Zapi ZAPIMOS H2B User manual

H2B USER'S MANUAL - 550145G Page 1/60
CONTENTS
Page
Legend .............................................................................................................. 3
1IntroductiontotheZAPIMOSfamily ............................................................. 4
2General H2B characteristics ......................................................................... 5
2.1 Technicalspecifications ......................................................................... 5
2.2 Controlunit............................................................................................. 6
2.2a Microswitches ............................................................................... 6
2.2b Potentiometer................................................................................ 6
2.3 Protectionfeatures ................................................................................. 8
2.4 Performancefeatures............................................................................. 9
2.5 H2B chopper diagnosis.......................................................................... 9
2.6 Thermalconsiderations .......................................................................... 9
2.7 Generalnotesandprecautions ..................................................... 10
2.8 Generalcontactorsandsafetyswitchforregenerativemodel ........ 11
3Installation.................................................................................................... 12
3.1 Choosingconnectioncables ................................................................ 12
3.2 Contactors ........................................................................................... 12
3.3 Fuses................................................................................................... 12
3.4 H2Bconnectors ................................................................................... 13
3.5 H2Bpowerconnectors ......................................................................... 14
3.6 Contactorsconnector ........................................................................... 15
3.7 H2Bchoppermechanicaldrawing........................................................ 16
4Parametermodifications ............................................................................. 17
4.1 Modifyingparametersusingthedigital-console .................................... 17
4.2 Chopperconfigurationandconnectionsdescription ............................. 20
5Traction ........................................................................................................ 22
5.1 H2Bregenerativetraction..................................................................... 22
5.1.1 Inputconnectorsdescription ....................................................... 23
5.1.2 Programmablefunctions(options) .............................................. 24
5.1.3 Parameter modification .............................................................. 26
5.1.4 Adjustmentchart......................................................................... 28
Variants for braking soft .............................................................. 28
5.1.5 Wiring diagram for H2B regenerative model with pedal .............. 29
5.1.6 Wiringdiagramfor H2Bregenerative modelwithhandle ............. 29
5.1.7 Wiringdiagram for H2B regenerative modelwith
speed check and pick-up ........................................................... 30
5.1.8 Wiring diagram for H2B regenerative model with speed check
and tacho-generator .................................................................... 31
5.1.9 Wiring diagram for H2B regenerative model with speed
check and backing ...................................................................... 32
5.1.10 Wiring diagram forH2B regenerative model power unit ............ 33
5.1.11 Wiringdiagram for H2B regenerative model power unit
with weakening.......................................................................... 34
5.1.12 Wiringdiagram forH2B powerunit regenerativewith bypass.... 35
5.1.13 Wiringdiagram forH2B powerunit regenerativewith
weakening................................................................................. 35
5.2 Sequenceofsettingsforregenerative .................................................. 36
5.3 H2B traction diagnosis......................................................................... 37
5.4 Decodingconsole displayed alarms..................................................... 38

Page 2/60 H2B USER'S MANUAL - 550145G
Page
6Pump ............................................................................................................ 46
6.1 H2Bstandardlifting.............................................................................. 46
6.1.1 Inputconnectors.......................................................................... 47
6.1.2 Programmablefunctions(options) .............................................. 47
6.1.3 Parameter modification .............................................................. 47
6.1.4 Adjustmentchart......................................................................... 49
6.1.5 Connectiondiagram for H2Bstandard lifting............................... 50
6.1.6 Connectiondiagramfor H2B pump unit with weakening.............. 50
6.1.7 ConnectiondiagramforH2B,with powerunitbypass
contactor and main contactor....................................................... 51
6.1.8 H2Bpowerunitstandardconnectiondiagram............................. 51
6.2 H2Blifting + 3rdmotor.......................................................................... 52
6.2.1 Inputconnectors.......................................................................... 53
6.2.2 Programmablefunctions(options) .............................................. 53
6.2.3 Parameter modification .............................................................. 54
6.2.4 H2Belectricalconnectiondiagramspump+ hydro...................... 54
6.2.5 H2Bpowerunitwiringlifting+hydrodrive+weakening ............... 55
6.3 Sequenceofsettingsforlifting.............................................................. 55
6.4 Settingtheproportionalsolenoidvalve ................................................. 56
6.5 H2B lifting diagnosis ............................................................................ 56
6.5.1 Decodingthe alarms displayed on console................................. 56
7Recommended spare parts for H2B .......................................................... 59
8Periodic maintenance to be regulary repeated ......................................... 60
= Theinformationsincludedintothemarkedparagraphsbythissymbolare
essentialforthesafety.
APPROVAL SIGNATURES
COMPANY DEPT. SERVICES MANAGEMENT EXECUTIVE
ENGINEERING SECTION EXECUTIVE
EXPORT MANAGER
Pubblicationn.: 550145G
Edition : May 2010

H2B USER'S MANUAL - 550145G Page 3/60
LEGEND
1^V =1stlift speedrequest
AV =Forward
CH =Key
DF =Brake diode
DV =Flywheeldiode
IN =Backward
IND =Weakening
MA =Forwardspeedmicroswitch
MCL =Hornmicroswitch
MD =Descentmicroswitch
MEF =Electricbrakeswitch
MI =Backwardmicroswitch
MS =Risemicroswitch
MT =Handlemicroswitch
MUM =Deadmanmicroswitch
NT =Contactornegative
RV =Speedreduction
VMN =Negativemotorvoltage

Page 4/60 H2B USER'S MANUAL - 550145G
1 INTRODUCTION TO THE ZAPIMOS FAMILY
TheZAPIMOSchopperfamilyisZAPI’sanswertotheneedsofusersofthe’90s.
Toensurethattheproductstaysonthemarketwithoutrunningtheriskofbecoming
technologicallyobsolete,ZAPIhasdesignedtheZAPIMOSfamilytoofferthefollowing
features:
-Advancedtechnologyandeconomicalcosts
-Maximumsafety
-Maximumflexibility
-Opentofuturetechnologicalinnovations
-Optimumlevelofprotection.
This implies:
-HighfrequencyMostechnology
-Real-timecontrolovertheinternalandexternalpartsthatcaninfluencethebehaviourof
themachine,withself-diagnosisofthecheckingcircuitsthemselves.
-Storedprogrammemachine(SPC)wherethehardwareiscompletelyseparatefromthe
functionsto beconfigured. The programmeis parametricand can alsobe modified by
thefinaluser.
-Variouschopperfunctionalconfigurationscanbeselectedbytheuser,withouttheneed
forhardwaremodifications.
-Anyfuturetechnologicalupdatesaremadecleartotheuser.
Thecommunicationprotocolwillcontinuetoevolve,thusofferingincreasingpossibilities
ofinteraction.
Forthisreason,theZAPIMOSfamilyoffersastandarddialoguemodewithexternal
systems,foreasyinterfacingwithcommerciallyavailablemachines. ZAPIoffersa
rangeofprogrammingconsoleswithvariousfeaturesandprices.
-Logicandpower unitsarefitted inasealed container(IP54),to guaranteeprotection
againstsplashes(water,acid,etc.)anddust,chips,orsmallparticles.
Accesstothelogicforreplacementorchecks,however,isveryeasy.
-TheH2Bchopperisthetop-of-the-linemodeloftheZapimosfamily.Itissuitablefor
operatingat voltages from 24 to 96 Vwith maximum currents of400 or 600 amp.
Suitable for use with series motors with powers from 2000 W to 15 kW.

H2B USER'S MANUAL - 550145G Page 5/60
2 GENERAL H2B CHARACTERISTICS
2.1 TECHNICAL SPECIFICATIONS
Voltage: ........................................................................................ 24V (14 ÷ 32V)
...........................................................................36 / 40 / 48V (22 ÷ 55V)
...........................................................................60 / 72 / 80V (36 ÷ 90V)
...................................................................................... 96V (57 ÷ 120V)
Maximumcurrent: .......................................................................... short size = 400 A
..................................................... long size = 600 A (80 V model: 500 A)
SYSTEM
VOLTAGE H2 400 (SHORT) H2 600 (LONG) H2 601
24V 400A 600A /
48V 400A 600A /
80V 400A / 500A / 600A
96V 400A / 500A / 600A
Frequency: ......................................................................................................16kHz
Motors(characteristics):..............................................DC wire wound serie 4 cables
Operatingambienttemperature:............................................................ -30 to +40°C
Maximumallowabletemperatureforchopperbody: ........................................... 85°C
DropvoltagewithI=200A:
SYSTEM
VOLTAGE H2 400 (SHORT) H2 600 (LONG) H2 601
24V 250mV 200mV /
48V 350mv 280mV /
80V 1.00V 550mV 550mV
Microprocessorlogicunit.
3differentconfigurationsthatcanbesetfromtheconsole:
1tractioncontrolandenergyregeneration
25-speedpumpcontrol
34-speedpumpcontrol+hydrodrivecontactorhandling
Therearetwo H2Bmodels,based on themaximumcurrent (400Aand 600A),which also
differin size.

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2.2 CONTROL UNIT
2.2a Microswitches
Microswitchessendavoltagesignalwhentherequestforstartupordesiredfunctionis
made.Microswitchesforforward,backward,andrapidinversion(ifpresent)aredimen-
sionedforcarryingthecurrentofonecontactor(3amp).
2.2b Potentiometer
Inthe3-wireconfiguration,theCPOT(C1)usefulinputsignalgoesfrom0Vto10V.
Theresistivevalueofthepotentiometermustbebetween500ohmand10kohm,aslower
valuesoverloadthepowersupply.
2-wirepotentiometer(pleaserequestwhileordering):
Itispossibletousethepotentiometerinthe2-wireconfigurationbutyoushouldstateits
ohmicvaluesincearesistoronthe logicboarsmustbeinstalledaccordingly.
CorrespondencebetweenthevoltagesignaltopinC1andmotorvoltage.
Theprocedureforautomaticpotentiometersignalacquisitioniscarriedoutfromthecon-
sole.Thismakesitpossibletoadjusttheminimumandmaximumusefulsignalinthere-
spectivedirections.
Thisfunctionisindispensablewhenitisnecessarytocompensateforasymmetryinthe
mechanicalworkingsthatcontrolthepotentiometer,especiallyasregardstheadjustment
oftheminimumwhichincertain cases, ifmadeinthetraditionalway, requires acalibration
thatislaboriousandcostly,butveryoftengivesunsatisfactoryresults.
Thesequenceofproceduresisdescribedintheprogrammingconsolemanual.

H2B USER'S MANUAL - 550145G Page 7/60
fig. 8a fig. 8b
Thetwographsshowtheoutputvoltagefromanuncalibratedpotentiometerwithrespectto
themechanical“zero”oftheknobofonehandle(MIandMAindicatethepointatwhichthe
speedmicroswitchesclose,0isthemechanicalzeroofthehandlerotation).Thefirstgraph
(Fig.8a)showsthecorrespondenceofthemotorvoltagewithouthavingmadetheacquisi-
tion,whilethesecondgraph(Fig.8b)showsthesamecorrespondenceaftersignal acqui-
sitionbythepotentiometer.Theacquisitionprocedureisinvalidatedbythemachineifthe
differencebetweenthemaximumvalueandtheminimumvalueislessthan2V.
This acquisition procedure makes it possible:
-touse“reversed”potentiometricsignals, i.e. thosewhicharecarriedfrom a highinitial
valuetoalowfinalvalue.
-touseanormalpotentiometerinsteadofonewithcentralzero.
Forthecorrectfunctioningofsignalacquisition,itisabsolutelynecessarythattherunning
microswitchesbeactivatedbythesameshaftthatmovesthepotentiometer.
Applicationexamples.
-Signaloverturn.
VACC = accelerator signal voltage to pin C1.
VMOT=percentageofbatt.voltageonthemotor.
-Centralzerosignal.

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2.3 PROTECTION FEATURES
-Battery inversions:
Itis necessaryto respectthe connections indicated in thediagrams inorder toavoid
damagetothepowerunit.Intheliftingversions,ageneralcontactormaybeconnected
whichishandledbythelogicagainstanypolarityinversions.
Thelogicisintrinsicallyprotectedagainstpolarityinversions.
-Connection errors:
Alltheinputsareprotectedagainstconnectionerrors.
Thecontactors donot acceptloads greaterthan 3amp, andare inany caseprotected
againstoverloadsandshortcircuits.
-Thermal protection:
Ifthetemperatureexceeds80°C,themaximumcurrentisreducedinproportiontothe
thermalincrease.Thetemperaturemayneverexceed85°C.
-Low battery charge:
Whenthebatterychargeislow,themaximumcurrentisreducedby50%,andinthe
liftingversionallfunctionsexcepthydrodrive(anddescent)areblocked.
Thisfeaturemaybeexcludedbytheconsole.
-External agents:
Thechopperbodyiscompletely sealed, andthusisprotectedagainst splashesof
liquid(IP54).
-Protection against accidental start-up:
Aprecisesequence ofoperationsis necessaryfor starting themachine.
Iftheseoperationsarenotcarriedoutcorrectly,themachinewillnotstart.
Therequestforrunningmustbeactivatedafterthekeyandhandlemicroswitch(orseat
microswitch).
-Protection against uncontrolled movements:
Thecontactorsdonotcloseif:
-thepowerunitisnotfunctioning
-theacceleratordoes notgo belowthe minimumvalue stored increasedby 2V
-thelogicisnotperfectlyfunctional
-onerunningmicroswitchisstuck.

H2B USER'S MANUAL - 550145G Page 9/60
2.4 PERFORMANCE FEATURES
-Optimumsensitivitytolowspeeds.
-Self-diagnosiswithindicationofthetypeofanomalybyanoptionalLED.
-Configurablefromtheconsole(tractionorlifting).
-Modificationofparametersfromtheconsole.
-Internalhour-meterwithvaluesthatcanbedisplayedontheconsole.
-Memorisationofthelast5alarmstripped,withrelativehour-metervalueandtempera-
turethatcanbedisplayedontheconsole.
-Consoletesterforrealtimecheckingofthemainparameterssuchasinputs,motor
voltage,battery,etc.
-Absenceofarconthecontactors
-Internalarcsuppressorofthecontactorscoils.
-Highmotorandbatteryefficiencythankstohighfrequencycommutation.
2.5 H2B CHOPPER DIAGNOSIS
Themicroprocessorcarriesoutdiagnosticproceduresonthemainchopperfunctions,
involving4basicpoints.
1) Diagnosisonkeystart-upwhichincludes:watchdogtest,currentsensortest,VMNtest,
contactorpilottest,testforrunningrequestpresent,highacceleratortest.
2) Standbydiagnosiswhichincludes:watchdogtest,VMNtest,contactorpilottest,cur-
rentsensortest.
3) Diagnosiswhilerunningwhichincludes:watchdogtest,VMNtest,currenttest,contac-
tortest,VMNtestincompleteconduction,contactoropening-closingtest.
4) Continuousdiagnosis:temperaturecheck,batterychargecheck.
The diagnostic message is indicated by a certain number of blinks of the LED connected
toconnectorA.
Thecurrentalarmmessagecodecanbedisplayedontheprogrammingconsole.
Adescription of thealarm codes, possible causesand solutions isgiven for each configu-
rationinthefollowingsections.
2.6 THERMAL CONSIDERATIONS
-Theheatgeneratedby thecontrolunitmust be dissipated.Forthisto bepossible,the
compartmentmustbeventilatedandthecoolingsurfacesample.
-Thecoolingsystemis dimensionedonthe basisofthe performance requiredofthe
machine.
Forsituationsinwhichventilationispoorandheatexchangedifficultbecauseofthe
materialsused,wesuggesttouseforcedairventilation.
-Thepowerdissipatedbythemodulevariesdependingonthecurrentandthework
cycle.

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2.7 GENERAL NOTES AND PRECAUTIONS
-NevercombineSCRlowfrequencychopperswithH2Bmodules,asthefiltercondens-
erscontainedintheH2BmodulealterSCRchopperfunctioning,subjectingittoexces-
siveworkloads.
Thus,ifyouwishtousetwoormorecontrolunits(e.g.lift+traction),theymustallbeof
thehighfrequencyZAPIMOSfamily.
-Donotconnectthechoppertoabatterywithadifferentnominalvoltagethanthatindi-
catedonthechopperidentificationplate.AhigherbatteryvoltagecancauseMOS
failure.Alowerbatteryvoltagepreventsthemodulefromfunctioning.
-Duringbatteryrecharge,theH2Bmodulemustbecompletelydisconnectedfromthe
battery,as,inadditiontoalteringthechargereadbythebatterycharger,themodulecan
bedamagedbytheoverloadvoltagesgeneratedbythecharger.
-TheH2Bmodulemustonlybesuppliedusingatractionusebattery;donotuseoutputs
ofconvertersorpowersuppliers.Forspecialapplications,pleaseconsultthenearest
ZAPIservicecentre.
-Startthemachinethefirsttimewiththewheelsraised,toensurethatconnectionerrors
donotcreatesafetyrisks.
-Withthekeyoff,thefiltercondensersinsidethemodulemayremainchargedforseveral
minutes.
Forsafeoperation,werecommendthatyoudisconnectthebatteryandshortcircuitthe
powerpositive andnegative on thechopper fora few secondswith a resistance of
between10ohm and 100ohm.
-Thesusceptibilityandtheelectromagneticemissionareremarkablyinfluencedbythe
installationconditions.Takeparticularcareofthelength,oftheelectricalconnections
and of the braided wires.
ThereforeZAPIdeclinesanyresponsibilityforbadrunningsthatcanbeattributedtothe
abovementionedcircumstances,aboveallifthemanufacturerofthemachinedoesn't
carryoutthetestsrequiredbytheregulationsinforce(conductedemissions,irradiated
emissions, IEC 801 - 2 (ESD), IEC 801 - 3 (irradiated susceptibility), IEC 801 - 4
(burst),IEC801-5(surge),IEC-6(conductedimmunity)).

H2B USER'S MANUAL - 550145G Page 11/60
2.8 GENERAL CONTACTORS AND SAFETY SWITCH FOR REGENERATIVE
MODEL
-Theconnectionofeventualinterruptionsystemsofthebatterymustbeexecutedscrupu-
louslyrespectingoneofthefollowingwirings.
-Withsafetyswitch
-Withswitchandgeneralcontactor
-Thesecircuitalsolutionsarenecessarytoavoidthechopperfailwhentheconnectionto
thebatteryisopenedduringthephaseofregenerativebraking.
Thechopper intrinsic protection is active when the voltageonthepinD1exceedsby
30%thebatterynormalvoltageorwhenthekeyisexcludedbeforetheopeningofthe
batteryconnection.

Page 12/60 H2B USER'S MANUAL - 550145G
3 INSTALLATION
Installthechopperwiththebase-plateonaflatmetallicsurfacethatiscleanandunpainted.
Applyalightlayerofthermo-conductivegreasebetweenthetwosurfacestopermitbetter
heatdissipation.
Despitetheprotectionprovidedagainstexternalagents,thecontinuousattackofcorrosive
substancesmaycausetheconnectorcontactstooxidise,thusjeopardisinggoodfunction-
ing.Keepthisinmindwhenchoosingtheinstallationpositiononthevehicle.
Usethespecialholesonthebase-plateforfasteningthechopper.
Makesurethatthewiringofthecableterminalsandconnectorsiscarriedoutcorrectly.
Fitanti-jammingfiltersonthehorn,solenoidvalves,andcontactorsnotconnectedtothe
choppersuchasthoseforactivatingthepumpmotororhydrodrivemotor,ifthelatterisnot
handledbythechopperitself.
3.1 CONNECTION CABLES
Fortheauxiliarycircuits,usecablesof0.5mm²section.
Forpowerconnectionstothemotorandtothebattery,usecableshavingsectionsof
35- 50mm².
Forthebestchopper performance,thecablesto thebatteryshouldbe runsideby side and
be as short as possible.
3.2 CONTACTORS
Choosethetypeofcontactorsonthebasisofthemaximumoperatingcurrentofthemotor
andthespecificchopperconfiguration.
-Thecurrentabsorbedbythecoilmustnotbegreaterthan3amp.
-Thecoilsuppressorsareinside thechopper;donotuse contactors witharcsuppres-
sors.
-Forcontactorswithmagneticsuppressors,makesureyourespectthepolarityindicated
onthecap.
3.3 FUSES
-Usea10ampfuseforauxiliarycircuit protection.
-Forprotectingthepowerunit,seethediagrams.
Thevalueshownisthemaximumallowable.Forspecialapplicationsorrequirements
thisvaluecanbereduced.
Forsafetyreasons,werecommendthatyouuseprotectedfusesinordertopreventthe
spreadoffusedparticlesintheeventofblowout.

H2B USER'S MANUAL - 550145G Page 13/60
3.4 H2B CONNECTORS
pin function description
A1 -LED AlarmLED negative:to beconnected tothe cathode
A2 +LED Alarm LED positive: to be connected to the anode
Outputcurrent12mA,forstandardtypeLED
B1 PCLRXD Serial reception positive
B2 NCLRXD Serialreceptionnegative
B3 PCLTXD Serialtransmissionpositive
B4 NCLTXD Serialtransmissionnegative
B5 GND Consolesupplynegative
B6 +12 Consolesupplypositive
B7 FUNCTIONSELECT Channelformini-console(speedsignal)
B8 UP/DOWN Channelformini-console(speedref.)
C1 CPOT Potentiometercentralpin:connectedtothepotentiometer
cursor.Forspeedregulation,theusefulsignalrangesfrom
0Volt (minimum speed) to10 V (maximum speed).
C2 NPOT Potentiometernegative:abatterynegative.
C3 PPOT Potentiometerpositive:a12Voutput.
Donotshortcircuitthisterminaltowardthebatterynega-
tiveor applya resistive loadof lessthan 500 ohm.
D1 +CHIN Tobeconnectedtothekey.
D2 +CHOUT Thepositive,tobesenttothefunctionrequestmicros-
witches,istakenfromthispin.
Thispositiveistakenaftertheinternaldiode.
E1 Pinstowhichthesignalsforfunctionrequest
E2 aresent;theirmeaningsvariesaccordingtothe
E3 modelselectedandpinprogramming.
E4 INPUT A detailed description is given in the chapters
E5 dedicated to the specific models. Pin E4, if forced
E6 tolow level, inhibitsthe effectof pinsE8 andE9.
E7
E8 RI(low) Activates the same request as for pin E4 with a low ca-
pacitylevel(lessthan10V).
E9 RI(low) LikeE8butelectricallydisconnected.

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ELECTRICAL CIRCUIT OF INPUT PINS
Pin C1 Pins E1, E2, E3, E4, E5, E6, E7
SYSTEM
VOLTAGE RIN
INPUT SIGNAL
LEVEL
HIGH LOW
24 10K >10V <50V
48 27K >20V <10V
80 47K >35V <18V
3.5 H2B POWER CONNECTORS
-SH Outputcurrentsense
+B Batterypositive
VMN Connectedtothepowermosfet drain,itsuppliesanegative to themotorwith
variabledutycycle
-B Batterynegative
+SH Inputcurrentsense

H2B USER'S MANUAL - 550145G Page 15/60
3.6 CONTACTORS CONNECTORS
CONN.
GWIRE COLOUR CONN. TRACTION FUNCTION PUMP FUNCTION
1 white-green 4 Positive of braking contactor PTFR /
2 red-black 1 Contactors positive PT Contactors positive PT
3 grey-black 2 Negative field weakening contactor
coil NTIND Negative field weakening contactor coil NTIND
4 blue-black 2 Negative backward contactor coil NTI Negative main contactor coil NTG
5 red-green 6 Negative braking contactor coil NTFR Negative proportional electrovalve coil
NEVP
6 yellow-black 5 Negative forward contactor coil NTA Negative hydro contactor coil NTIDR
7 optional - Negative of auxiliary contactor AUX
G7 /
8 optional - Battery negative pole /

Page 16/60 H2B USER'S MANUAL - 550145G
3.7 H2B CHOPPER MECHANICAL DRAWING

H2B USER'S MANUAL - 550145G Page 17/60
4 PARAMETER MODIFICATIONS
Modificationof theparameters, inaddition to the configuration of the inputs,is madedi-
rectlybyZAPIoncustomerspecifications,orthecustomermaymakeadjustmentshimself
usingtheprogrammingconsole.Theconsolecanremainconnectedtothechopperwhen
runningandtheparameterscanalsobevariedinrealtimeduringoperation.
Toconfirmdata,pressENTERwhenrequestedbythemessageontheconsole.
Theparametersthus modified andoptimisedon oneunitcan bestoredfrom the console
(SAVE)andthenreloaded(RESTORED)onanotherchopper,thusallowingfastand
standardisedcalibration(seeconsolemanualfordetails).
InH2Gsoftwareversion,parametersmodificationandPROGRAMVACCfunctionare
lockedbydefault. Toenable them, specialadj. PARAMCHANGEEN mustbe set toON.
Payspecial attentiontothepolarityoftheconsoleconnectorwhenitishookeduptothe
chopper.
HOOKINGUPMUSTONLYBEDONEWITHTHEMACHINEOFF.
4.1 MODIFYING PARAMETERS USING THE DIGITAL CONSOLE
Thedigitalconsoledisplaysthemodeltypeanditsbuilt-inhourmeter.
-SET MODEL:
REGENER
NOTCONF
STANDARD PUMP
PUMP+HYDRO
-SETOPTIONS(TRACTION):
BYPASSCONTACTOR bypass/weakeningcont
SPEED CONTROL on/off
BATTERY CHECK on/off
ANTIROLLBACK on/off
RELEASEBRAKING on/off
HOURCOUNTER running/keyon
QUICKINVERSION on/off
SAFETYSWITCH seat/handle
BACKINGFUNCTION on/off
SOFTBRAKING on/off
AUXFUNCTION none/bimotor
contactor/hydrocontactor
HYDROKEYON(*) on/off
-SETOPTIONS(PUMP):
BATTERYCHECK on/off
BYPASSCONTACTOR bypass/weakeningcont
HOURCOUNTER running/keyon
MAINCONTACTOR present/runningstatus

Page 18/60 H2B USER'S MANUAL - 550145G
-ADJUSTMENTS:
SETBATTERYTYPE 12V, 24V, 36V, 40V, 48V, 60V, 72V, 80V, 96V, 120V
ADJUSTBATTERY ....V
traction pump
-PARAMETERCHANGE:
ACCELERATIONDELAY ACCELERATIONDELAY
INVERS.BRAKING EV. ACCELER DELAY
BRAKING(*) DECELER. DELAY
RELEASEBRAKING EV. DECELER DELAY
PEDAL BRAKING MAXIMUMCURRENT
CUTBACK SPEED 1 HYD SPEED COARSE
CUTBACK SPEED 2 HYDSPEED FINE
CUTBACK SPEED 3 HYDROCOMPENS.
AUXILIARYTIME CREEP SPEED
COMPENSATION WEAKDROPOUT
BRAKINGMODUL HYDROTIME
MAXIMUMCURRENT 1ST SPEED COARSE
MAX SPEED FORW 1ST SPEED FINE
MAX SPEED BACK 1ST SPEED COMP.
CREEP SPEED 2ND SPEED COARSE
WEAKDROPOUT 2ND SPEED FINE
CURVEBRAKING 2ND SPEED COMP
CURVETIME 3RD SPEED COARSE
BACKINGTIME 3RD SPEED FINE
3RD SPEED COMP
4TH SPEED COARSE
4TH SPEED FINE
4TH SPEED COMP
MAX SPEED LIFT (*)
MINVALVEVOLT
MAX VALVE VOLT
AUXILIARYTIME
traction pump
-TESTER: VMN VMN
MOTORVOLTAGE MOTORVOLTAGE
ACCELERATOR LIFTINGCONTROL
MOTORCURRENT MOTORCURRENT
TEMPERATURE TEMPERATURE
CUTBACKSWITCH1 BATTERYVOLTAGE
CUTBACKSWITCH2 LIFTINGSWITCH
CUTBACKSWITCH3 DESCENTSWITCH
BRAKESWITCH 1ST SPEED SWITCH

H2B USER'S MANUAL - 550145G Page 19/60
HANDLE / SEAT SW. 2ND SPEED SWITCH
BATTERYVOLTAGE 3RD SPEED SWITCH
FORWARDSWITCH 4TH SPEEDSWITCH
BACKWARD SWITCH HYDROSPEEDREQ
BATTERYCHARGE(*) BATTERYCHARGE(*)
BACKING ENABLE (*)
QUICKINVERSION(*)
SPEED REFERENCE (*)
SPEED VALUE (*)
-SAVE: Chopperparameters are storedintheconsolememory.
10different memoriesare availablefor each choppermodel.
-RESTORE: Transferofparametersfromconsolememorytochoppermemory.
10different memoriesare availablefor each choppermodel.
-ALARM: Displayofin-choppermemoryalarms.
-PROGRAM VACC: Potentiometerstrokeparameter.
(*)H2Gsoftwareonly.

Page 20/60 H2B USER'S MANUAL - 550145G
4.2 CHOPPER CONFIGURATION AND CONNECTIONS DESCRIPTION
Thechoicesmaderegardingpowerconnectionsmustbecommunicatedtothechopper.
Inordertosupplythisinformation,youhavetoconnectthechoppertotheprogramming
consoleandaccessthesetmodel,setoptions,andadjustment menus (seespecificcon-
figurationdescriptions).
-CONFIGURATIONOFTHEMODEL: SETMODELMENU
Allows chopper to operate in one of the 3 possible modes.
1)REGENER.TR =regenerativetraction
2)STANDARD PUMP = standard lifting
3) PUMP+HYDRO=liftingwithhydrodrivecontactorhandling
-CONFIGURATIONOFOPTIONS: SETOPTIONSMENU
function option meaning
BYPASS CONTACTOR Bypass Bypasscontactor
Weakening cont Weakeningcontactor.
SPEED CONTROL On No speed check.
Off Speedcheck activated.
BATTERY CHECK On Nolowbatterychargealarm.
Off Lowchargealarmwith50%
max.currentiflessthan10%
ofcharge.
ANTIROLLBACK On NoAnti-rollback.
Off Anti-rollbackhandled.
RELEASE BRAKING On Noregenerativebrakingat
release.
Off Releasebraking.
HOUR COUNTER Running Hour-meteractiveonlywhen
running.
Key on Hour-meteractivewithkeyon.
QUICK INVERSION Off E1 = Reduction of speed
no.3.
On E1=Rapidinversioninput.
SAFETY SWITCH Seat E4 = Seat microswitch.
Handle E4=Handlemicroswitch.
BACKING FUNCTION Off E2 = Speed reduction no.2.
On E2 = Back request with
speedrelativeto cutback
speed #2 and timing of back