Zapi ZAPIMOS HP 350A - User Manual

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Summary

General Product Characteristics

Specifications

Technical details: voltages, current, frequency, temperature ranges.

Adjustment Tools

Using microswitches and potentiometers for speed control adjustments.

Performance Features

Unit performance: sensitivity, efficiency, and operating priorities.

Compensation Concept

Voltage power supply linked to load for optimal pump operation.

Protection Features

Protection against electrical issues, thermal overload, and external agents.

Thermal Considerations

Heat dissipation needs and cooling systems for the control unit.

General Notes on Use

Important operational notes and precautions for the H2P module.

Installation and Wiring

Connection Cables

Guidelines for selecting cable sizes for auxiliary and power connections.

Contactors

Advice on choosing contactors based on motor current and configuration.

Fuses

Recommendations for fuse types and ratings for circuit protection.

Logic Board Connectors

Pinout and function descriptions for logic board connectors.

Power Connectors

Pinout and function descriptions for power connectors.

Contactors Connector Description

Details of a 6-pin connector for controlling contactors.

Mechanical Drawing

Mechanical dimensions and mounting details of the chopper unit.

Parameter Configuration and Adjustment

Modifying Parameters using the Mini-Console

Steps to modify parameters like speed and compensation using the mini-console.

Programmable Console Function Description

Details console functions: model selection, programmable parameters.

Option and Chopper Configuration

Configuring model, options, and battery voltage settings.

Parameter List

Comprehensive list of adjustable parameters: acceleration, speed, compensation.

Sequence of Settings for Lifting

Step-by-step procedure for setting lifting function parameters.

System Diagnosis and Alarms

Decoding Alarms on Console

Explains alarm codes from blinking LEDs and their potential causes.

Summary

General Product Characteristics

Specifications

Technical details: voltages, current, frequency, temperature ranges.

Adjustment Tools

Using microswitches and potentiometers for speed control adjustments.

Performance Features

Unit performance: sensitivity, efficiency, and operating priorities.

Compensation Concept

Voltage power supply linked to load for optimal pump operation.

Protection Features

Protection against electrical issues, thermal overload, and external agents.

Thermal Considerations

Heat dissipation needs and cooling systems for the control unit.

General Notes on Use

Important operational notes and precautions for the H2P module.

Installation and Wiring

Connection Cables

Guidelines for selecting cable sizes for auxiliary and power connections.

Contactors

Advice on choosing contactors based on motor current and configuration.

Fuses

Recommendations for fuse types and ratings for circuit protection.

Logic Board Connectors

Pinout and function descriptions for logic board connectors.

Power Connectors

Pinout and function descriptions for power connectors.

Contactors Connector Description

Details of a 6-pin connector for controlling contactors.

Mechanical Drawing

Mechanical dimensions and mounting details of the chopper unit.

Parameter Configuration and Adjustment

Modifying Parameters using the Mini-Console

Steps to modify parameters like speed and compensation using the mini-console.

Programmable Console Function Description

Details console functions: model selection, programmable parameters.

Option and Chopper Configuration

Configuring model, options, and battery voltage settings.

Parameter List

Comprehensive list of adjustable parameters: acceleration, speed, compensation.

Sequence of Settings for Lifting

Step-by-step procedure for setting lifting function parameters.

System Diagnosis and Alarms

Decoding Alarms on Console

Explains alarm codes from blinking LEDs and their potential causes.

The ZAPIMOS HP 350A is a pump motor controller designed for use in electric vehicles, specifically for lifting and hydroguide applications. It is manufactured by ZAPI, an Italian company specializing in electronic, hydraulic, and industrial equipment.

Function Description

The ZAPIMOS HP 350A is a microprocessor-controlled unit that manages the pump motor's speed and operation. It can be configured for either a 5-speed pump control chopper or a 4-speed pump control chopper with an additional driver for a hydroguide contactor. The controller receives input signals from microswitches and potentiometers to determine the desired speed and direction of the pump motor. It features a compensation principle that links the pump's voltage supply to the load, allowing for efficient adjustment of motor voltage based on the current load. This design aims to optimize oil circulation and potentially reduce the cost of the hydraulic circuit.

Important Technical Specifications

Voltages: Available in multiple ranges: 24V (range A), 36/40/48V (range B), 60/72/80V (range C), and 96V (range D).
Max Current: 350 Amps.
Operating Frequency: 18KHz.
External Temperature Range: -30°C to 40°C.
Minimum Chopper Temperature: 85°C.
Motors: Compatible with series and compound motors.
Drop Voltage at 150 Amps:
- 24V: 300 mV
- 36/40/48V: 590 mV
- 60/72/80/96V: 910 mV
Potentiometer Input: In a 3-wire configuration, the CPOT (C1) input signal ranges from 0V to 10V. The resistive value of the potentiometer should be between 500 ohm and 10 kohm to avoid overloading the power supply. For 2-wire potentiometers, the ohmic value must be specified during ordering to allow for the installation of a corresponding resistor on the logic board.
Protection Features:
- Battery Inversions: The logic is intrinsically protected against polarity inversions. In lifting versions, a general contactor can be connected and managed by the logic for additional protection.
- Connection Errors: All inputs are protected against connection errors. Contactors do not accept loads greater than 3 amps and are protected against overloads and short circuits.
- Thermal Protection: If the temperature exceeds 80°C, the maximum current is reduced proportionally. The temperature should never exceed 85°C.
- Low Battery Charge: When battery charge is low, the maximum current is reduced by 50%. In lifting versions, all functions except hydrodrive (and descent) are blocked. This feature can be disabled via the console.
- External Agents: The chopper body is completely sealed, providing IP54 protection against liquid splashes.
- Accidental Startup: Requires a precise sequence of operations to start the machine. The machine will not start if operations are not carried out correctly or if the key and handle microswitch (or seat microswitch) are not activated after the request for running.
- Uncontrolled Movements: Contactors will not close if the power unit is not functioning, the accelerator does not go below the minimum stored value (increased by 2V), the logic is not perfectly functional, or a running microswitch is stuck.

Usage Features

Optimum Sensitivity: Provides excellent sensitivity at low speeds.
Self-Diagnosis: Features self-diagnosis with anomaly indication via an optional LED.
Configurability: Can be configured for traction or lifting applications from the console.
Parameter Modification: Parameters can be modified from the console, including acceleration/deceleration times, maximum current, creep speed, hydrodrive settings, and compensation levels. These adjustments can be made in real-time while the machine is running.
Hour-Meter: Includes an internal hour-meter with values displayable on the console.
Alarm Memory: Stores the last 5 tripped alarms, along with their hour-meter values and temperatures, which can be displayed on the console.
Console Tester: Allows real-time checking of main parameters such as inputs, motor voltage, and battery status.
Arc Suppression: Absence of arc on contactors and internal arc suppressor for contactor coils.
High Efficiency: Achieves high motor and battery efficiency through high-frequency commutation.
Speed Priority: Prioritizes the highest requested speed.
Potentiometer Acquisition: Supports automatic potentiometer signal acquisition, allowing adjustment of minimum and maximum useful signals. This enables the use of "reversed" potentiometric signals or normal potentiometers without a central zero.
Installation: Requires installation on a clean, unpainted flat metallic surface with thermo-conductive grease for heat dissipation. Proper wiring of cable terminals and connectors is crucial. Anti-jamming filters should be fitted on the horn, solenoid valves, and contactors not connected to the chopper.
Connection Cables: Auxiliary circuits require 0.5mm² cables. Power connections to the motor and battery require 35-5mm² cables, which should be run side-by-side and kept as short as possible for optimal performance.
Contactors: Type of contactors should be chosen based on the motor's maximum operating current and chopper configuration. Coil current must not exceed 3 amps. Internal coil suppressors mean external arc suppressors are not needed. For magnetic suppressors, polarity must be respected.
Fuses: A 10 amp fuse is recommended for auxiliary circuit protection. Power unit protection fuse values are specified in diagrams, with the maximum allowable value indicated. Protected fuses are recommended to prevent the spread of fused particles in case of blowout.
Console Usage: The programming console and mini-console allow parameter modification. The mini-console offers 10 intermediate levels for adjustments. Hooking up the console must be done with the machine off.

Maintenance Features

Electric Contacts: Check for outwear every 3 months. Replace if too strong or worn out.
Pedal Microswitch: Verify functionality with a tester every 3 months to ensure no electrical resistance between contacts and that the release has a firm sound.
Motor-Battery Power Links: Check every 3 months for excellent condition and wire cladding integrity.
Pedal and Contactor Springs: Ensure they can extend to full extension and check every 3 months.
Contactor Mechanical Movements: Check every 3 months for friction-free movement and ensure they do not stick.
Personnel and Parts: All checks should be performed by skilled personnel, and only original spare parts should be used.
Installation Compliance: Installation of the electronic controller must adhere to the diagrams in the manual. Any variations should be discussed with the supplier, as they are not responsible for problems arising from non-compliant wiring solutions.
Safety Warning: Do not use a vehicle with a faulty electronic controller.