Zapi EPS-ACW Manuale utente
ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: zapi@zapispa.it – web: www.zapispa.it
EN
User Manual
EPS-ACW
REACH
TRUCK
Publication N°: AF9ZP0BA
Edition: October 2014
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Copyright © 1975-2014 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.
AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 3/90
Contents
1INTRODUCTION ...................................................................................................................5
2FEATURES............................................................................................................................6
3MECHANICAL SPECIFICATIONS........................................................................................7
4MECHANICAL DRAWING ....................................................................................................8
5MOTOR AND GEAR BOX.....................................................................................................9
6ELECTRICAL SPECIFICATIONS.......................................................................................10
7BLOCKS DIAGRAM............................................................................................................11
7.1Speed Control Mode (Open Loop)............................................................................11
7.2Position Control Mode (Closed Loop).......................................................................12
7.3Steer Assist Mode (Torque Assisted).......................................................................12
8FUNCTIONS OF THE EPS-ACW........................................................................................13
8.1Manual Mode Steering..............................................................................................13
9SYSTEM COMPONENTS ...................................................................................................14
9.1Steering Motor..........................................................................................................14
9.2Gear Box and total reduction ratio............................................................................14
9.3EpsacW controller.....................................................................................................14
9.4Sensor in the steering wheel ....................................................................................15
9.4.1Stepper motor.............................................................................................15
9.5Feedback sensors ....................................................................................................
15
9.5.1Prox switches and Cam: mounting specification.........................................16
10CONNECTING DRAWING ..................................................................................................22
10.1Connector assignment for a configuration with 1ENC, 2SWs & 2CANs...................23
11INSTALLATION PROCEDURE...........................................................................................24
11.1One shot installation procedure for an arrangement without mechanical limitation..24
12SETTING THE EPS-ACW ...................................................................................................26
12.1Complete set-up description.....................................................................................26
12.1.1Manual mode with the Stepper Motor.........................................................26
12.2Quick set-up..............................................................................................................26
12.2.1Stepper Motor without mechanical angle limitation.....................................26
12.2.2Stepper Motor with mechanical angle limitation..........................................27
12.3Sectors vs. Cam position and switches configuration...............................................27
12.3.1Sectors when ENC SPEED is positive in CounterClockWise (CCW)
direction ......................................................................................................28
12.3.2Sectors when ENC SPEED is positive in ClockWise (CW) direction..........29
12.4AUX FUNCTION 11 manual setting..........................................................................29
12.5PULSE IN 180 DEG manual setting .........................................................................30
12.6Autoteaching.............................................................................................................31
13PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................33
13.1Adjustments via console...........................................................................................33
13.2Description of console (hand set) & connection .......................................................33
13.3Description of standard console menu .....................................................................34
13.3.1Settings in Stepper motor with Encoder and Two Toggles Switches..........35
13.3.2Config menu “SET OPTIONS” functions list...............................................36
13.3.3Config menu “ADJUSTMENTS” functions list.............................................39
13.3.4Config menu “SET MODEL” functions list...................................................42
13.3.5Main menu “PARAMETER CHANGE” functions list ...................................44
13.3.6Zapi menu “HARDWARE SETTINGS” functions list...................................47
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13.3.7Zapi menu “SPECIAL ADJUSTMENT” functions list..................................50
13.3.8Main menu “TESTER” functions list ...........................................................52
14TROUBLESHOOTING........................................................................................................57
14.1STATUS #1: selfcheck of the Motor and of the Power Drives..................................57
14.2STATUS #2: selfcheck of the Encoder and Transmission .......................................59
14.3STATUS #5: measure of the insulation of the motor and battery.............................61
15EPSACW ALARMS ............................................................................................................63
15.1Stop Traction when epsacW is no longer operative.................................................63
15.2EPSACW ALARMS LIST..........................................................................................64
15.3Alarms in selfcheck ROUTINES...............................................................................77
15.4CAN BUS “ALARMS” List.........................................................................................82
16SAFETY REQUIREMENTS & RECOMMENDATIONS.......................................................84
16.1Fault exclusions........................................................................................................84
16.1.1Mechanical coupling...................................................................................84
16.1.2Straight ahead switch (SW1)......................................................................85
16.2Safety Function to stop the Traction following an epsacW alarm.............................86
16.3Vehicle Master Control (VMC) Safety Functions......................................................86
16.4Closed Loop Mode ...................................................................................................87
16.5 Safety relevant parameters .........................................................................................87
16.6 Safety relevant notes...................................................................................................88
17INSTALLATION REQUIREMENTS & RECOMMENDATIONS ..........................................89
18PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................90
18.1Testing the faulty detection circuitry.........................................................................90
APPROVAL SIGNS
COMPANY FUNCTION INIZIALS SIGN
PROJECT MANAGER
TECHNICAL ELECTRONIC
MANAGER VISA
SALES MANAGER VISA
AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 5/90
1 INTRODUCTION
Eps_acw is an electrical steering controller thought to be mounted in a “piggy
back” arrangement with its steering motor (see Figure 2.1). Main application is to
steer any kind of forklift trucks including counterbalanced trucks. It can work
steer by wire but also steer assist (on demand). The motor technology can be
standard induction motor but also brushless permanent magnet (on demand).
Integrating motor and controller minimizes the wiring, reduces the installation
time and improves reliability.
An electrical steering system saves the consumption given by the losses in the
priority valve and in the pump motor of a hydraulics steering system increasing
the efficiency of the full truck even up to 10-15%. Furthermore, it opens the door
to an easy and wide customization approach. Redundancy in the microcontroller
and in the sensors make possible to fulfil ISO13849 category # 3 and PLd
requirements. On demand, and particularly suited for closed loop application
(position control mode), the same system may be supplied with two internal
encoders in the motor.
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2 FEATURES
Steering controller for ACIM (BLAC on demand) motors
Digital Control using Two Microprocessors
2 Can-Bus interfaces
Both microprocessors Can Bus connected
#2 Analog Inputs configured as a Stepper Motor interface.
#1 PWM output (CNA#14): general purpose voltage controlled and overcurrent
protected (max 0.7A @ Vbatt<=48V).
1# PWM output (CNA#10): driver of the friction device, current controlled and
overcurrent protected (max 1.3A @ Vbatt<=48V).
#2 General purpose digital inputs with inner 3.3K pull up to 13.5Vdc.
#1 Embedded Incremental Encoder interface
#1 Embedded motor thermal sensor: analog input in the range 0 to 5Vdc
#1 Embedded analog Input: in the range 0 to 5Vdc (not used)
Operating frequency:.............................................8 kHz with center aligned PWM
External temperature range:.............................................................-30 °C ÷ 40 °C
Maximum inverter temperature:......................................................................80 °C
International protection:....................................................................................IP65
Figure 2–1
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3 MECHANICAL SPECIFICATIONS
Max Gear Box Admitted Output Torque:................................................(IMS spec)
Tightening Torque in the joint Gearbox to Truck frame:......................(IMS spec)
Tightening Torque in the joint Gearbox to Motor flange (Ref 1):.........11 +/-1 Nm
Tightening Torque in the Motor Flanges (Ref 2):…………………......11 +/- 1 Nm
Tightening Torque in the Epsacw_heatsink-Motor joint (Ref 3): .1,5 +/- 0,2 Nm
Tightening Torque in the 3_UVW_Motor_Cables-Epsacw joints:.1,2 +/- 0,2 Nm
Tightening Torque on the Epsacw_small_cover (Ref 5):………...1,5 +/- 0,2 Nm
Tightening Torque on the Motor_encoder_cover (Ref 6):………..1,5 +/- 0,2 Nm
Figure 3–1
Ref 2
Ref 1
Ref 6
Ref 5
Ref 3
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4 MECHANICAL DRAWING
Figure 4-1
AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 9/90
5 MOTOR AND GEAR BOX
Steering Motor:......................... ........400W S2 1h @ 3000rpm AC induction motor
Max motor torque @ Imax=50Aac:........................................7Nm @ Vbatt=48V
Gear Box ratio (SP81 LN):................................................................................1:50
Total gears ratio (about):............................................................................1:200
Encoder resolution*....……....……………………………....….............4 pulses/rev
Thermal sensor:.................................................................................... KTY84-130
* Note: on demand, particularly suited for closed loop applications, version with two
encoders same resolution is available too
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6 ELECTRICAL SPECIFICATIONS
Eps-acW F07198:………………………………………….……..36/48V 70Arms
Minimum Battery Voltage:…………................................…….35V @ Vbatt=48V
Maximum Battery Voltage:……………………………...……….65V @ Vbatt=48V
Maximum current (36/48 V): ................................................. 2’ (alarm after 5secs)
Logic Supply current:..............................................................max 200 mA @ 24 V
Minimum Input (key) Supply Voltage after start-up:..........................................12 V
Power Fuse Rated Data.........................................................................40A 58V
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