Zapi EPS-AC0 Manuale utente
ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
EN
User Manual
EPS-AC0
Page - 2/95 AEMZP0BA - EPS-AC0 - User Manual
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.
AEMZP0BA - EPS-AC0 - User Manual Page - 3/95
Contents
1INTRODUCTION...................................................................................................................6
2SPECIFICATION...................................................................................................................7
2.1 Technical specifications .............................................................................................7
2.2 Block diagram.............................................................................................................7
2.3 Electrical specifications ..............................................................................................7
2.4 Mechanical specifications...........................................................................................8
2.4.1 Basic release................................................................................................8
3FUNCTIONS OF THE EPS-AC0...........................................................................................9
3.1 Manual Mode Steering ...............................................................................................9
3.2 Automatic Centering.................................................................................................10
3.3 Operational features.................................................................................................11
3.4 Diagnosis..................................................................................................................11
4SYSTEM COMPONENTS...................................................................................................12
4.1 Steering Motor..........................................................................................................12
4.2 Gear Box and total reduction ratio............................................................................12
4.3 Eps-ac0 controller ....................................................................................................12
4.3.1 Eps-ac0 PCB..............................................................................................13
4.4 Sensor in the steering handle...................................................................................14
4.4.1 Stepper motor.............................................................................................14
4.4.2 Twin pot......................................................................................................14
4.5 Feedback sensors....................................................................................................15
4.5.1 Encoder in the motor shaft and a Feedback Potentiometer.......................15
4.5.2 Encoder in the motor shaft and one (two) toggle switch(es) ......................17
4.5.3 Feedback Encoder .....................................................................................18
5AUTC MODE.......................................................................................................................21
6CONNECTING DIAGRAMS................................................................................................22
6.1 Power Connecting Diagram .....................................................................................22
6.2 EPS-AC0 Stepper Motor diagram ............................................................................23
6.3 EPS-AC0 Twin pot diagram......................................................................................24
7CONNECTIONS: SUGGESTIONS AND CAUTIONS.........................................................25
7.1 Stepper Motor connections ......................................................................................25
7.2 Twin pot connections................................................................................................25
7.3 Encoder connections................................................................................................25
7.4 Feedback pot connections .......................................................................................25
7.5 Digital Inputs connections ........................................................................................26
7.6 Safety contacts.........................................................................................................27
7.7 Motor thermal sensor connections...........................................................................27
8INSTALLATION: SUGGESTIONS AND CAUTIONS.........................................................28
8.1 Thermal consideration..............................................................................................28
8.1.1 Controller with Base Plate..........................................................................28
8.1.2 Controller with finned Heatsink...................................................................28
8.2 General suggestion ..................................................................................................29
8.3 Connection cables....................................................................................................29
8.4 Fuses........................................................................................................................30
8.5 Contactors................................................................................................................30
8.6 Installation of a CAN Communication System..........................................................31
8.7 Wiring: I/O connections ............................................................................................33
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8.8 Safety features .........................................................................................................34
8.9 EMC .........................................................................................................................34
8.9.1 Emission.....................................................................................................35
8.9.2 Electromagnetic Immunity ..........................................................................35
8.9.3 ESD............................................................................................................35
8.10 Fighting the dither.....................................................................................................36
9DESCRIPTION OF THE CONNECTORS ...........................................................................38
9.1 Connectors of the logic.............................................................................................39
9.1.1 CNA connector...........................................................................................39
9.1.2 CNB connector...........................................................................................39
9.1.3 CNC connector...........................................................................................40
9.2 Description of power connections ............................................................................41
10 INSTALLATION PROCEDURE ..........................................................................................42
10.1 Twin Pot with Encoder and Feedback pot: one shot installation procedure.............42
10.2 Twin Pot with Encoder, Straight Ahead Switch and Feedback pot: one shot installation
procedure.................................................................................................................43
10.3 Stepper Motor with Encoder and Feedback pot: one shot installation procedure....45
10.4 Stepper Motor with Encoder and Toggle Switch(es): one shot installation procedure46
11 SETTING THE EPS-AC0 ....................................................................................................49
11.1 Complete set-up description.....................................................................................49
11.1.1 Stepper Motor only.....................................................................................49
11.1.2 Stepper Motor & AUTC...............................................................................49
11.1.3 RTC (Twin Pot) only...................................................................................49
11.1.4 RTC & AUTC..............................................................................................50
11.2 Quick set-up .............................................................................................................50
11.2.1 Stepper Motor only.....................................................................................50
11.2.2 Stepper Motor & AUTC...............................................................................51
11.2.3 RTC only or RTC & AUTC..........................................................................51
12 PROGRAMMAING & ADJUSTMENTS USING DIGITAL CONSOLE................................52
12.1 Adjustments via console...........................................................................................52
12.2 Description of console (hand set) & connection.......................................................52
12.3 Description of standard console menu.....................................................................53
12.3.1 Stepper motor with Encoder and Feedback pot.........................................54
12.3.2 RTC with Encoder and Feedback pot.........................................................55
12.3.3 Stepper motor with Encoder and Toggle switch(es)...................................56
12.4 Function configuration..............................................................................................57
12.4.1 Config menu “SET OPTIONS” functions list...............................................58
12.4.2 Config menu “ADJUSTMENTS” functions list ............................................62
12.4.3 Config menu “SET MODEL” functions list..................................................65
12.4.4 Main menu “PARAMETER CHANGE” functions list...................................68
12.4.5 Zapi menu “HARDWARE SETTINGS” functions list ..................................75
12.4.6 Zapi menu “SPECIAL ADJUSTMENT” functions list..................................76
12.4.7 Main menu “TESTER” functions list ...........................................................78
13 OTHER FUNCTIONS..........................................................................................................82
13.1 Acquiring the Motor resistance.................................................................................82
13.2 Alignment at the rest position...................................................................................82
13.3 Straight ahead steering numbness...........................................................................82
13.4 Special Debugging and Troubleshooting system.....................................................83
14 EPS-AC0 ALARMS LIST....................................................................................................84
AEMZP0BA - EPS-AC0 - User Manual Page - 5/95
14.1 Main menu “ALARMS” list........................................................................................84
14.1.1 One Blink Alarms........................................................................................84
14.1.2 Two Blinks Alarms......................................................................................86
14.1.3 Three Blinks Alarms ...................................................................................87
14.1.4 Four Blinks Alarms .....................................................................................90
14.1.5 Five Blinks Alarms......................................................................................91
14.1.6 Six Blinks Alarms........................................................................................91
14.1.7 Thirty-two Blinks Alarms.............................................................................92
14.1.8 No Blink Alarms (Warning).........................................................................92
14.2 CAN BUS “ALARMS” List.........................................................................................93
15 RECOMMENDED SPARE PARTS.....................................................................................94
16 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................95
16.1 Testing the faulty detection circuitry.........................................................................95
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGNS
PROJECT MANAGER MI
TECHNICAL ELECTRONIC
MANAGER VISA PP
SALES MANAGER VISA PN
Publication N°: AEMZP0BA
Edition: May 2006
Page - 6/95 AEMZP0BA - EPS-AC0 - User Manual
1 INTRODUCTION
This equipment (Eps-ac0: AC0 Electrical Power Steering) may perform two steer by
wire functions on a truck:
1) manually controlled power steering
2) automatic centering (AUTC).
Manually controlled steering may use either a stepper motor (used as a
tachogenerator) or a twin pot fixed to the steering wheel.
Feedback sensors are mandatory to close the loop when an automatic function is
required (Automatic Centering).
Feedback sensors are mandatory to close the loop in manual mode if a twin pot is
mounted on the steering wheel.
Feedback sensors are strongly suggested (to improve safety) in manual mode if a
stepper motor is mounted on the steering wheel (open loop).
The feedback sensor may be an incremental encoder on the steering motor shaft in
combination with one straight-ahead switch. A second switch may be adopted,
together with the first one, in the 90 degrees position to improve safety. Besides a
feedback potentiometer may be chosen in alternative to the straight-ahead switch.
The eps-ac0 runs an inexpensive, robust and maintenance free three phases
AC induction motor. Also, our patented system makes possible to use a very low-
resolution encoder (4 pulses/rev are more than enough) mounted on the
steering motor shaft.
The on board CAN interface makes the communication exchange between our
eps-ac0 and other units in the truck rapid and simple. Via CAN it is possible to
enhance the steering performances with additional functions like: steer sensitivity
changes with the traction speed, traction speed modulation vs. the steered angle,
via CAN automatic centering request and so on.
Configuration options, steering adjustment, measurement functions, and
troubleshooting operations are integrally supported by the ZAPI hand held
controller equipped with Eprom release number CKULTRA ZP3.01 or subsequent.
Having two microprocessors provides improved safety and operation. The first
microprocessor performs operations and a second one executes supervisor
functions. Both the aboard microprocessors are CAN BUS connected, as
consequence the eps-ac0 may receive a remote steering command directly via
CAN fulfilling the norm (the redundant check of the steering command
complies with the Category #3 requirement).
The microprocessors combined with the ZAPI hand held controller make servicing
easy and direct, reducing adjustment and troubleshooting time. Increased steering
motor performance and reduced noise levels are achieved by using MOSFET
technology.
The reference SW release for this manual is ZP0.70.
AEMZP0BA - EPS-AC0 - User Manual Page - 7/95
2 SPECIFICATION
2.1 Technical specifications
Steering controller for AC asynchronous 3-phase motors
Digital Control using Two Microprocessors
Can-Bus interface
Both microprocessors Can Bus connected
Encoder Interface
Stepper Motor or Twin Pot Interface
Analog Feedback pot interface (1024 steps resolution)
Analog KTY84-130 thermal sensor input
Analog input with 1024 steps resolution (one input)
Analog input with 4096 steps resolution (one input)
Two digital inputs
Double Safety Relay inside
Operating frequency:.............................................8 kHz with center aligned PWM
External temperature range:.............................................................-30 °C ÷ 40 °C
Maximum inverter temperature:......................................................................75 °C
Environment protection:....................................................................................IP54
2.2 Block diagram
Figure 2-1
2.3 Electrical specifications
Battery Voltage:.......................................................................................24 V-36 V
Maximum current (24 V-36 V):..................................................... 50 A (RMS) for 2'
Logic Supply current:..............................................................max 200 mA @ 24 V
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Minimum Input (key) Supply Voltage after start-up:..........................................12 V
2.4 Mechanical specifications
2.4.1 Basic release
It has Molex Minifit connector with international protection IP54.
EPS-AC0
Figure 2–2
AEMZP0BA - EPS-AC0 - User Manual Page - 9/95
3 FUNCTIONS OF THE EPS-AC0
The eps-ac0 controls a steer system for warehouse trucks. It executes the following
functions:
1) Manual mode steering
2) Automatic Centering.
3.1 Manual Mode Steering
Manual mode steering requires a command sensor in the hand wheel. The hand
wheel may be of two types:
1) Multiturn steering wheel without end-strokes.
2) Handlebar, tiller or joy-stick with end-strokes to limit the angle.
With a Multiturn steering wheel, the sensor in the hand-wheel shall be a stepper
motor used as a tacho-generator (see Figure 3-1). Then the control will turn the
steering motor moving at a speed proportional to the stepper motor speed (Open
loop Mode).
Stepper Motor
Figure 3-1
With a Handlebar (tiller or joy-stick), the sensor in the hand-wheel will be a twin pot
(see Figure 3-2 below). Then the system works as a position control loop with a rigid
correspondence between the angle of the handlebar and the angle of the steered
wheel (Closed Loop Mode). In this case a feedback sensor on the steered wheel is
mandatory.
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Twin Pot
Figure 3–2
The same controller may work either with the stepper motor or the twin pot without
hardware modification. It is just enough to set the SYSTEM CONFIG to the correct
value (see 12.4.3.1).
3.2 Automatic Centering
Automatic Centering turns the steered wheel straight ahead to keep the steer
aligned meanwhile travelling inside an aisle between rails (see Figure 3-3).
Figure 3–3
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