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User Manual - Zapi Inc USA

electronic • oleodynamic • industrial equipments construction via parma, 59 – 42028 – poviglio (re) – italy tel +39 0522 960050 (r.a.) – fax +39 0522 960259

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Text of User Manual - Zapi Inc USA

ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 42028 POVIGLIO (RE) ITALY Tel +39 0522 960050 ( ) Fax +39 0522 960259 e-mail: web: EN User Manual HVC Page - 2/31 AEHZP0AA - HVC - User Manual Copyright 1975-2006 Zapi All rights reserved The contents of this publication is a ZAPI property; all related authorizations are covered by Copyright. Any partial or total reproduction is prohibited. Under no circumstances will Zapi 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. is a registered trademark property of Zapi NOTES LEGEND 4 The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention. U 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. AEHZP0AA - HVC - User Manual Page - 3/31 Contents 1 INTRODUCTION TO ZAPI CAN 2 GENERAL CHARACTERISTIC ........................................ ........................................ ............6 Functional characteristics ........................................ ........................................ ...........6 3 INSTALLATION Material overview ........................................ ........................................ ........................7 Connection cables ........................................ ........................................ ........7 Fuses ........................................ ........................................ ............................7 Installation of the Wirings: CAN connections and possible interferences .................................8 Wirings: I/O connections ........................................ .....................................10 Insulation of truck Protection and safety features ........................................ ........................................ ..10 Protection Safety EMC ........................................ ........................................ ........................................ ..11 4 OPERATIONAL FEATURES ........................................ ........................................ ..............14 5 DESCRIPTION OF THE CNA connector: Molex Mini-fit jr. 10 CNB connector: Molex Mini-fit jr. 8 CNC connector: Molex Mini-fit jr. 6 pins ........................................ ...........................15 CND connector: Modu2 ........................................ ........................................ ............15 CNE connector: Strip P. 2, 6 DRAWINGS ........................................ ........................................ ........................................ .17 Mechanical drawing ........................................ ........................................ ..................17 Functional 7 PROGRAMMING & ADJUSTMENTS USING DIGITAL Adjustments via console ........................................ ........................................ ...........19 Description of console and connection ........................................ .............................19 Description of standard console menu ........................................ .............................20 Description of programmable functions (options) ........................................ .............20 Description of parameters that may be programmed (parameter change) ...............22 Adjustments range ........................................ ........................................ ....................22 Proportional valve carrier frequency ........................................ .................................24 Tester Description of the console save function ........................................ ..........................25 Description of the console restore Description of the set model Function ........................................ ..............................26 Description of alarms menu ........................................ ........................................ ......28 8 CONTROLLER DIAGNOSTIC ........................................ ........................................ ............29 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 Page - 4/31 AEHZP0AA - HVC - User Manual APPROVAL SIGNS COMPANY FUNCTION INITIALSSIGN GRAPHIC AND LAYOUT CP PROJECT MANAGER FG TECHNICAL ELECTRONIC MANAGER VISA PP SALES MANAGER VISA PN Publication N : AEHZP0AA Edition: September 2006 AEHZP0AA - HVC - User Manual Page - 5/31 1 INTRODUCTION TO ZAPI CAN SYSTEM Distributed intelligent systems are not new in Zapi: the first one has gone in production in the '95 with a serial communication link (RS232). Today we use a more sophisticated and safe communication protocol: CAN BUS. In this way it is possible to reduce the harness allocating the modules exactly near the sensor or the actuators and connecting the modules with only 4 wires (CAN and supply). HVC is one of this modules designed to drive the hydraulic electrovalves and connect some inputs which normally are in the actuators proximity but with complete independent functions. Page - 6/31 AEHZP0AA - HVC - User Manual 2 GENERAL CHARACTERISTIC Functional characteristics Voltage [V] ........................................ ........................................ ...................12/24 V Output for ON-OFF valves ON-OFF [n ]....................................... ......................... 4 Output for proportional valves [n ] ........................................ ................................. 1 Digital inputs [n ]....................................... ........................................ ..................... 5 Analog inputs [n ]....................................... ........................................ .................... 1 RS-232 [n ] ........................................ ........................................ ............................ 1 CAN [n ]....................................... ........................................ .................................. 1 Input Digital inputs: - 3 inputs (A2, A6, 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 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). AEHZP0AA - HVC - User Manual Page - 7/31 3 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours, they mean: 4 These are information useful for anyone is working on the installation, or a deeper examination of the content U 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 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. Connection cables For the auxiliary connections, use cables of mm section. For the valves connections, use cables of mm section. Fuses - Use a A Fuse for protection of the auxiliary circuits. - For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow. Installation of the hardware U 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. U 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. Page - 8/31 AEHZP0AA - HVC - User Manual Wirings: CAN connections and possible interferences 4 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: - The best cable for can connections is the twisted pair; if it is necessary to increase the immunity of the system to disturbances, a good choice would be to use a cable with a shield connected to the frame of the truck. Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded. - In a 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. U Wrong Layout: 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. Module 1 Module 3 Module 2 R RCan Bus Power cables AEHZP0AA - HVC - User Manual Page - 9/31 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. U Correct Layout: 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). U Correct Layout: Note: Module 1 power Module 2 power > 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. Module 1 Module 2 Module 3 RRCan Bus Power cablesCenter of the Ground connection Module 1 Module 2 Module 3 RRCan Bus Power cablesPage - 10/31 AEHZP0AA - HVC - User Manual 4 Can advantages The complexity of today systems needs more and more data, signal and information must flow from a node to another. CAN is the solution to different problems that arise from this complexity - simplified design (readily available, multi sourced components and tools) - lower costs (less and smaller cables ) - improved reliability (fewer connections) - analysis of problems improved (easy connection with a pc to read the data flowing through the cable). Wirings: 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. U A cable connected to the wrong pin can lead to short circuits and failure; so, before turning on the truck for the first time, verify with a multimeter the continuity between the starting point and the end of a signal wire. - For information about the mating connector pin assignment see the paragraph description of the connectors . Insulation of truck frame U As stated by EN-1175 Safety of machinery Industrial truck , chapter , 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. Protection and safety features 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. Safety Features U ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of control system and to UNI EN1175-1 norm. U The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefully designed. AEHZP0AA - HVC - User Manual Page - 11/31 ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements. Machine manufacturer holds the responsibility for the truck safety features and related approval. The positive of EVs coils (outputs B6, B7 for ON/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. - Positive of the valves taken from the PEV (1, 2) and PEVP outputs. EMC U 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 ZAPI's control. Zapi can offer assistance and suggestions, based on its years experience, on EMC related items. However, ZAPI declines any responsibility for non-compliance, malfunctions and failures, if correct testing is not made. The machine manufacturer holds the 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 electromagnetic energy generated or received by an electrical device. So the analysis works in two directions: 1) The study of the emission problems, the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy; we talk about conduction issues when guiding structures such as wires and cables are involved, radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space. In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and generate RF energy, but wires and cables have the key role to propagate the disturbs because they works as antennas, so a good layout of the cables and their shielding can solve the majority of the emission problems. 2) The study of the immunity can be divided in two main branches: protection Page - 12/31 AEHZP0AA - HVC - User Manual from electromagnetic fields and from electrostatic discharge. The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device. There are well defined tests which the machine has to be exposed to. These tests are carried out at determined levels of electromagnetic fields, to simulate external undesired disturbances and verify the electronic devices response. 3) The second type of immunity, ESD, concerns the prevention of the effects of electric current due to excessive electric charge stored in an object. In fact, when a charge is created on a material and it remains there, it becomes an electrostatic charge ; ESD happens when there is a rapid transfer from a charged object to another. This rapid transfer has, in turn, two important effects: A) this rapid charge transfer can determine, by induction, disturbs on the signal wiring and thus create malfunctions; this effect is particularly critical in modern machines, with serial communications (canbus) which are spread everywhere on the truck and which carry critical information. B) 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 shielded box; using shielded cables; C) LAYOUT: a good layout of the cables can minimize the antenna effect; cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level. 2) ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are valid also for immunity. Additionally, further protection can be achieved with ferrite beads and bypass capacitors. 3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent 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 AEHZP0AA - HVC - User Manual Page - 13/31 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. Page - 14/31 AEHZP0AA - HVC - User Manual 4 OPERATIONAL FEATURES HVC has been designed to work on a CANBUS system. So, it follows the commands received by 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. AEHZP0AA - HVC - User Manual Page - 15/31 5 DESCRIPTION OF THE CONNECTORS CNA connector: Molex Mini-fit jr. 10 pins A1 CMM Positive supply of digital input devices (+BATT) A2 DI0 Digital Input N 0, 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) 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 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 CAN termination : connect to CAN_L to insert 120 ohm termination resistance C6 CAN_H CAN high signal in CND connector: Modu2 D1 PCLRXD Serial communication interface D2 NCLRXD Serial communication interface Page - 16/31 AEHZP0AA - HVC - User Manual D3 PCLTXD Serial communication interface D4 NCLTXD Serial communication interface D5 GND Negative supply D6 +12 +12 V supply D7 - D8 - CNE connector: Strip P. 2,54 The E connector, which is accessible only by opening the HVC cover, is used to program HVC by a dedicated MON 08 programmer. AEHZP0AA - HVC - User Manual Page - 17/31 6 DRAWINGS Mechanical drawing Page - 18/31 AEHZP0AA - HVC - User Manual Functional drawing AEHZP0AA - HVC - User Manual Page - 19/31 7 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 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). Description of console and connection Page - 20/31 AEHZP0AA - HVC - User Manual Description of standard console menu 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 AEHZP0AA - HVC - User Manual Page - 21/31 Flow chart showing how to make changes to Options Menu. 1) Opening Zapi Menu. HVC ZAPI 12V 0A 00000 2) Press ROLL UP & SET UP buttons together to enter the SET MENU. % ' % ' ' ' 3) The Display will show: SET MODEL. CONFIG MENU SET MODEL 4) Press ROLL UP or ROLL DOWN buttons until SET OPTIONS Menu appears. % ' ' ' ' ' 5) SET OPTIONS appears on the display. CONFIG MENU SET OPTIONS 6) Press ENTER to go into the SET OPTIONS Menu. ' % ' ' ' ' 7) The display will shows the first option. EVP TYPE DIGITAL 8) Press SET UP or SET DOWN buttons in order to modify the value for selected option. ' ' % ' ' % 9) New value for selected option appears. EVP TYPE ANALOG 10) Press OUT to exit the Menu. ' ' ' ' % ' 11) Confirmation request appears. ARE YOU SURE? YES=ENTER NO=OUT 12) Press ENTER to accept the changes, or press OUT if you do not accept the changes. ' % ' ' ' ' ' ' '' % '13) SET OPTIONS Menu appears. CONFIG MENU SET OPTIONS 14) Press OUT again. Display now shows the Opening Zapi Menu. ' ' ' ' % ' Page - 22/31 AEHZP0AA - HVC - User Manual Description of parameters that may be programmed (parameter change) In addition to the Configuration, Parameter settings can be factory set (Zapi default parameters), or the customer can make changes according to the application, using a Digital Console. During the setting up procedure on the machine, the Console can remain connected to the controller during travel. The Parameters can be modified in real time, during operation. Pay attention to the polarity of the Console Connector. Refer to chapter and of this Manual for connection details. CONNECTION OF THE CONSOLE TO THE CONTROLLER MUST BE MADE WITH THE KEY SWITCH TURNED OFF. The following Parameters can be modified: 1) 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 0 A. Adjustments range MIN EVP: range 0 100, 250 steps. (*) MAX EVP: range 0 100, 250 steps. (*) 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. AEHZP0AA - HVC - User Manual Page - 23/31 Flow Chart showing how to make Program changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Menu. HVC ZAPI 12V 0A 00000 2) Press ENTER to go into the GENERAL MENU. ' % ' ' ' ' 3) The Display will show: PARAMETER CHANGE. MAIN MENU PARAMETER CHANGE 4) Press ENTER to go into the PARAMETER CHANGE menu. ' % ' ' ' ' 5) The Display will show the first parameter. MIN EVP 22 6) Press ROLL UP and ROLL DOWN buttons until desired parameter appears. % ' ' % ' ' 7) The names of the Parameters appear on the Display. MAX EVP 88 8) When the desired Parameter appears, the Display will show a Level Number that will be between 0 and 9. Press either SET UP or SET DOWN buttons to change the Level value. ' ' % ' ' % 9) The Display will show the New Level. MAX EVP 100 10) When you are satisfied with the results of the changes you have made, Press OUT. ' ' ' ' % ' 11) The Display asks: ARE YOU SURE? . 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 CHANGE. MAIN MENU PARAMETER CHANGE Page - 24/31 AEHZP0AA - HVC - User Manual 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 (it can be adjusted in steps of 10 Hz). Tester menu Following parameters can be measured in real time in the TESTER menu: 1) ID 0 Level of MODE 0 digital input (with J2 1-2): - ON / GND : input active, switch closed - OFF / +12 V : input not active, switch open. 2) ID 1 Level of MODE 1 digital input (with J2 1-2): - ON / GND : input active, switch closed - OFF / +12 V : input not active, switch open. 3) INPUT 0 Level of DIGITAL INPUT 0: - ON / +VB: input active, switch closed - OFF / COND: input not active, switch open. 4) INPUT 1 Level of DIGITAL INPUT 1: - ON / +VB: input active, switch closed - OFF / COND: input not active, switch open. 5) INPUT 2 Level of DIGITAL INPUT 2: - ON / +VB: input active, switch closed - OFF / COND: input not active, switch open. 6) ANALOG INPUT 1 Voltage of the analog input. 7) 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. 8) SET POINT Proportional valve current setpoint. 9) PWM FREQUENCY Carrier frequency of the EVP driver signal; it is programmed by the net s master via canbus. 10) CONTROL WORD Command message received by the net s master via canbus. AEHZP0AA - HVC - User Manual Page - 25/31 Flow Chart showing how to use the TESTER function of the Digital Console. 1) Opening Zapi Menu. HVC ZAPI 12V 0A 00000 2) Press ENTER to go into the GENERAL MENU. ' % ' ' ' ' 3) The Display will show: PARAMETER CHANGE. MAIN MENU PARAMETER CHANGE 4) Press ROLL UP or ROLL DOWN button until TESTER menu appears on the display. % ' ' % ' ' 5) The Display shows: TESTER. MAIN MENU TESTER 6) Press ENTER to go into the TESTER function. ' % ' ' ' ' 7) The first variable to be tested is shown on the Display. ID 0 ON 8) Press either ROLL UP or ROLL DOWN buttons. % ' ' % ' ' 9) Next variable for measurement appears. ID 1 ON 10) When you have finished, Press OUT. ' ' ' ' % ' 11) The Display shows: TESTER. MAIN MENU TESTER 12) Press OUT again and return to Opening Zapi Menu. ' ' ' ' % ' 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. 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. 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 Page - 26/31 AEHZP0AA - HVC - User Manual controller. As a result of using this function, all parameters will be overwritten with incorrectly values and HVC controller will not work correctly. In order to perform RESTORE FUNCTION, use ZAPI PC Win console. 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. 1) Opening Zapi Menu. HVC ZAPI 12V 0A 00000 2) Press ROLL UP & SET UP buttons together to enter SET MENU. % ' % ' ' ' 3) The Display will show: SET MODEL. If 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 option is present in this menu. CONNECTED TO 9 6) Press SET UP or SET DOWN buttons in order to select the desired value for selected option. ' ' % ' ' % 7) New desired value appears. CONNECTED TO 2 8) Press OUT to exit the Menu. ' ' ' ' % ' 9) Confirmation request appears. ARE YOU SURE? YES=ENTER NO=OUT 10) Press ENTER to accept the changes, or press OUT if you do not accept the changes. ' % ' ' ' ' ' ' '' % '11) SET MODEL Menu appears. CONFIG MENU SET MODEL 12) Press OUT again. Console now disconnects and reconnects. ' ' ' ' % ' 13) Display now shows the Opening Zapi Menu of the ZAPI product corresponding to option selected at point 7. AC2 ZAPI 48V 0A 00000 AEHZP0AA - HVC - User Manual Page - 27/31 The table below indicates which parameter can be set to connect ZAPI product to Console. PARAMETER CONNECTED PRODUCT 1 SICOS 2 TRACTION CONTROLLER 3 MASTER CONTROLLER 4 SLAVE CONTROLLER 5 PUMP CONTROLLER 6 EPS 9 HVC 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. Page - 28/31 AEHZP0AA - HVC - User Manual 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. 1) Opening Zapi Display. HVC ZAPI 12V 0A 00000 2) Press ENTER to go into the General menu. ' % ' ' ' ' 3) The Display will show: MAIN MENU PARAMETER CHANGE 4) Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display. % ' ' % ' ' 5) The Display will show: MAIN MENU ALARMS 6) Press ENTER to go into the ALARMS function. ' % ' ' ' ' 7) The Display will show the most recent Alarm. CODE 00005 #02 20 C 8) Each press of the ROLL UP button brings up following Alarms. Pressing ROLL DOWN returns to the most recent. % ' ' % ' ' 9) If an Alarm has not occurred, the Display will show: ALARM NULL. CODE 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? . CLEAR LOGBOOK? YES=ENTER NO=OUT 12) Press ENTER for Yes, or OUT for NO. ' % ' ' ' ' ' ' '' % ' 13) Press OUT to return to the Opening Zapi Display. ' ' ' ' % ' AEHZP0AA - HVC - User Manual Page - 29/31 8 CONTROLLER DIAGNOSTIC Analysis of alarms displayed on the console 1) CAN BUS KO 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 short 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 it is 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 it is 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. Page - 30/31 AEHZP0AA - HVC - User Manual 9 RECOMMENDED SPARE PARTS FOR CONTROLLER Part Number Description C12359 Minifit Connector 6 pins Female C12414 Minifit Connector 8 pins Female C12500 Minifit Connector 10 pins Female C12777 Female Minifit pin harness side AEHZP0AA - HVC - User Manual Page - 31/31 10 PERIODIC MAINTENANCE TO 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. Using a suitable test meter, confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals. Switches should operate with a firm click sound. Microswitches should be checked 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 checked every; ........................................ ........................................ ...... 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; ........................................ ........................................ .............................. 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 matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain. NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.

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