⚡ ZAPI H2B User Manual

ZAPIMOS High-Frequency Controller - Interactive Guide

Welcome to the Zapi H2B Interactive Manual

ℹ️ About This Manual This interactive manual covers the ZAPI H2B chopper controller, part of the ZAPIMOS family. Use the navigation menu to explore different sections.
⚙️ Technical Specs 🔧 Installation Guide 🔍 Troubleshooting ⚠️ Alarm Codes

Key Features of the H2B Controller

Operating Voltage

24-96V

Maximum Current

600A

Frequency

18 kHz

Protection Rating

IP54

Four Main Configurations

🔄 Regenerative Traction

Motor control with energy regeneration during braking. This configuration returns energy to the battery during deceleration.

  • Energy recovery during braking
  • 3 speed reductions
  • Rapid inversion capability
  • Programmable braking curves

➡️ Standard Traction

Basic motor control without regeneration.

  • Simple motor control
  • 3 speed reductions
  • Handle or seat microswitch input
  • Quick inversion support

⬆️ Standard Pump/Lifting

5-speed pump control for lifting applications.

  • 4 lifting speeds with compensation
  • Proportional descent control
  • Main contactor handling
  • Bypass or weakening options

⬆️➕ Pump + Hydro

4-speed pump control plus hydrodrive motor management.

  • 4 lifting speeds
  • Dedicated hydrodrive motor control
  • Programmable delay timing
  • Proportional descent valve
⚠️ Important Safety Notice Never combine SCR low-frequency choppers with H2B modules. All controllers must be from the ZAPIMOS high-frequency family.
Home / Introduction

Introduction to the ZAPIMOS Family

The ZAPIMOS chopper family represents ZAPI's advanced solution for electric vehicle control systems.

Design Philosophy

High-frequency MOS technology provides superior performance while maintaining competitive pricing. The 18 kHz switching frequency ensures smooth motor operation and high efficiency.

Real-time monitoring of all critical systems with self-diagnosis capabilities:

  • Internal logic and power circuits
  • External components (contactors, sensors)
  • Temperature and current levels
  • Battery voltage and charge status

Stored Programme Control (SPC) architecture allows:

  • User-configurable operation modes
  • Parameter adjustment without hardware changes
  • Multiple configurations in a single controller
  • Easy updates and customization

Standard communication protocol enables easy interfacing with various programming consoles and integration with external monitoring systems.

IP54-rated sealed enclosure protects against water splashes, dust, acid, and harsh industrial environments.

Home / Specifications

Technical Specifications

Voltage Ranges

Nominal Voltage Operating Range
24V 14V - 32V
36V / 40V / 48V 22V - 55V
60V / 72V / 80V 36V - 90V
96V 57V - 120V

General Specifications

Parameter Value
Switching Frequency 18 kHz
Motor Type DC wire wound series, 4-cable
Operating Temperature -30°C to +40°C
Max Body Temperature 85°C (auto-protection at 80°C)
Protection Rating IP54 (sealed enclosure)
Logic System Microprocessor-based SPC

Four Available Configurations

Mode Description Key Features
Regenerative Traction Motor control with energy regeneration Energy recovery, braking control, 3 speed reductions
Standard Traction Basic motor control Directional control, 3 speed reductions
Standard Pump 5-speed pump control 4 lift speeds + descent, proportional valve
Pump + Hydro 4-speed pump + 3rd motor Lift control + hydrodrive motor
Home / Installation

Installation Guide

⚠️ Critical Installation Requirements
  • Mount on clean, flat metal surface with thermal grease
  • Power cables: 35-50mm² cross-section
  • Battery polarity: +B = positive, -B = negative
  • Contactors must NOT have external arc suppressors
  • Disconnect controller during battery charging

Installation Steps

  1. Physical Mounting: Secure to flat metal surface with thermal compound
  2. Cable Selection: Use appropriately sized cables
  3. Contactor Installation: ≤3A coil current, no external suppressors
  4. Fuse Selection: 10A for auxiliary circuits
  5. Connector Assembly: Follow color codes and pin assignments
  6. Pre-Startup Checks: Verify all connections
⚠️ POLARITY WARNING The power stage is NOT protected against reverse polarity. Connecting the battery backwards will destroy the power stage immediately.
Home / Configuration

Configuration Overview

The H2B controller is configured using either a mini console (10-level adjustment) or digital console (full programming).

Initial Configuration Sequence

  1. Select Controller Model: Choose voltage and configuration mode
  2. Configure Options: Set operational features
  3. Set Battery Voltage: Program actual battery voltage
  4. Input Testing: Verify all wired inputs
  5. Potentiometer Calibration: Perform automatic signal acquisition
  6. Parameter Programming: Adjust operational parameters
✅ Potentiometer Auto-Calibration

The H2B features automatic potentiometer calibration that compensates for mechanical asymmetries.

Home / Diagnosis

Diagnosis & Troubleshooting

The H2B includes comprehensive diagnostic capabilities.

Real-Time Monitoring

  • Battery voltage
  • Motor current (instantaneous)
  • Motor voltage (PWM output)
  • Controller temperature
  • Potentiometer position
  • Input/Output states
  • Hour meter

Self-Diagnostic System

  1. Key-On Diagnosis: Complete system check
  2. Standby Diagnosis: Continuous monitoring
  3. Running Diagnosis: Additional checks during operation
  4. Continuous Diagnosis: Temperature and battery monitoring
Home / Alarm Codes

LED Alarm Codes

Count the number of LED blinks to identify the alarm type.

Blinks Alarm Type Description
1 Logic Anomaly EEPROM error or watchdog fault
2 Incorrect Start Wrong startup sequence
3 VMN Test Error Power stage not responding
4 Accelerator Error Accelerator voltage too high
5 Current Sensor Error Current reading fault
6 Contactor Driver Fault Short circuit on output
7 Thermal Protection Temperature >80°C
8 Contactor Won't Open Contactor stuck
9 Contactor Stuck Closed Brake/direction contactor issue
Continuous Low Battery Battery charge <10%
Steady ON Double Request Both directions requested

Common Solutions

Solution:

  1. Turn key OFF
  2. Ensure accelerator is at minimum
  3. Turn key ON
  4. Activate seat/handle microswitch
  5. Select direction then press accelerator

Solution:

  • Check accelerator is fully returned
  • Check potentiometer wiring
  • Test potentiometer resistance (500Ω to 10kΩ)
  • Re-calibrate via PROGRAM VACC

Solution:

  • Allow controller to cool
  • Check mounting surface and thermal grease
  • Verify adequate ventilation
  • Consider forced-air cooling
Home / Maintenance

Maintenance Schedule

Every 3 Months

Component Inspection/Action
Electric Contacts Check contactor wear; replace when excessive
Microswitches Verify firm contact closure
Power Cables Inspect for damage, check connections
Springs Check pedal and contactor springs
Contactor Movement Verify friction-free operation
⚠️ SAFETY WARNING

DO NOT USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER

Home / Spare Parts

Recommended Spare Parts

Part Type Specification Application
Potentiometers 5kΩ, 330° Accelerator input
Microswitches 10A, 250V Direction and function inputs
Power Fuses 425A, 500A Main battery fuse
Contactors SW Series SW 80, 180, 181, 182 Various applications
Logic Boards ZP321C (voltage-specific) Controller logic replacement
📞 Ordering Spare Parts

Contact ZAPI or your authorized distributor. Always provide controller model, serial number, and battery voltage.

© 1995 ZAPI S.p.A. - Publication 550145D

Interactive Manual Created for Reference Purposes