User Manual - Zapi Inc USA
Contents
1. 02 05 re Lad 68 02 i m NI m MAL ER IL O H mus WW 1 N dem 156 c 1 C ES E E Oy L J i d S a f M Y SW RARE U Ub EI Wes A 13 2 X 942 8 CONNEC TOR ATE WITH A MOLEX MN HI JR RECEPTACLE 5557 10 P FEMALE CRIMP TERMINAL 5556 B MOLEX MN FIT JR RECEPTACLE 5557 8 P FEMALE CRIMP TERMINAL 5556 MOLEX MN HT JR RECEPTACLE 5557 6 P FEMALE CRIMP TERMINAL 5556 AEHZPO0AA HVC User Manual Page 17 31 6 2 Functional drawing2. DISPLAY PARAM MAX B REVERSE ING COMPENS ACCEL emm ER AX SP SP 2 S P I SPEED II E S P II SPEED IH BYPASS FIELD WEAK RESTORE MOT V POT L TEMP V BATT ALARMS V MOT VMN MOT LSW TEST ACCELERATOR 7 MOTOR DATA L 1 3 ROLL ENTER S BUT T UNS NN ROLL OUT se Eo 514 Anm AEHZPO0AA HVC User Manual Page 19 31 7 3 Description of standard console menu H ADING MAIN MENU eiie EVP 0 100 CONFIG MENU MAX EVP 0 100 EVP OPEN DELAY 0 20 Sec EVP CLOSE DELAY 0 20 Sec SET MODEL CONNECTED TO SET OPTIONS TYPE Analog Digital ADJUSTMENTS NOT AVAILABLE TESTE DO ON OFF D 1 ON OFF UT O ON OFF PUT 1 ON O UT 2 ON OFF ANALOG INPUT 1 0 256 PARAMETER SET POINT 24100 PWM FREQUENCY HZ CONTROL WORD 0265535 RESTORE PARAMETER ALARMS N 2 h N C ROGRAM VACC SPECIAL ADJUSTMENTS SYNCRO FREQ 10 2000 Hz
3. gt et DUE e 1 BA 4 M g GND Eon cun F Zn 1 AIC C 7 MODE T PANIN BATT ANIN 4 e 56 O 66 OC ED S HVC peve Pear waa cor OOTP dn O O D i EV 909 cq E a DO D lt Vc IE m 9 4 NEV3 M a NEV4 24V POWER_SUPPLY 4 PEV IN t L J 3 9 4 ae i CAN H HVC CONNECTOR CNA ZAPI MINIFIT 10 POLES CNB ZAPI MINIFIT 8 POLES CNC ZAPI MINIFIT 6 POLES NOTE CNA amp AND CNA 8 CAN USED AS MODED 1INPUT OR AS GENERICS PURPOSE INPUTS Page 18 31 HVC 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 HVC connector D or it can be physically connected to another controller in the CANBUS net then virtually connected to HVC which is node 9 of the net 7 2 Description of console and connection CONSOLE CONNECTOR aaya ee a OF ZAPI PRODUCT s CONSOLE CONNECTOR Eu N
4. 24 9 Description of the console save function 25 7 10 Description of the console restore function 25 7 11 Description of the set model Function 26 7 12 Description of alarms menu nnne nnne nnn nnns 28 B CONIROLLER DIAGNOSTIC i u u 29 8 1 Analysis of alarms displayed on the console 29 9 RECOMMENDED SPARE PARTS FOR CONTROLLER 30 10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 31 AEHZPOAA HVC User Manual Page 3 31 APPROVAL SIGNS COMPANY FUNCTION INITIALS GRAPHIC AND LAYOUT PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N AEHZPOAA Edition September 2006 Page 4 31 AEHZPO0AA HVC 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 a
5. 7 4 Description of programmable functions options The options can be set on the SET OPTIONS Menu Function Option Meaning EVP TYPE DIGITAL set EVP to ON OFF valve type ANALOG set EVP to PROPORTIONAL valve type Page 20 31 HVC User Manual Flow chart showing how to make changes to Options Menu HVC ZAPI VD D 12V DA 00000 1 Opening Zapi Menu 2 Press ROLL UP amp SET UP buttons together to enter the SET MENU 3 The Display will show SET MODEL pudo SET MODEL 4 Press ROLL UP or ROLL DOWN buttons until SET OPTIONS Menu appears 5 SET OPTIONS appears on the display CORTO MENU SET OPTIONS 6 Press ENTER to go into the SET OPTIONS Menu EVP TYPE 7 The display will shows the first option 8 Press SET UP or SET DOWN buttons in order to modify the value for selected option EVP TYPE 9 New value for selected option appears ANALOG 10 Press OUT to exit the Menu s ARE YOU SURE YES ENTER ND DUT 11 Confirmation request appears 12 Press ENTER to accept the changes or press OUT if you do not accept the changes 13 SET OPTIONS Menu appears SET OPTIONS 14 Press OUT again Display now shows the Opening Zapi Menu AEHZPOAA HVC User Manual Page 21 31 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
6. V A ZA ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma 59 42028 POVIGLIO RE ITALY Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it User Manual Copyright 1975 2006 Zapi S p A All rights reserved The contents of this publication is a ZAPI S p A 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 N 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 2 31 AEHZPO0AA HVC User Manual Contents 1 INTRODUCTION TO
7. 8 pins 15 5 3 CNC connector Molex Mini fit jr 6 pins 15 GNO connector Modu2 15 55 CNE connector Strip 2 54 16 B rere errr ere 17 6 1 Mechanical drawing nnns nena nnne nnn nns 17 6 2 Tunc oral drawWlfiQ Deus fuac dca dw E 18 7 PROGRAMMING ADJUSTMENTS USING DIGITAL CONSOLE 19 7 1 Adjustments via console weiss lave tct crac RE dat t 19 7 2 Description of console and connection 19 7 3 Description of standard console MENU 20 7 4 Description of programmable functions options 20 7 5 Description of parameters that may be programmed parameter change 22 7 6 Adjustments range nn nennen r nnns sn nnne nns 22 7 f Proportional valve carrier frequency 24 LS STO uuu uu LL
8. 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 HVC User Manual This is apparently a 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 N Correct Layout Module 1 Note Module 1 power Module 2 power Module 3 power The chain starts from the BATT post of the controller that works with the highest current and 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 N Correct Layout iis Module 2 Center
9. 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 Hemember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER AEHZPOAA HVC User Manual Page 31 31
10. 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 AEHZPOAA HVC User Manual Page 9 31 EY Can advantages 3 2 2 Wirings A 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 I O connections After crimping the cable verify 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
11. 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 The following Parameters can be modified 1 MIN EVP This parameter adjusts the minimum current of the EVP if it is set as proportional see set options menu 2 MAX EVP This parameter adjusts the MAXIMUM current of the EVP if it is set as proportional see set options menu 3 EVP OPEN DELAY Proportional valve current ramping up time this parameter sets the proportional valve current ramp to change from 0 A to operating current 4 EVP CLOSE DELAY Proportional valve current ramping down time this parameter sets the proportional valve current ramp to change from operating current to O A 7 6 Adjustments range MIN EVP range 0 100 250 steps MAX EVP range 0 100 250 steps 7 EVP OPEN DELAY range 0 20 sec EVP CLOSE DELAY range 0 20 sec NOTE with the standard shunt resistances of the proportional valve circuit the coil current range corresponding to 0 100 is 0 1 A HVC User Manual Flow Chart showing how to make Pr
12. CAN termination connect to CAN L to insert 120 ohm termination resistance C6 CAN_H CAN high signal in 5 4 CND connector Modu2 D1 PCLRXD Serial communication interface D2 NCLRXD Serial communication interface AEHZPOAA HVC User Manual Page 15 31 D3 D4 D5 D6 D7 D8 PCLTXD NCLTXD GND 12 Serial communication interface Serial communication interface Negative supply 12 V supply 5 5 CNE connector Strip P 2 54 Page 16 31 The E connector which is accessible only by opening the HVC cover is used to program HVC by a dedicated MON 08 programmer HVC User Manual 6 DRAWINGS E Mechanical drawing WE il d d x L 2
13. N OFF VALVES output B5 for proportional valves comes from the valve positive voltage supply input C2 being controlled by an electronic high side switch In this way HVC is able to open not only the negative side of the valve coil but also the positive side The positive for valves input C2 can be independent from the HVC 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 HVC failures or malfunctioning Thus the more safe solution is PEV supplied to C2 controlled by another intelligent module A Positive of the valves taken from the PEV 1 2 and PEVP outputs 3 4 EMC 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 connections and the shields This situation is beyond 5 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 responsability 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 e
14. ZAPI CAN SYSTEN 5 CHARACTER TIO 6 2 1 Functional characteristics a 6 A a ana 6 s INMSDAEERTIOB FIDES 7 3 1 Material overvieW M 7 3 1 1 Connection cables a nnne snas a nas 7 OX MEE DUI RITE 7 3 2 Installation of the hardware 7 3 2 1 Wirings CAN connections and possible interferences 8 3 2 2 X Wirings I O connections 10 3 2 3 Insulation of truck frame 10 33 Protection and safety features a 10 3 3 1 Protection TU UT 10 332 TIT 10 2A usni y 11 4 OPERATIONAL FEATURES uuu 14 5 DESCRIPTION OF THE CONNECTORS J RE J J T J 15 5 1 CNA connector Molex Mini fit jr 10 pins 15 5 2 CNB connector Molex Mini fit jr
15. ach 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 ND DUT 12 Press ENTER for Yes or OUT for NO a i 19 Press OUT to return to the Opening Zapi Display Page 28 31 AEHZPO0AA HVC User Manual 8 CONTROLLER DIAGNOSTIC E Analysis of alarms displayed on the console 1 CANBUSKO There is a problem related to the CAN BUS line The error is signalled if the HVC 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 2 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 3 UNDERVOLTAGE This fault is signalled if an undervoltage condition is detected in the HVC power supply 4 FF VALVES Flip flop circuit that manages on off valve drivers short circuit protection does not reset in the correct way The diagnosis is executed during the initialization and when the on off valves aren t driven The problem is probably in the hardware circuit 5 COIL SHORTED ON OFF valves drives are protected against coil short circuit if a sh
16. 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 20mA ON OFF valves Their outputs are ON OFF driver full voltage applied to the valve coil Proportional valve It is driven in current mode with programmable frequency The proportional valve voltage supply is the same used for ON OFF valves the current range has to be defined via handset using the parameters of the PARAMETER CHANGE menu minimum current 200 mA maximum current 1 A Page 6 31 AEHZPO0AA HVC 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 N 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 items which are important to guarantee system performance and safety 3 1 Material overview Before to start it is necessary to have the required 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 f
17. ing 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 every 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 O OS GV Y DdPI Merton MON DUM NE 3 MONTHS Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every wy 3 MONTHS Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 MONTHS Checks should be carried out by qualified 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 requirements 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
18. lectromagnetic 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 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 HF 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 study of the immunity can be divided in two main branches protection AEHZPOAA HVC User Manual Page 11 31 Page 12 91 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 The sec
19. nd connecting the modules with only 4 wires CAN and supply HVC is one this modules designed to drive the hydraulic electrovalves and connect some inputs which normally are in the actuators proximity but with complete independent functions AEHZPOAA HVC User Manual Page 5 31 2 GENERAL CHARACTERISTIC 2 1 Functional characteristics N unu Dn uz 22 uum 12 24 V Output for ON OFF valves ON OFF n 4 Output for proportional valves n a aa 1 IGG MOUS ii Lu au xu uu SM 5 Analog inputs n a arar 1 u natus ass 1 CANIN us uu s unn 1 Ol 601 s u ui IP54 2 2 Input Digital inputs 3 inputs A7 they accept PNP type sensor or switches connected to BATT The inputs range is BATT BATT the commutation threshold is about 10 V 2 inputs A4 A8 work in 0 12 V range The connection type depends by the position of a inside logic jumper J2 J2 1 2 the internal resistance works as pull up at 12 V so the external switch must be closed to BATT J2 2 3 the internal resistance works as pull down at BATT so the external switch must be closed to 12 V or 24 V Analog inputs HVC provides 1 analog input The analog device can
20. ning Zapi Menu 2 Press ENTER to go into the GENERAL MENU MES MN NENNEN 3 The Display will show PARAMETER CHANGE 7 PARAMETER GHANGE 4 Press ROLL UP or ROLL DOWN button until TESTER menu appears on the display 5 The Display shows TESTER ic Coe anal TESTER 6 Press ENTER to go into the TESTER function ta 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 E TESTER 12 Press OUT again and return to Opening Zapi Menu Ll L MES MN 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 console save function The SAVE PARAM function is allowed in the HVC 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 HVC controller but ZAPI recommend don t use this because should make several problems to the AEHZPOAA HVC User Manual Page 25 31 controller As a result of using this function all parameters will be overwritten
21. nt 7 IP ZAPI VD D 48V OA 00000 Page 26 31 AEHZPO0AA HVC User Manual The table below indicates which parameter can be set to connect ZAPI product to Console PARAMETER CONNECTED PRODUCT 1 SICOS EPS 6 EPS 9 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 AEHZPOAA HVC User Manual Page 27 31 7 12 Description of alarms menu The microprocessor in the controller records the last five Alarms that have occurred Items remembered relative to each Alarm 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 HVC ZAPI VO O 12v 0A 00000 1 Opening Zapi Display 0 E O g 2 Press ENTER to go into the General menu MAIN PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display MAIN MENILJ 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 um 8 E
22. ogram changes using Digital Console fitted with Eprom CK ULTRA HVC ZAPI VD D 12V DA 00000 1 Opening Zapi Menu 2 Press ENTER to go into the GENERAL MENU 3 The Display will show PARAMETER CHANGE ois 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 Display 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 YES ENTER NO OUT 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 AEHZPOAA HVC User Manual Page 23 31 7 7 Proportional valve carrier frequency In the Special Adjustment menu which is a submenu of the Alarm menu it is possible to adjust 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 name of the parameter is SYNC FREQ the resolution is 10 Hz i
23. ond 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 in the 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 electronic 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
24. or 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 N 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 N 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 AEHZPOAA HVC User Manual Page 7 31 3 2 1 Wirings CAN connections and possible interferences EY A Page 8 31 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 modules of a vehicle connected as illustrated in this image CAM 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
25. ort is present across the coil the flip flop circuit is set and the alarm is signalled 6 EV DRIV SHORTED One of the on off valves drivers is shorted and so it drives its coils in a wrong way getting a possible no safety condition check the external connection if itis ok the driver is probably damaged 7 EVP DRIV SHORTED The proportional valve driver is shorted and so it drives its coils in a wrong way getting a possible no safety condition check the external connection if itis ok the driver is probably damaged 8 EV DRIVER KO One of the On Off valves drivers is open does not close when it is commanded by the microcontroller and so it can t drive its coil 9 EVP DRIVER KO The proportional valve driver is open does not close when it is commanded by the microcontroller and so it can t drive its coil 10 POSITIVE NOT OK The positive of the valves is absent AEHZPOAA HVC User Manual Page 29 31 9 RECOMMENDED SPARE PARTS FOR CONTROLLER e C12359 Minifit Connector 6 pins Female C12414 Minifit Connector 8 pins Female C12500 Minifit Connector 10 pins Female C12777 Female Minifit pin harness side Page 30 31 AEHZPO0AA HVC User Manual 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 every 3 MONTHS Check the Foot pedal or Tiller microswitch Us
26. 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 ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and bypass capacitors ELECTROSTATIC IMMUNITY Three ways can be followed to prevent 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 transferring ESD sensitive HVC User Manual 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 AEHZPOAA HVC User Manual Page 13 31 4 OPERATIONAL FEATURES HVC has been designed to work on a CANBUS system So it follows the commands received b
27. t can be adjusted in steps of 10 Hz 7 8 Tester menu Following parameters can be measured in real time in the TESTER menu 1 2 3 4 5 6 7 8 9 ID 0 Level of MODE 0 digital input with J2 1 2 ON GND input active switch closed OFF 12V input not active switch open ID 1 Level of MODE 1 digital input with J2 1 2 ON GND input active switch closed OFF 12V input not active switch open INPUT 0 Level of DIGITAL INPUT 0 ON VB input active switch closed OFF COND input not active switch open INPUT 1 Level of DIGITAL INPUT 1 ON VB input active switch closed OFF COND input not active switch open INPUT 2 Level of DIGITAL INPUT 2 ON VB input active switch closed OFF COND input not active switch open ANALOG INPUT 1 Voltage of the analog input EVP REQ Proportional valve current setpoint received via canbus this value gives the EVP driver SETPOINT minimum and maximum values of which are defined by EVP MIN and EVP MAX parameters SET POINT Proportional valve current setpoint PWM FREQUENCY Carrier frequency of the EVP driver signal it is programmed by the net s master via canbus 10 CONTROL WORD Page 24 31 Command message received by the net s master via canbus HVC User Manual Flow Chart showing how to use the TESTER function of the Digital Console HVG ZAPI VO O 12v OA 00000 1 Ope
28. the end of a signal wire For information about the mating connector pin assignment see the paragraph description of the connectors 3 2 3 Insulation of truck frame N 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 3 3 Protection and safety features 3 3 1 Protection features 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 IP54 3 3 2 Safety Features controllers are designed according to the prEN954 1 specifications for safety related parts of control system and to UNI EN1175 1 norm N The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed Page 10 31 HVC User Manual 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 B6 B7 for O
29. with Incorrectly values and HVC controller will not work correctly In order to perform RESTORE FUNCTION use ZAPI PC Win console 7 11 Description of the set model Function 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 HVC ZAPI VD D 12v 0A 00000 1 Opening Zapi Menu 2 Press ROLL UP amp SET UP buttons together to enter SET MENU 3 The Display will show SET MODEL another menu is displayed press ROLL UP or ROLL DOWN until SET MODEL appears CONFIG MENU SET MODEL 4 Press ENTER to go into the SET MODEL Menu 5 The display will shows the first option only CONNECTED TO CONNECTED TO option is present in this menu 9 6 Press SET UP or SET DOWN buttons in order to select the desired value for selected option CONNECTED TO 7 New desired value appears 8 Press OUT to exit the Menu s ARE YOU SURE YES ENTER ND DUT 9 Confirmation request appears 10 Press ENTER to accept the changes or press OUT if you do not accept the changes CONFIG MENU SET MODEL 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 poi
30. y CAN communication and broadcast the input status on the CAN All the outputs that drive the valves can work at the same time The EVP valve is typically used to drive a lowering proportional valve Page 14 31 AEHZPO0AA HVC User Manual 5 DESCRIPTION OF CONNECTORS 5 1 CNA connector Molex Mini fit jr 10 pins A1 CMM Positive supply of digital input devices BATT A2 DI0 Digital Input N range BATT BATT A3 BATT HVC negative supply A4 MODE 0 CAN node selection digital input range 0 12 V A5 GND Negative supply of the analog device A6 DI1 Digital Input N 1 range BATT BATT A7 DI2 Digital Input N 2 range BATT BATT A8 MODE 1 CAN node selection digital input range 0 12 V A9 PPOS Positive supply of analog devices 12 V or 5 V A10 ANIN Analog input range 0 5 V or 0 12 V 5 2 CNB connector Molex Mini fit jr 8 pins B1 NEVP Negative of the proportional electrovalve B2 NEV1 Negative of the on off electrovalve N 1 B3 NEV2 Negative of the on off electrovalve N 2 B4 NEV3 Negative of the on off electrovalve N 3 B5 PEVP Positive of the proportional electrovalve B6 PEV1 Positive of the on off electrovalve N 1 2 B7 PEV2 Positive of the on off electrovalve N 3 4 B8 NEV4 Negative of the on off electrovalve N 4 5 3 CNC connector Molex Mini fit jr 6 pins C1 CH HVC positive supply C2 PEV Electrovalves positive supply C3 CAN L CAN low signal in C4 BATT HVC negative supply C5 CAN_T
Download Pdf Manuals
Related Search