ZAPIMOS USER's MANU USER's MANUAL
Contents
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3. 32 Spare parts Cc ee 33 Periodic Mainteinance 2 4 2 34 A Theinformations included into the marked paragraphs by this symbol are essential for the safety Pubblication n 550114B Ediition July 1994 Page 1 Page 2 LEGEND 1 Quadrant 2 Quadrants Forward Forward contactor coil General contactor coil Backward contactor coil Pump contactor coil Key Horn Electrobrake coil Electrovalve coil Reverse Weakening Belly switch Forward microswitch Horn switch Down microswitch Electric brake switch Reverse microswitch Lifting switch Tiller switch Up microswitch Contactor minus Potentiometer Speed reduction 1 Forward physical contact General physical contact Backward physical contact Motor minus voltage 1 INTRODUCTION TO THE ZAPIMOS FAMILY The Zapimos chopper family is the solution offered by ZAPI to meet the users require ments in the 90 s To ensure that the product remain on the market for a sufficiently long period of time without running the risk of becoming technically obsolete ZAPI has designed the Zapi mos family which features the following specifications Advanced technology Top safety Very high flexibility Possibility of updating based on future technological innovations Very high level of protection This includes High frequency Mos technology Real time control of in
4. 2 444418088 14 22 8971 Mr 15 4 SONOS sss assassin 16 4 1 Description of variable parameters 17 4 2 Parameter change via economic console 18 4 3 Description of digital console functions 19 4 4 Sequence of settings 20 5 H1DN diagnosis r 21 5 1 Decoding of the alarms on 22 6 Schematic 1 12 25 6 1 Description of H1DN cables 2Q layout 25 Connection diagram of H1DN 20 26 Connection diagram of H1DN 20 27 6 2 HIDN AUTOSTOP aier PAR UE DEA 28 6 3 Description of HTDN 4 and 3 cables 1Q 28 Connection diagram of H1DN 4 cables with changeover contactors TOL CINIBE Ct 29 Connection diagram of H1DN 4 cables with changeover contactors gorge 30 Connection diagram of H1DN cables 1Q tiller 31 Connection diagram of H1DN cables 1Q pedal
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6. zu ACCELERATION DELAY Sec BRAKING IMax UT BACK 1 2 VBatt B a o N 2 e o N o 8 N P o gt qi a N _ a a N 16 N C COMPENSATION K I CREEP SPEED VBatt 2 5 F console be constantly connected to the parameters be changed in real time during operation The parameters set and optimized can be recorded via the console SAVE and then re loaded RESTORE into another chopper thereby making it possible to obtain rapid and standard settings See console manual for further details The logic unit inside the chopper features a trimmer for adjusting the max value of the potentiometer if it is connected to 2 wires To perform setting remove the upper cover connect a tester for voltage measurement between the CPOT and NPOT connectors bring the potentiometer control unit to max stroke and rotate the logic unit trimmer until a voltage of 4 8 4 9Volt is read With the programming console this operation is made easier in that the value is read directly on the display A N EN e 43 2
7. d gt A M S m A gt N 16 4 1 DESCRIPTION OF VARIABLE PARAMETERS Acceleration Braking Speed 1 reduction Speed 2 reduction Acceleration delay Braking Cut back speed 1 Cut back speed 2 Compensation Compensation Creep speed Lowest speed First ramp IMax Max speed forward Highest speed forward Max speed reverse Highest speed reverse Release braking Braking current when direction selector is released TRIMMER FOR ADJUST MAXIMUM POTENTIOMETER WHEN USED IN 2 WIRES CONNECTION e ZAPI ZP361C Page 17 4 2 PARAMETER CHANGE VIA ECONOMIC CONSOLE The parameters which can be changed are as follows au 1 CREEP SPEED spam MW 2 ACCELERATION DELAY 3 BRAKING 4 CUT BACK SPEED 1 Loa 5 CUT BACK SPEED 2 0 CONNECTED Adjustments possible within the range specified Page 19 at 10 intermediate adjustment levels Connect the economic console to the chopper B connector this operation should be performed when the machine is off Riconnect the battery switch on the machine by turning the key Position the rotating selector to the function requiring change By pressing the SET UP button the parameter value can be increased w
8. ett le fe f 5 2 2 1712278878 7268 72 887289786 STET ET m rm Py s lt FANSS 5931 HIG 22424245 5g 255 2 A 5555 zz et 9 4 3 wnt p yy a VOSE D 79 gt V le 4211445 Gduvog HSVG 6 8 9 S s fal 0 32 RECCOMENDED SPARE PARTS Code Description 07008 Potentiameter 5 25 C22000 Microswitch 10A 250V 1 way C16504 Protected power fuse 300A C16530 Protected power fuse 250A C16503 Protected power fuse 200A C16502 Protected power fuse 160A C16520 Glass 5x20 fuse 6 3A C16530 Protected power fuse 250A C12373 9 way molex female connector C12371 3 way molex female connector C12370 2 molex female connector C12769 Female connector molex C12204 9 female lock connector C12203 6 female lock connector C12205 4 way female lock connector C12768 Male connector for female lock C12230 9 male lock connector C12229 male lock connector C12228 4 male lock connector C12767 Female connector for male lock C29520 Albright contactor 24V SW 88 1 C29548 Albright simple contactor 24V SW 80 B 1 Page 33 PERIODIC MAINTEINANCE TO BE REGULARLY REPEATED Check outwear of electric contacts t
9. COSTRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI 42028 POV GL O R E Via Parma 59 ITAL A Tel 0522 960050 r a Thx 530021 ANDRE Fax 0522 960259 ZAPIMOS HIDN USER s MANUAL Page ISON 2 1 Introduction to the ZAPIMOS 3 2 Characteristics 4 2 1 Specifications 4 2 2 m c 5 2 2a Microswitches M 5 2 20 Potentiometer 5 D 7 2 4 Safety devices adeps SOEUR ra peace n 7 e S Performa E a ee 8 2 6 Thermic considerations xcti un ostii Dre n nt 9 2 7 General advices AN 9 2 8 Susceptibility and electromagnetic 9 GS I cino 10 3 1 Choice connecting 2 2 44044 4 4 0 10 SPACO Di SR 10 Rare hao 10 3 4 Mechanical draWIQxu ree 11 3 5 Connector description 12 3 6 Power connector description 14 3 7 Description of the
10. For BRAKING run the machine and invert the direction with the pedal pressed down then regulate the braking level Page 20 5 H1DN DIAGNOSIS Description of 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 on page 18 19 1 BLINK Logic anomaly EEPROM DATA KO EEPROM PAR KO EEPROM CONF KO EEPROM OFF LINE CHOPPER NO CONF WATCH DOG 2 BLINKS Running request on startup or error handle speeds sequence IN CORRECT START 3 BLINKS Error on VMN test NO FULL COND VMN BACK LOW VMN FORW LOW 4 BLINKS Accelerator high in standby this error inhibits operation VACC NOT Ok 5 BLINKS Error in reading current this error inhibits operation 1 HIGH AT STAND 0 EVER 6 BLINKS Malfunctioning of the contactor driver circuit CONTACTOR DRIVER 7 BLINKS Excessive temperature greater than 75 TH PROTECTION 8 BLINKS Contactors do not close CONT DONT CLOSE CONTINUOUS BLINKING 32 BLINKS Low battery charge battery with 1096 of residual charge BATTERY LED REMAINS ON Double running request FORW BACK Page 21 5 1 DECODING ALARMS DISPLAYED ON THE CONSOLE 1 2 3 4 9 6 CHOPPER NO CONFIG This alarm appears if there has not yet been logic unit configuration In this case apply the model and input configuration procedure as described in
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12. enter the specific menu see console description The available standard configurations are as follows Power unit configurations programmable from the console 3 cables with main contactor i max 150A 4 cables with remote control inverter max 300A Auxiliary inputs with configuration made from the console SEAT MICROSWITCH DELAY HANDLE HANDLE MICROSWITCH SPARE BE 5 4 2 E1 DEFINED Depending on the customer s request the chopper is supplyed comes with its configuration and name plate indicating the model and max current Page 14 3 8 DIODES In 1 Quadrant versions for 4 or 3 cable motors external diodes should be fitted to allow for adjustable braking Upon customer s request ZAPI will supply the system with a module containing easily connecting diodes both for the 4 cable and 3 cable versions 92 4 CABLES 1 QUADRANT 3 CABLES 1 QUADRANT VMNA VMNI Page 15 4 SETTINGS Similarly to chopper configuration parameter settings can be directly made at ZAPI according to the customer s specifications or by the customer via the programming con sole or the economic console which allows changes only to the parameters indicated with an asterisk The chopper parameters shown below can be changed between ten intermediate levels within the specified range PROGRAMMED LEVEL v gt gt m o m 2 2 2 w m o
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14. C1 connector and the 13V5 internal power supply This enables to adjust the signal to different potentiometer values In the 2 wire configuration the end of stroke value should range from 300 ohm to 10 Kohm In the 3 wire configuration the end of stroke value should range from 500 ohm to 10 Kohm Lower values overload the power supply unit higher values make it possible linearity errors 2 WIRE PEDAL 2 WIRE TILLER 3 WIRE PEDAL 3 WIRE TILLER lt PPOT lt CPOT O O ce Pa O ce O ce apup O ca lt NPOT gt 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 the programming console manual Page 5 Vmot Vacc Vmot Vmot Vocc Vmot 4 100 4 5V 100 5V 100 100 4V 20 0 0 0 100 0 MA 100 100 0 100 MECHA ANDLE ANGLE MECHANICAL HANDLE ANGLE ig 8a ig The two graphs show
15. Do not short this terminal to battery negative and do not apply a resistance load of less than 500ohm To be connected to key switch return Signal for handle safety device activation The safety device is activated with opened microswitch or if the applied voltage is less than 12Volt If not used it can be wired to Key positive or disconnected from the programmable console E1 E2 E3 E4 E5 E6 E7 E8 E9 TILLER SEAT Input whose function should be defined from the console or re Free NT2 RV2 spare free RV1 spare free AV 1 quested at the time of order Its configuration can be a handle or seat microswitch 5 sec delayed signal input otherwise it can remain unused The function is activated if the level is brought to a value greater than 12Volt Not used Energises the field weakening or bypass contactor It provides connection to B ve when active Max 3A Input for speed reduction operation RV2 If connected to a potential of more than 12Volts reduction is inhibited Ifleft free or connected to B ve it performs the reduction function operates Activation of this input can be programmed from the console Input for speed reduction operation RV1 If connected to a potential of more than 12Volt reduction is inhibited while if left free or connected to Battery negative the reduction function operates Activation of this input can be programmed from the console
16. Selects reverse It should be connected to the reverse microswitch and activates the contactor when greater than 12Volts Selects forward It should be connected to the forward microswitch and activates the contactor when greater than 12Volts It operates the main contactor or the running contactors When active it provides connection to B ve Not used Page 13 3 6 POWER CONNECTOR DESCRIPTION B VE 1 VE 1 VMNA connected to the ve It is power circuit positive which thus does supply the control logic 1 To be connected to the motor rotor It provides a direct positive from the battery down stream of the current measuring circuit Do not connect this terminal to loads other than the traction motor B ve It is connected to the B ve This feed is also common to the control logic circuit 2 It is the forward direction driver VMNA It supplies a B ve via a mosfet circuit when the forward direction is active For connections see diagrams 3 It reverse direction driver VMNI It supplies a B ve via a mosfet circuit when the reverse direction is active 3 7 DESCRIPTION OF CONNECTIONS The choices concerning the power unit and some auxiliary signals should be programmed into the chopper In the absence of this information the chopper sends an alarm ALARM 1 and will not operate To provide this information simply connect the chopper to the console and
17. avoid particle dispersion in case of blowout Page 10 3 4 CHOPPER H1DN MECHANICAL DRAWING Le Page 11 3 5 CONNECTOR DESCRIPTION E9ESE7E6ESEAEG3E 2 De Dl C3Ce B8 B7 B6 B5 B4 B3 Be Bl Al Pos A1 A2 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 D1 D2 Function LED LED PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FUN SEL UP DOWN CPOT NPOT PPOT Key IR spare free Page 12 N 52 z O c eg n M Z x B zo Su UO ZC 2 1 Description Alarm Led minus to be connected to the cathode Alarm Led plus to be connected to the anode Output current 12mA for standard Led Serial reception plus Serial reception minus Serial transmission plus Serial transmission minus Console supply minus Console supply plus Economic console channel Economic console channel Potentiometer central to be connected to the potentiometer slider For speed adjustment the useful signal ranges from Volt lowest speed to 5Volt highest speed Potentiometer minus This is a battery negative Potentiometer plus This is a 12Volt output It is not used if the potentiometer is wired with 2 cables
18. the relevant paragraph of the console manual The alarm is blocking VMN FORW LOW The test is performed at rest An alarm is sent if VMN forward voltage terminal 2 is found to be less than 1 3 of battery voltage Possible causes a In 2 Quadrant configurations check that stator cabling is correct and that there are no interruptions b Check that motor has no frame fault c In 1 Quadrant configurations with bypass check that bypass contacts are not welded close d Chopper out of order replace VMN BACK LOW See Item 2 NO FULL COND The test is performed under full conduction If in this condition it turns out that VMN is more than 1 3 of battery voltage something is wrong in the diagnostics circuit thus impairing safety For this reason the machine stops operating It this fault persists replace the logic unit CONT DONT CLOSE This test is performed with an operating request It should be checked that the contactor closes and that VMN is greater that 2 3 of the battery voltage If not an alarm is sent Possible causes a Main or running contactor disconnected or faulty isolated contacts b Isolated or interrupted motor c Chopper power unit failure replace I EVER This test is performed during operation It should be checked that current during operation is greater than a minimum given value If this is not the case an alarm is displayed and the machine stops Possible causes a Incorrect motor
19. S lu js 1 I HO S I L Kd Ve 9 XVI N d iH C 2 NGLH 9 g OON i e g 47214445 HSVG gt T 20 27 6 2HIDN AUTOSTOP Standard HIDN performs release braking function This mean that when throttles or the pedal is released the HIDN chopper performs a braking with a reverse flowing current The intensity of this brakaking is adjustable by the RELEASE BRAKING parameter in the consolle By setting the RELEASE BRAKING parameter at zero the Atostpo function is not performed therefore the chopper behavies as a standard controller with no auto stop function 6 3 DESCRIPTION OF H1DN 4 AND 3 CABLES 1Q LAYOUT Configuration with consolle Select the model 4C T PIN SELECTION DRWG 072399B DRWG 072400B DRWG 072445B DRWG 072446B RV1 RV1 RV1 RV1 RV2 RV2 RV2 RV2 INVERS FREE INVERS FREE HANDLE SEAT HANDLE SEAT Characteristics Max current 300A Running direction is changed only via the contactors Braking diodes should be fitted as per diagram in order to obtain chopper controlled braking Speed cut backs are active when microswitch contacts are open When throttle or pedal is released the HIDN chopper performs a braking with a reverse flowing current The intensity of this brakaking is adjustable by the RELEASE BRAKING parameter in consolle The AUTO
20. STOP braking can be performed if the motor reaches a certain minimum speed In the 3 cable version the power interconnections should be modified as shown in drawings s 072399B amp 072400B Page 28 O3SIA A WLI DI IDIAUd 82027 662 0 195 OF 31492 IH 40 WVSOVIG vas Jay 7 u oud oubasiq auos 210 oqo SLONGOYd 1492 JU 3Hl OL 19 SI JSN Q3 071V AINO 3HI NOILVZISDHIOV N3LIISA Y X04 1432X3 SI lt 11 1 34 095 1492 V SI 5 TIGNVH TIYIS ES hd 7 H3 IW CN SWO TIW i T TANVA YOLIVLNOJ Faia VOGL XVW g 5 GINA Xo d 1 AS 5 2 3 270 lt 02 FHL 01 i J di qI 1 24 O O O O i n l 5 35 2228 78 728 E225 8 7 8 6 1 V a 2 fr 20 m
21. chine the first time with the wheels raised to ensure that connection errors do not create safety risks With the key off the filtre 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 negative on the chopper for a few seconds with a resistance of between 10 ohm and 100 ohm 2 8 SUSCEPTIBILITY AND ELECTROMAGNETIC EMISSION The electromagnetic susceptibility and emission are remarkably influenced by the modality of installation a special attention must been put on the lenght and the paths of the electric connections and the shields Therefore ZAPI declines any responsability regarding the bad working imputable to above mentioned cases especially if the truck s builder doesn t execute the required test from the norm in force The emission conducted the irradiated emission IEC 801 2 ESD IEC 801 3 irradiated susceptibility IEC 801 4 BURST IEC 801 5 SURGE IEC 6 the immunity conducted Page 9 3 INSTALLATION Fit the chopper with its base plate on a flat unpainted clean metal surface Apply a thin layer of thermoconductive grease between the two surfaces to ensure optimum heat dissipation Even if protection is available against external agents the continuous attack by corrosive agents may cause oxidation of the connector contacts thereby impairing their operation This factor should be kept well in mi
22. connection For example the rotor may have been connected to the chopper B terminal instead of terminal 1 b The current sensor has failed replace power unit Page 22 7 HIGH AT STAND This test should be performed at rest It should be checked that current is equal to zero If this is not the case an alarm is displayed and the machine stops Possible causes a Terminal 1 has been connected to a load other than the driving motor e g to the pump motor or auxiliary loads b The current sensor or the logic unit may have failed Replace the logic unit first If faulty operation persists change the power unit 8 WATCH DOG This test is performed both at rest and during operation It is self diagnosing within the logic unit Replace the logic unit in case an alarm is displayed 9 FORW BACK This test is always performed An alarm is displayed if two running requests are simultaneously available Possible causes a Faulty cabling b Failed running microswitch C If faulty operation persists replace the logic unit 10 INCORRECT START Incorrect starting sequence The machine starts only if the key handle or seat run sequence is followed Possible causes a Failed running or handle microswitch b Incorrect operator s sequence C Incorrect cabling 11 VACC NOT OK This test is performed at rest The alarm shows that the accelerator voltage is greater than 1 Volt Possible causes a One potent
23. ercentage of battery voltage on the motor Page 6 2 3 SPEED Speed may be adjusted Max speed adjustment from 10 to 100 via the programming console only Speed reduction device with microswitch go ahead RV1 from 10 to 100 Speed reduction device with microswitch go ahead RV2 from 10 to 100 When one of the three reduction devices is in automatic function the chopper adjusts the voltage to keep speed constant The feed back parameter can be changed from the console to obtain the desired characteristic 2 4 SAFETY DEVICES Battery Inversion Abready present in the 3 cable version with general contactor In other versions there should be a main contactor which isolates Batt optional Connection errors All inputs are protected against connection errors except for inputs NT1 and NT2 which do not accept direct connections with Batt or loads greater than 3A Thermal protection If temperature exceeds 75 C the max current is reduced proportionally to the tempe rature rise Temperature is never allowed to exceed 85 C Discharged battery If the battery is down discharged max current is reduced by 50 External agents The chopper is protected against dust and fluid splashes IP54 as it is semi enclosed Page 7 Safety against accidental starting A precise sequence of operations is required to start the machine If such operations are not correctly performed the machine will not sta
24. fault data 15 EEPROM CONF KO Failure in the memory area which contains the data for chopper configuration The alarm is blocking Move to the configuration phase and perform chopper re configuration Subsequently switch off and on again If the failure persists replace the logic unit 16 EEPROM KO Failure in the memory chip Replace the logic unit The alarm is blocking 18 TH PROTECTION It indicates that chopper temperature has exceeded 75 C Max current is progressively reduced until a zero value is reached at the tempera ture of 85 C If the alarm is displayed while the machine is in cold state a Check thermal sensor connection b Faulty thermal sensor c Interrupted power unit connection d Faulty logic unit 19 BATTERY Battery is dis charged When the alarm is displayed the machine stops At this stage start again with renewed running request Max current is reduced by 50 Page 24 6 SCHEMATIC DIAGRAMS 6 1 DESCRIPTION OF H1DN 3 CABLES 2Q LAYOUT Configuration with console Select the model 3C PIN SELECTION DIS 072395B DIS 072398B omw 0 0mm m HANDLE SEAT FREE FREE Characteristics Max current 150A Static change of the running direction The main contactor closes the first time that there is a 4 operating request and opens when the handle is at rest Speed cut backs are active when microswitches are open Page 25
25. hey should be replaced when matchboard is too strong and wornout Electric contacts should be checked every 3 months Check pedal microswitch verify with a tester that there is no electric resistance between the contacts by measuring the voltage drop between its terminals Also the release should have a firm sound The pedal 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 mecanical 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 INCLUDED IN THIS MANUAL AND ANY VARIATION SHOULD BE DONE ACCORDINGLY WITH THE SUPPLIER THE SUPPLIER IS NOT RESPONSIBLE FOR ANY PROBLEM THAT ROSE FROM USING WIRING SOLUTIONS DIFFERENT FROM THE ONES SUGGESTED ON THIS MANUAL DO NOT USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER Page 34
26. hile pressing the SET DOWN button the same value can be decreased Warning Changes are made by counting the number of pulses sent by the push buttons Therefore to increase or decrease one parameter by several points you should release and press the button again as required Keeping a push button continuously pressed does not allow you to obtain continuous parameter variation Parameter variation occurs in real time making it possible to immediately check the set values Page 18 4 3 DESCRIPTION OF DIGITAL CONSOLE FUNCTIONS Power configuration H1DN 3 cables 20 H1DN 4 cables T 1Q Input configuration RV1 RV2 IR SP Parameter programming Acceleration Braking Cut back speed 1 Cut back speed 2 Compensation Creep speed Max current Max speed forward Max speed reverse Release braking Tester VMNA VMNI T1 and T2 driver IN AV RV1 RV2 SP IR inputs Accelerator voltage Current Temperature Battery voltage Motor voltage Display of stored alarms Internal hour meter Accelerator stroke programming forward and reverse SAVE function data storage Restore function parameter loading onto a chopper Motor Data See console manual for details Page 19 4 4 SEQUENCE OF SETTINGS H1DN 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 manufacturer s name programme release configuration and hour metre
27. iometer wire has become disconnected b The potentiometer is not calibrated c The potentiometer is faulty interrupted 12 CONTACTOR DRIVER This test is performed both at rest and during operation It should be checked that the voltage on the drivers which control contactors is in line with the running state High at rest low during running With the console tester function check which driver whether T1 or T2 is in the correct running O or resting 1 state Possible causes a External short circuit towards Batt of the cabling coming from NT1 or NT2 b Driver failure due to overloading or short circuit to Batt of the cabling from NT1 or NT2 Replace the logic unit after performin troubleshooting Page 23 13 EEPROM DATA KO Failure in the memory area which contains the hour meter and motor data as well as the stored alarms The alarm is blocking When switching the key on and off if the alarm is still displayed replace the logic unit If the alarm disappears please remember that the hour meter starts again from zero the alarm area is cancelled and the motor data contains default data 14 EEPROM PAR KO Failure in the memory area which contains the setting parameter data The alarm is blocking When switching the key on and off if the alarm is still displayed replace the logic unit If the alarm disappears please remember that the hour meter starts again from zero the alarm area is cancelled and the motor data contains de
28. nd when selecting the location of the chopper within the vehicle To fix the chopper use the suitable holes available in the base plate Check that cable terminal and connector cabling has been accurately performed It is recommended to fit suppression elements to the horn solenoid vales and all contactors not connected to the chopper 3 1 CHOICE OF CONNECTING CABLES For auxiliary circuits use cables with 0 5 mm cross section area For power connections to the motor and battery in the 2 Quadrant versions use cables with 16 25 mm cross section while in the 1 Quadrant versions use cables with 25 35 mm cross section area To increase the chopper performance the cables connecting to the battery should be as short as possible and laid next to each other 3 2 CONTACTORS Contactors should be selected based upon on the motor max operating current and on the configuration The current absorbed by the coil should not exceed 3A Coil suppression is internal to the logic Do not use contactors with suppression elements connected Inthe case of contactors using magnetic suppression on the contacts check polarity as shown on the cap 3 3 FUSES To protect auxiliary circuits use a fuse with max 6 3A To protect the power unit see diagrams The indicated value is the max permissible value For special applications or requirements this value can be reduced For safety reasons it is recommended to use protected fuses in order to
29. ner and outer components which may affect machine behaviour with self diagnosis of the control circuits Recorded program machine SPC where the physical component hardware is kept completely separated from the functions to be implemented The program is parametric with possibility of intervention on the part of the end user Any in house technological updating is made clear to the user The communication protocol will evolve over the next few years to offer increasing possibilities of interaction For this purpose the Zapimos family features a dialog mode with standard external system to be easily interfaced with commercially available machines also offers a wide range of Programming Consoles with different types of per formance and different prices Logic and power units are fitted in a semi enclosed case IP54 to ensure protection against splashes water acid etc dust chips and smallware Access to the logic unit remains very easy allowing for quick replacement or inspection H1DN is the smallest chopper of this family It is suitable for operation on voltage 24V with motors in the range 500W to 2KW An interesting option is a completely static version with 3 cable motors Page 3 2 CHARACTERISTICS 2 1 SPECIFICATIONS Chopper H1DN is suitable for controlling 3 and 4 terminal series wound motors Frequency 18 KHz Voltage 24V 16 30 Max Current 2 Quadrants 150A for 4 min 1 Quadrant 300A f
30. or 2 min Temperature 30 40 C DIODI DROP VOLTAGE CONFIGURATION CURRENT CONTACTORS FRENO 1 3 IMAX 3 CABLES 2Q 150A GENERAL E 200mV 3 CABLES 1Q 4 CABLES 1Q 3 CABLES 2Q 3 CABLES 1Q 4 CABLES 1Q 4 2 2 CONTROL UNITS 2 2a Microswitches Microswitches send a voltage signal when a direction request or a desired function is activated The tiller microswitch or the dead man microswitch conduct the current to exite the contactors and the electrobrake They should be able to handle currents up to 5 amps For safety reasons it is mendatory to use this microswitch according to the reported diagrams To stop the chopper there are 4 possible levels 1 Chopper opens up the contactors automatically through its safety features in a time shorter than 100 msecs 2 Open of tiller microswitch or dead man microswitch 3 Key 4 Battery connector 3 and 4 are always of easy access so that the use of the tiller microswitch gives an effective alternative way to stop the chopper When the key is turned on this microswitch should be open so that the microprocessor is able to verify its status every time that power is supplied to the chopper 2 2b Potentiometer It can be connected in both 2 or 3 wire configurations The signal on CPOT C1 ranges from 0 to 5 volts In order to have a correct functioning of the 2 wire configuration a 20 Kohm trimmer is present on the logic board This trimmer is placed between the CPOT
31. rt They are as follows 1 Key Handle microswitch Running microswitch 2 Key Seat microswitch 5sec delayed Running microswitch Safety against uncontrolled movements Contactors will not close if The power unit is not operating The accelerator is not allowed to reach below 1 Volt The logic unit is not operating correctly Oneofthe running microswitches is closed Request for rapid inversion is available independently of the running microswitches 2 5 PERFORMANCE Very good sensitivity at low speed Anti Roll Back Rapid inversion Braking with current control Electric brake coupling Field weakening or bypass control with adjustable output current Diagnosis with failure indication by means of an optional LED Parameter adjustment via the console see specific paragraph Internal hour meter suitable for being displayed on the console Storing of the last 5 alarms which have occurred with the corresponding hour meter values which can be displayed in the console and chopper temperature Tester function via the console to check main parameters in real time i e inputs motor voltage and battery voltage function DATA MOTOR optimizes the motor chopper combination registering the relevant characteristics of the motor that influences the electric braking Page 8 2 6 THERMAL CONSIDERATIONS heat generated by the control unit must be dissipated For thi
32. s 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 exchange difficult because of the materials used it is advisable to use forced air ventilation The power dissipated by the module varies depending on the current and the work cycle 2 7 GENERAL NOTES AND PRECAUTIONS Never combine SCR low frequency choppers with H1DN modules as the filtre condensers contained in the H1DN 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 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 H1DN 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 H1DN module must only be supplied using a traction use battery do not use outputs of straighteners or power suppliers For special applications consult the nearest ZAPI service centre Start the ma
33. the output voltage from an uncalibrated potentiometer with respect 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 rotation 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 correspondence after signal acquisition by the potentiometer The acquisition procedure is invalidated by the machine if the difference between the maximum value and the minimum value is less than 2V This acquisition procedure makes it 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 Application examples Signal overturn VACC VMOT volt 7190 7 60 r 80 27 70 7 r 60 r 50 r 40 r 30 r 20 M10 WIRE PEDAL 2 WRE PEDAL PPOT c1 O cPoT N G OQ O WO 1 ov K C2 NPOT C2 NPOT gt O 2 NPOT O 2 BEAT 10 20 30 40 50 60 70 80 90100 STROKE VACC accelerator signal voltage to pin C1 VMOT p
34. value Ifthe module has already been configured the procedure passes directly to step two 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 chopper model Select the desired options 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 pages 16 Set accleration by moving the machine forward and backward Setthe 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 setthe speed reductions activate the desired reduction request microswitch take the compensation level to 0 set the speed CUTBACK etc with machine 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 RELEASE BRAKING is set by running the machine and then completely releasing the accelerator pedal without pressing other pedals 10
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