in hourmeter SEL MODEL SEL OPTION REGENER STANDARD TR STANDARD PUMP PUMP HYDRO PIN G3 SPEED BATTERY ARB RELEASE HOURS PIN E1 PIN E4 bypass weak free check free check free check free braking running keyon cut b 3 quick I seat handle PIN E2 BRAKING SELBATTERY fine adjustment AUXFUNCTION CURRENT GAIN HYDRO CONTACTOR BIMOTOR CONTACT Cut b 2 backing normal soft 24V 36 40 48V 60 72 80V 96V traction pump PROGRAM ACCELERATION DELAY ACCELERATION DELAY INVERS BRAKING EV ACCELER DELAY RELEASE BRAKING DECELER DELAY PEDAL BRAKING EV DECELER DELAY CUTBACK SP1 SP2 SP3 1 AUXILIARY TIME HYD SPEED COARSE COMPENSATION HYD SPEED FINE BRAKING MODULATION HYDRO COMPENS MAX CREEP SPEED MAX SPEED FORW WEAK DROPOUT MAX SPEED BACK HYDRO TIME CREEP SPEED SPEED COARSE 1 2 3 4 WEAK DROPOUT SPEED FINE 1 2 3 4 CURVE BRAKING SPEED COMP 1 2 3 4 CURVE TIME MIN VALVE VOLT BACKING TIME MAX VALVE VOLT Page 18 H2B general description tracti
37. battery negative 2 disconnecting the contactor wire always excited from board connector if the contactor is no longer excited replace the logic board B8 A running contactor is stuck on working position unlock the contact it could be possible to replace the contactor D1 Wrong connections of the motor cables The stator and the armature are crossed CORRECT CONNECTION MISTAKE CONNECTION Page 46 H2B diagnosis traction 6 7 8 9 D2 There is a current dispersion 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 C5 The most probably reason is that the failure is inside the controller replace it E1 If there s the bypass contactor check that it is not stuck or it is too much slow in opening For verifying this possibility disconnect the bypass and check if the failure disappears if this happens replace the logic PAY ATTENTION the contactors connected to the controller must not have arc suppressers on the contactor coils because these are inside the control ler and then the external ones modify the contactor opening times VMN HIGH Test carried out in standby If the VMN voltage is greater than 2 3 VBATT an alarm is shown Possible c
38. ctors coils High motor and battery efficiency thanks to high frequency commutation 2 5 H2B CHOPPER DIAGNOSIS The microprocessor carries out diagnostic procedures on the main chopper functions involving 4 basic points Diagnosis on key start up which includes watchdog test current sensor test VMN test contactor pilot test test for running request present high accelerator test Standby diagnosis which includes watchdog test VMN test contactor pilot test current sensor test Diagnosis while running which includes watchdog test VMN test current test contactor test VMN test in complete conduction contactor opening closing test Continuous diagnosis temperature check battery charge check The diagnostic message is indicated by a certain number of blinks of the LED con nected to connector A The current alarm message code can be displayed on the programming console A description of the alarm codes possible causes and solutions is given for each con figuration in the following sections 2 6 THERMAL CONSIDERATIONS The heat generated by the control unit must be dissipated For this to be possible the compartment must be ventilated and the cooling surfaces ample The cooling system is dimensioned on the basis of the performance required of the machine For situations in which ventilation is poor and heat exchanoe difficult because of the materials used we suggest to use forced air ventilation The power dissipat
39. del with speed check and 30 5 1 9 Wiring diagram 2 regenerative model with speed check and Sanc CA 31 5 1 10 Wiring diagram for H2B regenerative model power unit 32 5 1 11 Wiring diagram for H2B regenerative model power unit With weakening u us 33 5 1 12 Wiring diagram for H2B power unit regenerative with bypass 34 5 1 13 Wiring diagram for H2B power unit regenerative with ie 34 5 2 H2B standard traction Soh 35 5 2 1 Input connectors ERES 36 5 2 2 Programmable function options 36 5 2 3 Parameter modification traction 37 5 2 4 Adjustment chart a edic dre 37 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 5 3 Sequence of settings for regenerative standard traction 40 5 4 ZB traction diagnosis
40. description Page 11 3 INSTALLATION Install the with the base plate 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 Keep this in mind when choosing the installation position on the vehicle Use the special holes on the base plate for fastening the chopper Make sure that the wiring of the cable terminals and connectors is carried out correctly Fit anti jamming filters on the horn solenoid valves and contactors not connected to the chopper such as those for activating the pump motor or hydrodrive motor if the latter is not handled 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 the best chopper performance the cables to the battery should be run side by side and be as short as possible 3 2 CONTACTORS Choose the type of contactors on the basis of the maximum operating current of the motor and the specific chopper configuration The current absorbed by the coil must not be greater than 3 amp The coil suppressors are inside the chopper do not use contactors with
41. dling Proportional solenoid valve handling for descent BATT DIAGNOSTIC LED CONSOLE FUSE 10 50 H2B standard lifting 6 1 1 Input connectors pin E1 E2 E3 E4 E5 E6 E7 E8 E9 function 4TH S 3RD S 2ND S HYD S 1STS DOWN UP HYD S HYD S description Input for 4th speed request The speed is active when the pin is high connected to Input for 3rd speed request The speed is active when the pin is high connected to Input for 2nd speed request The speed is active when the pin is high connected to Input for hydrodrive speed request The speed is active when the pin is high connected to The programmable timing HYDRO TIME is associated to this input Input for 1st speed request The speed is active when the is high connected to 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 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 4 5 6 7 9 2 4 8 10 15 20 25 30 40 50 In this case the function descent is not carried out N B for avoiding the activation descent is not when the lift request
42. ds the battery negative for dust dirt or because the contact doesn t lean completely for a mechanical defect of the contactor CLEAN BRAKE CONTACTOR NORMALY CLOSED CONTACTS It could be necessary to replace the contactor It may be due to 1 of following causes of motor connecting interruption a brushes lift up from collector 10 1 b brushes cable burn up fig 2 C M Missing the braking contactor negative cable fig 3 d Interruption either on motor winding on motor itself cabling H2B diagnosis traction Page 43 Fig 1 Fig 2 Fig 3 BRUSH LLECTOR Hi B1 Forward contactor is supplied with a correct voltage but it doesn t close Possible causes 1 Contactor coil is interrupted verify its resistance using an ohmmeter 2 Contact can t move due to mechanic block 3 Nominal working coil voltage is greater than battery one B2 Backward contactor TI is supplied with a correct voltage but it doesn t close everything said at point B1 for TA is valid here B3 Backward and forward contactor are supplied with a correct voltage but they don t close see point B1 C1 Supply don t come up to TA please check cabling and connections from TA coil to connectors PT and 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 connector
43. e test is carried out in standby If the VMN voltage is lower than 1 3 of the battery voltage an alarm is signalled Possible causes a Check the motor wiring to make sure it is correct b Chopper broken replace NO FULL COND The test is carried out in full conduction If in this condition the VMN is found to be greater than 1 3 VBATT the diagnostic circuit is faulty causing a safety risk and thus machine operation is inhibited If the defect persists replace the logic TH PROTECTION An indication that the chopper temperature has exceeded 80 C The maximum current is gradually reduced reaching 0 at a temperature of 85 C If the alarm occurs while cold a Check the thermal sensor connection b Thermal sensor failure c Connection on the power interrupted check the connector that connects the logic to the power unit d Logic failure H2B lifting 3rd motor Page 61 4 battery charge is low The alarm is signalled only ifthe BATTERY CHECK option has been selected All functions except hydrodrive are inhibited INCORRECTSTART A running request is present on key startup Possible causes a Operator error b Request microswitch stuck 6 HIGH AT STAND Test carried out in standby checks that the current is nil If this is not verified an alarm is signalled This alarm shuts down the machine Possible causes Current sensor broken and logic failure First replace the l
44. ed and optimised on one unit can be stored from the con sole SAVE and then reloaded RESTORED on another chopper thus allowing fast and standardised calibration see console manual for details Pay special attention to the polarity of the console connector when it is hooked up to the chopper HOOKING UP MUST ONLY BE DONE WITH THE MACHINE OFF 4 1 MODIFYING PARAMETERS USING THE MINI CONSOLE The parameters that can be modified are Traction Lifting 1 CREEP SPEED 1 1STSPEED e ACCELERATION 2 ACCELERATOR DELAY 2 2ND SPEED ema 3 BRAKING 3 SPEED 22228 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 intermediate levels Connect the mini console to connector on the chopper the hook up MUST BE MADE WITH THE KEY OFF Supply the machine by activating the key Position the dial selector on the function to be modified The SET UP button increases the value of the parameter while SET DOWN de creases it Note the variations are made through a count of the number of impulses sent from the buttons thus for increasing or decreasing more than one point you need to release and then repress the button Keeping the button pressed continuously does not provide continuous variation of the parameters The parameters are modified in real time making it possible to check the values set immediately The modified parameters are
45. ed by the module varies depending on the current and the work cycle H2B general description Page 9 2 7 GENERAL NOTES AND PRECAUTIONS AN Never combine SCR low frequency choppers with H2B modules as the filter con densers contained in the 2 module alter SCR chopper functioning subjecting it to excessive workloads Thus if you wish to use two or more control units e g lift traction they must all be of the high frequency ZAPIMOS family Do not connect the chopper to a battery with a different nominal voltage than that indicated on the chopper identification plate A higher battery voltage can cause MOS failure A lower battery voltage prevents the module from functioning During battery recharge the H2B module must be completely disconnected from the battery as in addition to altering the charge read by the battery charger the module can be damaged by the overload voltages generated by the charger The H2B module must only be supplied using a traction use battery do not use outputs of converters 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 safety risks With the key off the filter condensers inside the module may remain charged for several minutes For safe operation we recommend that you disconnect the battery and short circuit the power positive and ne
46. es under adjustable compensation with the COMPENSATION parameter 13 MAX SPEED BACK Max speed wit backward direction on This speed reduction goes under adjustable compensation with the COMPENSATION parameter 14 CREEP SPEED defines the minimum voltage applied to the motor with the run ning request activated Provides a more immediate response in starting off 15 WEAK DROPOUT threshold of current for opening the weakening contactor if programmed as such and not as bypass in which case the output threshold is fixed and not programmable 16 CURVE BRAKING current for curve braking activated with RV1 request if the PWM is greater than 80 and the motor current less than 40 17 CURVE TIME curve braking time associated to RV1 If 0 braking is not carried out 18 BACKING TIME backing request activating time delay If programmed at level 9 there is no time delay and the on status is present if a request is present Page 26 H2B regenerative traction 5 1 4 Adjustments chart PROGRAMMED LEVEL 89 311 378 PROGRAMMED LEVEL PARAMETER I o pepe 1 pe pe H2B regenerative traction Page 27 5 1 5 Wiring diagram for 2 regenerative model with pedal H2B CHOPPER 7 LL asd 5 82 ccc 86 S wean 244441 0 lt 0 gt gt gt oo
47. gative on the chopper for a few seconds with a resistance of between 10 ohm and 100 ohm The susceptibility and the electromagnetic emission are remarkably influenced by the installation conditions 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 doesn t carry out the tests required by the regulations in force conducted emissions irradiated emissions IEC 801 2 ESD IEC 801 3 irradiated susceptibility IEC 801 4 burst IEC 801 5 surge IEC 6 conducted immunity Page 10 H2B general description 2 8 GENERAL AND SWITCH FOR REGENERATIVE MODEL N The connection of eventual interruption systems of the battery must be executed scrupulously respecting one of the following wirings With safety switch SAFETY SWITCH With switch and general contactor SAFETY H2B AUX CHARGE These circuital solutions are necessary to avoid the chopper fail when the connection to the battery is opened during the phase of regenerative braking The chopper intrinsic protection is active when the voltage on the pin D1 exceeds by 30 the battery normal voltage or when the key is excluded before the opening of the battery connection H2B general
48. harge alarm Activates the check that reads the battery voltage in standby When the residual charge is less than 10 the maximum current is halved and the LED blinks continuously Page 24 H2B regenerative traction 4 5 RELEASE 6 HOURS 7 PINE1 8 PIN E4 9 PIN E2 10 BRAKING free check free check running key on cut b 3 quick I seat handle cut b 2 backing Normal Soft No anti rollback Anti rollback No regenerative braking at release Braking active at the moment of pedal release with increment of the braking current by means of the brake pedal Hour metre only active when running Hour metre active with the key on Associates the function of no 3 speed reduction request to the E1 connector Associates at the connector E1 with the following char acteristics plugging with 1 2 x Imax restart in forward direction with 0 5 x Imax and slower acceleration to avoid wheel slippering Also the truck will stop if the safety button is released and a forward or reverse request is present The QUICK I function is active if the request of motion in the direction opposite to the forks is present and if the safety button pushes on the operator Associates the function for rapid inversion to connector E1 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 second
49. m persists when the key is switched off and on again replace the logic 5 gt 62 2 lifting 3rd motor 12 alarm similar to 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 13 WATCHDOG The test is made in both running and standby It is a self diagnosis test within the logic If an alarm should occur replace the logic 14 COIL SHORTED There is an overcharge or a short circuit towards the positive of the battery on the during negative contactor output 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 The alarm shows an occurred overcharge and not the fail of a chopper component When the external cause is removed it is possible to restart again 15 DRIVER SHORTED The test is carried out in standby It checks that the during voltage of the drivers commanding the contactors is at a coherent value with the forecasted state Possible cause a Logic failure b Drivers broken because of an overvoltage in the cabling of the negative contac tors Replace the logic after having removed the cause H2B lifting 3rd motor Page 63 7 RECOMMENDED SPARE PARTS H2B ART
50. n 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 OV to 10V The resistive value of the potentiometer must be between 500 ohm and 10 kohm as lower values overload the power supply 2 WIRE PEDAL 5 WIRE HANDLE C3 PPOT C c1 C C2 C2 2 wire potentiometer please request while ordering It is possible to use the potentiometer 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 MOTOR 4 VOLTAGE Vbatt 1004 90 4 80 4 70 4 60 4 50 4 40 4 30 4 20 4 104 PEDAL 10 20 30 40 50 60 70 80 90100 VOLTAGE The procedure for automatic potentiometer signal acquisition is carried out from the console This makes it possible to adjust the minimum and maximum useful signal in the respective directions This function is indispensable when it is necessary to compensate for asymmetry in the mechanical workings that control the potentiometer especially as regards the adjust ment of the minimum which in certain cases if made in the traditional way requires a calibration that is laborious and costly but very often gives unsatisfactory results The sequence of procedures is described in
51. n the lifting version all functions except hydrodrive and descent are blocked This feature may be excluded by the console External agents The chopper body is completely sealed and thus is protected against splashes of liquid IP54 Protection against accidental start up A precise sequence of operations is necessary for starting the machine If these operations are not carried out correctly the machine will not start The request for running must be activated after the key and handle microswitch or seat microswitch Protection against uncontrolled movements The contactors do not close if the power unit is not functioning the accelerator does not go below the minimum value stored increased by 2 V the logic is not perfectly functional one running microswitch is stuck Page 8 H2B general description 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 Console tester for real time checking of the main parameters such as inputs motor voltage battery etc Absence of arc on the contactors Internal arc suppressor of the conta
52. ogic and if the defect persists replace the power unit 7 1 0 EVER Test carried out in running Checks that the current during running is greater than a minimum value If not an alarm is signalled and the machine is shut down Possible causes a The current sensor is faulty Replace the power unit 8 EEPROM PAR KO Fault in the area of memory in which the adjustment parameters are stored This alarm inhibits 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 and replaced by the default values 9 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 voltage etc thus it must be reprogrammed Consult the console manual 10 EEPROM DATA KO The data in the area of memory that handles the hour metre is incorrect This alarm does not shut down the machine If the alarm disappears when the machine is switched off and on again keep in mind that the hour metre data has been reset to zero 11 EEPROM OFF LINE Fault in the nonvolatile memory that contains data relative to the area for the hour metre the alarms stored and the programming parameters If the alar
53. oil to the connector C1 PTFR and C5 NTFR 4 DIR CON CLOSED Test carried out during the passage to standby or braking Checks that the running contactor opens by comparing the consistent status of the VMN potential Possible causes a Running contactor stuck or slow to open b Logic failure H B diagnosis traction Page 45 5 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 1 TEST RESULT 2 TEST RESULT 3 TEST RESULT DESCRIPTION DETECTED POINT YES gt gt gt gt C5 DISCONNECT THE MOTOR CABLE CONNECTED TO A RUNNING THE STUCK zd AND CONTACTORIS YES CONTACTOR COIL THEN VERIFY IF NO LOCKED IN ISSUPPLIED NO B8 THE ALARM STILL WORKING PRESENT POSITION D1 NO D2 D3 RUNNING WITH CONTACTORS ON RUNNING T x 72 POSITIONS AS SOON AS THE ACCELERATOR IT PRESENT THE YES gt gt gt gt PEDAL IS BYPASS OR THE COMPLETLY WEAKENING RELEASED FOR CONTACTOR DOING A RELEASE i BRAKING NO gt gt gt gt c5 B7 If the running contactor remains stuck you can verify 1 ifthe wire going from NTA to NTI is casually in short with a metallic part connected to the
54. on 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 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 parameters from console memory to chopper memory 10 different memories are available for each chopper model ALARM Display of in chopper memory alarms PROGRAM VACC Potentiometer stroke parameter H2B general description Page 19 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 CONFIGURATION OF THE MODEL SEL MODEL MENU Allows chopper to operate in one of the 4 possible modes 1 REGENER TR regenerative traction 2 STANDARD TR standard traction 3 STANDARD PUMP standard lifting 4 PUMP HYDRO lifting with hydrodrive contactor handling CONFIGURATION OF OPTIONS SEL OPTIONS MENU function pin option meaning PIN G3 Bypass Bypass contactor Weak Weakening contactor SPEED Free No speed check Check Speed check activ
55. ontact of the braking contactor is stuck Unlock the contact and clean it if it is too much damaged replace the contactor b The braking contactor remains excited for a defect in the logic board or because the NTFR wire is in short towards the negative For understanding if the defect is produced by one of these causes select the running and press the pedal without giving the seat or tiller request if the activa tion only of the braking contactor is in synchrony with the pedal or selector command verify what follows disconnect the wire from the NTFR connector and do again the test above if the contactor remains disactivated replace the logic otherwise if the contactor moves check that there is not a wire in short with a metallic part 2 DIR CONT OPEN Test carried 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 herefollowing FAULT TEST RESULT TEST RESULT DESCRIPTION AT POINT YES gt gt Al CONDITION UNDER WHICH FAULT 1 DETECTED ONLY AT FORWARD RUNNING REQUEST ONLY AT BACKWARD RUNNING REQUEST AT BOTH RUNNING REQUEST YOU SEE FORWARD CONTACTOR TA CLOSING FOR 0 3sec THEN OPENING YOU SEE BACKWARD CONTACTOR 11 CLOSING FOR 0 3sec THEN OPENING YOU SEE FORWARD OR BACKWARD CONTACTOR TA OR CLOSING FOR 0 3sec THEN OPENING WHEN REQUESTING FORWARD RUNN
56. r by incrementing the level until it begins to descend With the lever in maximum speed position set the MAX VALUE VOLT parameter by decreasing the level until you notice that the descent speed begins to reduce Acceleration and deceleration are set by obtaining the right compromise between response speed and smoothness of movement Page 60 2 lifting 3rd motor 6 5 2 LIFTING DIAGNOSIS Description 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 KO EEPROM OFF LINE CHOPPER NO CONF WATCHDOG 2 BLINKS Running request on startup or error in handle speeds sequence INCOR RECT START 3 BLINKS Error on VMN test FUL CONDUCTION 4 BLINKS Accelerator high in standby this error inhibits machine operation VACC gt 1 V 5 BLINKS Error in reading current this error inhibits machine operation 1 HIGH AT STAND 1 0 EVER 6 BLINKS Malfunctioning of the contactor driver circuit DRIVER SHORTED COIL SHORTED 7 BLINKS Excessive temperature greater than 80 C TH PROTECTION CONTINUOUS BLINKING 32 BLINKS Low battery charge battery with lt 10 of residual charge BATTERY 6 5 1 Decoding the alarms displayed on console H2B LIFTING 1 2 3 STAND BY VMN LOW Th
57. s A detailed description is given in the section DECODING THE ALARMS DISPLAYED ON CONSOLE on point 5 5 1 BLINK 2 BLINKS 3 BLINKS 4 BLINKS 5 BLINKS 6 BLINKS 7 BLINKS 8 BLINKS Logic anomaly EEPROM DATA KO EEPROM PAR EEPROM CONF KO EEPROM OFF LINE CHOPPER NO CONF WATCH DOG Running request on startup or error in handle speeds sequence INCORRECT START Error on VMN test NO FULL CONDUCTION VMN LOW Accelerator high in standby this error inhibits operation NOT Error in reading current this error inhibits operation 1 HIGH AT STAND I 0 EVER Malfunctioning of the contactor driver circuit DRIVER SHORTED COIL SHORTED Excessive temperature greater than 80 C TH PROTECTION Contactors do not open or VMN high in standby BRAKE CONT OPEN DIR CONT OPEN VMN HIGH 9 BLINKS Contact stuck BRAKE CON CLOSED only for regenerative DIR CON CLOSED only standard traction CONTINUOUS BLINKING 32 BLINKS Low battery charge battery with lt 10 of residual charge BATTERY LED REMAINS ON Double running request FORW BACK H2B standard traction Page 41 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 gt 2 3 VBATT an alarm is issued Possible causes a The normally open c
58. s PT NTA and NTI For points C1 C2 C3 replacing controller may be necessary For H2B standard configuration the solutions at point 1 2 1 2 3 1 C2 C3 are valid for the last two points please respect the different connections rather than the regenerative configuration 3 BRAKE CONT OPEN regenerative only Test carried out during the passage to running After closure of the running contact the braking contactor closes verifying that the VMN goes from lt 1 3 to gt 2 3 If this does not occur an alarm is shown For finding out the causes follows the diagnosis procedure herefollowing Page 44 H2B diagnosis traction FAULT TEST RESULT 2 TEST RESULT 3 TEST RESULT DESCRIPTION AT POINT A4 YES gt gt gt gt A5 AT RUNNING REQUEST YES 4 THE CLOSES FOR WHEN THERE S THE CHECK WITH AN 0 3sec RUNNING REQUEST IS YES OHMMETER OF THE TFR NO THERE A VOLTAGE AT PIN COIL IS INTERRUPTED NO BTFR FOR A TIME OF 0 3sec NO gt gt C4 A4 There is not a good contact on the NA of TFR clean the contact if it is too much damaged replace the contactor B4 Replace the contactor coil or the complete contactor Contactor mechanically locked unlock it and replace it B6 Contactor with working nominal voltage bigger than the feeding one C4 Supply doesn t come up to the contactor coil please check the cabling and the connections from the c
59. s on deactivation Like the seat option but without delay Associates the speed reduction no 2 to the pin E2 Associates the pin E2 to the backward request It ena bles to execute a timed movement with no seat micros witch The backing request and a forward backward request should be simultaneous Under these condi tions the acceleration pedal has no effect Also the system has a fixed speed that is defined and the BACKING SPEED chart programmable through the CUT BACK SP 2 parameter for a time programmable with the BACKING TIME parameter Every braking current is handled at normal values as showed on the adjustments chart Every braking current is reduced by 25 when the soft way is selected it is necessary that the jumpers in the card are configured 1 3 and 2 4 and that the maximum current level IMax is programmed to a value not inferior to Six H2B regenerative traction Page 25 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 1 ACCELER DELAY acceleration time i e the minimum time during which the motor voltage varies from 0V to the maximum 2 INVERS BRAKING basic braking current in direction inversion A value is added to this value based on the accelerator plus
60. signalled and the machine is shut down Possible causes a The current sensor is faulty Replace the power unit b Wrong connections of the motor cables to the power bars SH and SH 15 EEPROM PAR KO Fault in the area of memory in which the adjustment parameters are stored This alarm inhibits 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 param eters stored previously have been cancelled and replaced by the default values Page 48 H2B diagnosis traction 16 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 thus it must be reprogrammed Consult the console manual 17 EEPROM DATA KO The data in the area of memory for the hour metre is incorrect This alarm does not shut down the machine If the alarm disappears when the key is switched off and on again keep in mind that the hour metre data has been reset to zero 18 EEPROM OFF LINE Fault in the nonvolatile memory that contains data relative to the area for the hour metre the alarms stored and the programming parameters If the alarm persists when the key is switched off and on again replace the logic 19 CHOP NO CONF
61. speed ref Potentiometer central connected to the potentiometer cursor For speed regulation the useful signal ranges from 0 Volt minimum speed to 10 V maximum speed Potentiometer negative a battery negative Potentiometer positive a 12 V output Do not short circuit this terminal toward the battery negative or apply a resistive load of less than 500 ohm To be connected to the key The positive to be sent to the function request micros witches is taken from this pin This positive is taken after the internal diode Pins to which the signals for function request are sent their meanings varies according to the model selected and pin programming A detailed description is given in the chapters dedicated to the specific models Pin E4 if forced to low level inhibits the effect of pins E8 and E9 Activates the same request as for pin E4 with a low capacity level less than 10 V Like E8 but electrically disconnected H B general description Page 13 ELECTRICAL CIRCUIT OF INPUT PINS Pin C1 Pins E2 E4 E6 E7 ONLY PINS E6 AND E7 INPUT r 5 gt 5 47K 5 47K 220N d I BATT VOLTAGE INPUT SIGNAL SYSTEM RIN LEVEL 3 5 2 POWER CONNECTORS 8 SH SH Output current sense B Battery positive VMN Connected to the power mosfet dr
62. ter modifications 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 modifica tions are stored in the chopper s nonvolatile memory 1 ACCELER DELAY Pump motor acceleration time 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 Deceleration time relative to descent 5 AUXILIARY TIME Not used in the pump configuration 6 IMAX Defines the maximum chopper current All current adjustments are ex pressed as a percentage of this value The adjustment range is from 50 level 0 to 100 level 9 7 HYD SPEED COARSE Coarse hydrodrive speed from 0 to 100 Vbatt on the motor Page 52 H2B standard lifting 8 HYD SPEED FINE Fine hydrodrive speed a value 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 9 HYDRO COMPENS Compensation in current for hydrodrive request 10 CREEP SPEED Defines the minimum value of voltage applied to the motor with running request active Allows a more immediate response at start up 11 WEAK DROPOUT Threshold of current for opening the weakening contactor if programmed
63. th maximum current reduced at 5096 free No antirollback check Antirollback running Hour metre only active when running key on Hour metre active with the key on cutb 3 E1 3rd speed reduction quick E1 Input for rapid inversion seat 4 Seat microswitch handle 4 Handle microswitch cutb 2 E2 No 2 speed reduction backing E2 Backing request A detailed description of these pins is given on point 5 1 2 Page 36 H2B standard 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 Braking current base value CUT BACK SP 1 1st speed reduction CUT BACK 2 2nd speed reduction CUT BACK SP 3 3rd speed reduction AUXILIARY TIME Time delay to activate the auxiliary function COMPENSATION Compensation for speed reductions BRAKING MODUL Braking current increment in inversion with accelerator IMAX Maximum chopper current 10 MAX SPEED FORW Maximum forward speed 11 SPEED BACK Maximum backward speed 12 CREEP SPEED Minimum acceleration threshold 13 WEAK DROPOUT Weakening output current threshold 14 CURVE BRAKING Curve braking current RV1 15 CURVE TIME Curve braking time 16 BACKING TIME Time delay to activate the back request 9 continuous
64. tor handling Maximum speed control Backing request with associated speed and programmable timing DIAGNOSTIC LED STATO REC 5 CONSOLE FUSE 10A SEAT MS gt BRAKE MS of o BACKWARD MS TED MEME EJ A FORVARD M S BATT Page 22 H2B regenerative traction 5 1 1 Input connector description E1 E2 E3 E4 E5 E6 E7 E8 E9 QUICK RV2 BACKING RV1 MSED HANDLE MF MI MA Input for 3rd speed reduction request The request is active when the pin is disconnected To disconnect link to 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 Input for 2nd speed reduction request The request is active when the pin is opened low level and discon nected if the pin is positive high level or the speed is programmed to level 9 If itis programmed as back request backing when the pin is taken to a low level combined with a running request the running is activated with setted speed through the parameter CUTBACK 2 according to the values defined at the point BACKING SPEED of the adjustment chart and for a time with the parameter BACKING TIME When this function is required it isn t necessary to active the pin E4 SEAT MICROSWITCH Input for 1st speed reduction request which is
65. tup time Status Output G5 Lifting status O running Main C Output G5 Main contactor A detailed description of the meanings is given on point 6 1 2 as per the H2B standard lifting model 6 2 3 Parameter modifications h2b configuration pump 3rd motor The parameters is same a the point 6 1 3 and the chart 6 1 4 Page 58 H2B lifting 3rd motor 6 2 4 2 electrical connection diagrams pump hydro Ji H2B CHOPPER 1 lt lt 9 zz 20 9 2 5 Soe e 5 x x 3z 85 KEKER e lt C S m gt 2222525252 oo azo Z a 260 987654321 2 1 3 2 1 87654321 e 1 00000000 0 RED 0 O O O O O O O E TO KASI TO THE CONSOLE hf THE RUNNING OF THE TRACTIONS CHOPPER CAN NEGATIVE 6 2 5 H2B power unit wiring lifting hydroguide weakening H2B lifting 3rd motor Page 59 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 Otherwise
66. vel of protection This implies High frequency Mos technology Real time control over the internal and external parts that can influence the behav iour of the machine with self diagnosis of the checking circuits themselves Stored programme machine SPC where the hardware is completely separate from the functions to be configured The programme is parametric and can also be modi 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 The communication protocol will continue to evolve thus offering increasing possibili ties of interaction For this reason the ZAPIMOS family offers a standard dialogue mode with external systems for easy interfacing with commercially available machines ZAPI offers a range of programming consoles with various features and prices Logic and power units are fitted in a sealed container IP54 to guarantee protection against splashes water acid etc and dust chips or small particles Access to the logic for replacement or checks however is very easy The H2B chopper is the top of the line model of the Zapimos family It is suitable for operating at voltages from 24 to 96 V with maximum currents of 400 or 600 amp Suitable for use with series motors with powers from 2000 W to 15 kW Page 4 H2B general description 2 GENERAL 2 CHAR
67. ward and backward Set the CREEP speed starting from level 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 begins to move To set the speed reductions activate the desired reduction request microswitch take the compensation level to 0 set the speed CUTBACK etc with machine in standby on a flat surface and the acclerator pedal pressed all the way down Then apply a load on the machine or put it on a slope and in these conditions set the compensation level until you reach the desired speed 10 RELEASE BRAKING is set by running the machine and then completely releasing the accelerator pedal without pressing other pedals 11 For INVERSION BRAKING first set the MODUL BRAKING level at 0 run the ma chine and invert the direction with the pedal pressed down then regulate the brak ing level 12 MODUL BRAKING with accelerator A parameter that increments the inversion braking according to the level of the accelerator signal set it by inverting the direc tion with the pedal pressed all the way down 13 Release braking with brake pressed PEDAL BRAKING Set by pressing the brake pedal lightly during a release Page 40 H2B standard traction 5 4 H2B TRACTION DIAGNOSIS Description of the alarms signalled by the diagnostic LED The alarm code is shown in parenthese

ZAPIMOS H2B USER'S MANU USER'S MANUAL

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