Zapi ADPZP0CC User manual

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel [phone] (r.a.) – Fax [phone]
e-mail: [email protected] – web: www.zapispa.it
EN
User Manual
MHYRIO
FLASH
CONTROLLER
(MULTIFUNCTIONAL
HYDRAULIC REMOTE I/O)

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Copyright © 1975-2006 Zapi S.p.A.
All rights reserved
The contents of this publication is a ZAPI S.p.A. property; all related authorizations are covered
by Copyright. Any partial or total reproduction is prohibited.
Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make changes or improvements to its products at any time and
without notice.
The present publication reflects the characteristics of the product described at the moment of
distribution. The publication therefore does not reflect any changes in the characteristics of the
product as a result of updating.
is a registered trademark property of Zapi S.p.A.
NOTES LEGEND
4The symbol aboard is used inside this publication to indicate an annotation or a
suggestion you should pay attention.
UThe 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.

ADPZP0CC - MHYRIO FLASH CONTROLLER - User Manual Page - 3/36
Contents
1INTRODUCTION TO ZAPI CAN SYSTEM............................................................................5
2GENERAL CHARACTERISTIC ............................................................................................6
2.1 Functional characteristics ...........................................................................................6
2.2 Input............................................................................................................................6
3INSTALLATION HINTS.........................................................................................................7
3.1 Material overview........................................................................................................7
3.1.1 Connection cables ........................................................................................7
3.1.2 Fuses............................................................................................................7
3.2 Installation of the hardware.........................................................................................7
3.2.1 Wirings: CAN connections and possible interferences.................................8
3.2.2 Wirings: I/O connections.............................................................................10
3.2.3 Insulation of truck frame..............................................................................10
3.3 Protection and safety features..................................................................................10
3.3.1 Protection features......................................................................................10
3.3.2 Safety Features...........................................................................................11
3.4 EMC..........................................................................................................................11
4OPERATIONAL FEATURES ..............................................................................................14
5DESCRIPTION OF THE CONNECTORS............................................................................15
5.1 Connector CNA: ZAPI Minifit 22 poles......................................................................15
5.2 Connector CNB: ZAPI Minifit 6 poles........................................................................15
5.3 Connector CNC: ZAPI Minifit 6 poles .......................................................................15
5.4 Connector CND: ZAPI Minifit 4 poles .......................................................................16
5.5 Connector CNE: ZAPI Minifit 8 poles........................................................................16
5.6 Connector CNF: ZAPI Minifit 10 poles......................................................................16
5.7 Connector CNG: ZAPI Minifit 16 poles .....................................................................17
6DRAWINGS.........................................................................................................................18
6.1 Mechanical drawing..................................................................................................18
6.2 Functional drawing....................................................................................................19
7PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................20
7.1 Adjustments via console...........................................................................................20
7.2 Description of console and connection.....................................................................20
7.3 Description of standard console menu .....................................................................21
7.4 Description of programmable functions (options) .....................................................22
7.5 Description of parameters that may be programmed (parameter change)...............24
7.6 Adjustments table .....................................................................................................25
7.7 Description of the tester function ..............................................................................27
7.8 Description of the console save function..................................................................30
7.9 Description of the console restore function...............................................................30
7.10 Description of the set model Function ......................................................................31
7.11 Description of alarms menu......................................................................................33
8CONTROLLER DIAGNOSTIC ............................................................................................34
8.1 Analysis of alarms displayed on the console............................................................34
9RECOMMENDED SPARE PARTS FOR CONTROLLER...................................................35
10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................36

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APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
MANAGER VISA PP
SALES MANAGER VISA PN
Publication N°: ADPZP0CC
Edition: October 2006

ADPZP0CC - MHYRIO FLASH CONTROLLER - User Manual Page - 5/36
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).
Mhyrio is one of this modules born to drive the hydraulic electrovalves and
connect some inputs which normally are in the actuators proximity but with
complete independent functions.

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2 GENERAL CHARACTERISTIC
2.1 Functional characteristics
Voltage [V].........................................................................................24/36/48/80 V
Output for ON-OFF valves [n°] ..............................................................................3
Output for proportional valves [n°].........................................................................8
Incremental Encoder (phase A and B) [n°]............................................................1
Digital inputs [n°]....................................................................................................8
Analog inputs [n°]...................................................................................................2
RS-232 [n°]............................................................................................................1
CAN [n°].................................................................................................................1
Protection..........................................................................................................IP64
Mhyrio is produced to work with one defined battery voltage (the required voltage
has to be specified in the order).
2.2 Input
Digital inputs: accepts PNP type sensor or switches connected to the positive.
The voltage can be battery voltage or 24 V if the valves are supplied at 24 V
(specify in the order).
Analog inputs: Mhyrio Flash accepts two analog inputs. The range have to be
specified in the order (0-20 mA, 0-5 V, 0-10 V, 0-VBatt).
13 V, 200 mA output is provided to supply potentiometer or similar device.
Encoder: encoder electronic output can be PNP, NPN or PUSH PULL type.
Encoder supply is 13 V. Maximum frequency is 500 Hz.
ON-OFF valves drivers programmable and can drive the coil in full conduction or
in PWM mode for supply the coil at the nominal programmed voltage
independently by the battery voltage. Option: 0-12; 1-24; 2-36; 3-48; 4-72; 5-80.
Proportional valves are driven in current mode with fixed frequency. The
voltage is the same used for ON-OFF valves and the current range have to be
defined. Via handset it is adjustable in a big range, but the shunts can be
adapted to every types of valves (minimum current 200 mA, maximum current up
to 2 A).

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3 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
4These are information useful for anyone is working on the installation, or a
deeper examination of the content
UThese are Warning boxes, they describe:
- operations that can lead to a failure of the electronic device or can be
dangerous or harmful for the operator;
- items which are important to guarantee system performance and safety
3.1 Material overview
Before to start it is necessary to have the required material for a correct
installation. Otherwise a wrong choice of cables or other parts could lead to
failures/ misbehaviour/ bad performances.
3.1.1 Connection cables
For the auxiliary connections, use cables of 0.5 mm² section.
For the valves connections, use cables of 0.75 mm² section.
3.1.2 Fuses
- Use a 6.3 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.
3.2 Installation of the hardware
UBefore 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.
UDo 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.

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3.2.1 Wirings: CAN connections and possible interferences
4CAN 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.
UWrong 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
R
Can Bus
Power cables

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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.
UCorrect 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).
UCorrect 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
1Module
2
Module
3
R
R
Can Bus
Power cables
Center of the Ground connection
Module
1Module
2
Module
3
R
R
Can Bus
Power cables

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4Can 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).
3.2.2 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.
UA 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”.
3.2.3 Insulation of truck frame
UAs stated by EN-1175 “Safety of machinery – Industrial truck”, chapter 5.7,
“there shall be no electrical connection to the truck frame”. So the truck
frame has to be isolated from any electrical potential of the truck power
line.
3.3 Protection and safety features
3.3.1 Protection features
- Battery polarity inversion
It is necessary to fit a MAIN CONTACTOR to protect the MHYRIO against
reverse battery polarity and for safety reasons.
- 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 IP64.

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3.3.2 Safety Features
UZAPI controllers are designed according to the prEN954-1 specifications for
safety related parts of control system and to UNI EN1175-1 norm.
UThe safety of the machine is strongly related to installation; length, layout
and screening of electrical connections have to be carefully designed.
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.
On the connection pins A13 and B3 is output a positive coming from the valves
positive voltage but controlled with an electronic high-side switch. This positive
can be used to feed one or more valves involved in safety problems. In this way
MHYRIO FLASH opens not only the negative side of the valve coil, but also the
positive one.
The positive switch is tested by the microprocessor at every key switching on, by
feedbacking this output voltage to the µC A/D converter.
Furthermore, it is possible to input a positive for valves, independent by the
Mhyrio Flash supply, to input B6. It is strongly suggested that this positive
is cut by a device controller by another intelligent module, which is thus
able to open the valves positive in case of Mhyrio Flash failures or
malfunctioning.
Thus the more safe solution is:
- PEV supplied to B6, controlled by another intelligent module.
- Positive to group 1 valves (lifting-lowering), taken by outputs A13 and
B3.
3.4 EMC
UEMC 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 responsibility 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.

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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
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

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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
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.

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4 OPERATIONAL FEATURES
Mhyrio Flash has been designed to work on a CAN-BUS system. So, it follows
the commands received by CAN communication and broadcast the input status
and the encoder counting on the CAN.
The 8 proportional valves are separated in 4 groups used for 4 different
functions. Only one valve of the group can be active.
It is possible to activate more function at the same time. These can be:
- function 1-2-3
- function 1-2-4
3 and 4 cannot be activate at the same time.
FUNCTION1 is related to EVP1 and 2 (outputs G8, G7); typically this
function is lifting-lowering.
FUNCTION2 is related to EVP3 and 4 (outputs G6, G5); typically this
function is reach in/out.
FUNCTION3 is related to EVP5 and 6 (outputs G4, G3); typically this
function is tilting fw/rev.
FUNCTION4 is related to EVP7 and 8 (outputs G2, G1); typically this
function is shifting right/left.

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5 DESCRIPTION OF THE CONNECTORS
5.1 Connector CNA: ZAPI Minifit 22 poles
A1 I2 Digital Input N° 2
A2 I3 Digital Input N° 3
A3 I4 Digital Input N° 4
A4 I5 Digital Input N° 5
A5 I6 Digital Input N° 6
A6 PEV Positive supply of digital input devices
A7 I7 Digital Input N° 7
A8 OPT I8 Digital Input N° 8
A9 GND Negative supply
A10 CANH CAN high signal
A11 CANT2 CAN high signal output
A12 I1 Digital Input N°1
A13 PEVS Positive of electrovalves (safety)
A14 PEV Positive supply of digital input devices
A15 PEV Positive supply of digital input devices
A16 PEV Positive supply of digital input devices
A17 PEV Positive supply of digital input devices
A18 GND Negative supply
A19 GND Negative supply
A20 GND Negative supply
A21 GND Negative supply
A22 CANT1/CANL CAN low signal output/CAN low signal
5.2 Connector CNB: ZAPI Minifit 6 poles
B1 CANH CAN high signal
B2 KEY Key input
B3 PEVS Positive of electrovalves (safety)
B4 CANL CAN low signal
B5 -BATT Negative supply
B6 PAUX Positive supply for electrovalves
5.3 Connector CNC: ZAPI Minifit 6 poles
C1 AN1 Analog input N°1
C2 GND Negative supply

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C3 GND Negative supply
C4 AN2 Analog input N°2
C5 +12 +12V supply
C6 +12 +12V supply
5.4 Connector CND: ZAPI Minifit 4 poles
D1 GND Encoder negative supply
D2 A Encoder phase A input
D3 +12 Encoder positive supply
D4 B Encoder phase B input
5.5 Connector CNE: ZAPI Minifit 8 poles
E1 PCLRXD Serial communication interface
E2 NCLRXD Serial communication interface
E3 PCLTXD Serial communication interface
E4 NCLTXD Serial communication interface
E5 GND Negative supply
E6 +12 +12V supply
E7 BOOT Flash memory bootstrap
E8 GND Flash memory bootstrap
5.6 Connector CNF: ZAPI Minifit 10 poles
F1 R Resistance
F2 NEV3 Negative of ON/OFF electrovalve N°3
F3 NEV2 Negative of ON/OFF electrovalve N°2
F4 NEV1 Negative of ON/OFF electrovalve N°1
F5 PEV Positive of ON/OFF electrovalve N°3
F6 Z Zero
F7 AS1 Analog select #1
F8 AS2 Analog select #2
F9 PEV Positive of ON/OFF electrovalve N°1
F10 PEV Positive of ON/OFF electrovalve N°2
AS1 and AS2 select the software versions when more than one Mhyrio is
installed on the same truck. There are 9 possibilities:
Z................................. OPEN
Z.........................................R
Z......................................... Z
OPEN......................... OPEN
OPEN.................................R

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OPEN.................................Z
R.................................OPEN
R.........................................R
R.........................................Z
5.7 Connector CNG: ZAPI Minifit 16 poles
G1 NEV8 Negative of the proportional electrovalve N°8
G2 NEV7 Negative of the proportional electrovalve N°7
G3 NEV6 Negative of the proportional electrovalve N°6
G4 NEV5 Negative of the proportional electrovalve N°5
G5 NEVP4 Negative of the proportional electrovalve N°4
G6 NEVP3 Negative of the proportional electrovalve N°3
G7 NEVP2 Negative of the proportional electrovalve N°2
G8 NEVP1 Negative of the proportional electrovalve N°1
G9 PEV Positive of the proportional electrovalve N°6
G10 PEV Positive of the proportional electrovalve N°2
G11 PEV Positive of the proportional electrovalve N°3
G12 PEV Positive of the proportional electrovalve N°8
G13 PEV Positive of the proportional electrovalve N°5
G14 PEV Positive of the proportional electrovalve N°1
G15 PEV Positive of the proportional electrovalve N°7
G16 PEV Positive of the proportional electrovalve N°4

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6 DRAWINGS
6.1 Mechanical drawing

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6.2 Functional drawing

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7 PROGRAMMING & ADJUSTMENTS USING
DIGITAL CONSOLE
7.1 Adjustments via console
Adjustment of Parameters and changes to the controller’s configuration are made
using the Digital Console. Mhyrio Flash has not an external connector for console
connection. The Console must be connected to the console connector of another
ZAPI product that communicates with MHYRIO FLASH via CAN-BUS line.
UPay attention to the polarity of the Console Connector when connecting to
the controller. The bevel on the connector should be uppermost.
7.2 Description of console and connection
Digital consoles used to communicate with MHYRIO FLASH controllers must be
fitted with EPROM CK ULTRA, minimum “Release Number 3.06”.