Zapi EPS-ACW User manual

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel [phone] (r.a.) – Fax [phone]
e-mail: [e-mail] – web: www.zapispa.it
EN
User Manual
EPS-ACW
REACH
TRUCK
Publication N°: AF9ZP0BA
Edition: October 2014

Page - 2/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
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
1INTRODUCTION ...................................................................................................................5
2FEATURES............................................................................................................................6
3MECHANICAL SPECIFICATIONS........................................................................................7
4MECHANICAL DRAWING ....................................................................................................8
5MOTOR AND GEAR BOX.....................................................................................................9
6ELECTRICAL SPECIFICATIONS.......................................................................................10
7BLOCKS DIAGRAM............................................................................................................11
7.1Speed Control Mode (Open Loop)............................................................................11
7.2Position Control Mode (Closed Loop).......................................................................12
7.3Steer Assist Mode (Torque Assisted).......................................................................12
8FUNCTIONS OF THE EPS-ACW........................................................................................13
8.1Manual Mode Steering..............................................................................................13
9SYSTEM COMPONENTS ...................................................................................................14
9.1Steering Motor..........................................................................................................14
9.2Gear Box and total reduction ratio............................................................................14
9.3EpsacW controller.....................................................................................................14
9.4Sensor in the steering wheel ....................................................................................15
9.4.1Stepper motor.............................................................................................15
9.5Feedback sensors ....................................................................................................
15
9.5.1Prox switches and Cam: mounting specification.........................................16
10CONNECTING DRAWING ..................................................................................................22
10.1Connector assignment for a configuration with 1ENC, 2SWs & 2CANs...................23
11INSTALLATION PROCEDURE...........................................................................................24
11.1One shot installation procedure for an arrangement without mechanical limitation..24
12SETTING THE EPS-ACW ...................................................................................................26
12.1Complete set-up description.....................................................................................26
12.1.1Manual mode with the Stepper Motor.........................................................26
12.2Quick set-up..............................................................................................................26
12.2.1Stepper Motor without mechanical angle limitation.....................................26
12.2.2Stepper Motor with mechanical angle limitation..........................................27
12.3Sectors vs. Cam position and switches configuration...............................................27
12.3.1Sectors when ENC SPEED is positive in CounterClockWise (CCW)
direction ......................................................................................................28
12.3.2Sectors when ENC SPEED is positive in ClockWise (CW) direction..........29
12.4AUX FUNCTION 11 manual setting..........................................................................29
12.5PULSE IN 180 DEG manual setting .........................................................................30
12.6Autoteaching.............................................................................................................31
13PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................33
13.1Adjustments via console...........................................................................................33
13.2Description of console (hand set) & connection .......................................................33
13.3Description of standard console menu .....................................................................34
13.3.1Settings in Stepper motor with Encoder and Two Toggles Switches..........35
13.3.2Config menu “SET OPTIONS” functions list...............................................36
13.3.3Config menu “ADJUSTMENTS” functions list.............................................39
13.3.4Config menu “SET MODEL” functions list...................................................42
13.3.5Main menu “PARAMETER CHANGE” functions list ...................................44
13.3.6Zapi menu “HARDWARE SETTINGS” functions list...................................47

Page - 4/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
13.3.7Zapi menu “SPECIAL ADJUSTMENT” functions list..................................50
13.3.8Main menu “TESTER” functions list ...........................................................52
14TROUBLESHOOTING........................................................................................................57
14.1STATUS #1: selfcheck of the Motor and of the Power Drives..................................57
14.2STATUS #2: selfcheck of the Encoder and Transmission .......................................59
14.3STATUS #5: measure of the insulation of the motor and battery.............................61
15EPSACW ALARMS ............................................................................................................63
15.1Stop Traction when epsacW is no longer operative.................................................63
15.2EPSACW ALARMS LIST..........................................................................................64
15.3Alarms in selfcheck ROUTINES...............................................................................77
15.4CAN BUS “ALARMS” List.........................................................................................82
16SAFETY REQUIREMENTS & RECOMMENDATIONS.......................................................84
16.1Fault exclusions........................................................................................................84
16.1.1Mechanical coupling...................................................................................84
16.1.2Straight ahead switch (SW1)......................................................................85
16.2Safety Function to stop the Traction following an epsacW alarm.............................86
16.3Vehicle Master Control (VMC) Safety Functions......................................................86
16.4Closed Loop Mode ...................................................................................................87
16.5 Safety relevant parameters .........................................................................................87
16.6 Safety relevant notes...................................................................................................88
17INSTALLATION REQUIREMENTS & RECOMMENDATIONS ..........................................89
18PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................90
18.1Testing 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.

Page - 6/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
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

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 7/90
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

Page - 8/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
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

Page - 10/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
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

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 11/90
7 BLOCKS DIAGRAM
Below is the blocks diagram of the motor control implemented in the the epsacw. It
is an Indirect Field Oriented Control but it can be turned to a sensorless motor
control (on demand).
Figure 7-1 Motor Control
There are three main steering modes that it is possible to adopt for a steer
application (and the blocks diagram of the external control loop will be one of three
according the adopted steering mode: see 7.1 - 7.2 - 7.3 below).
7.1 Speed Control Mode (Open Loop)
In a Speed Mode (Open Loop), the steering motor speed is proportional to the
speed of a tacho generator at the steering wheel. This is the one implemented
in the current application and dealt in this manual.
Figure 7.1-1 – Open Loop Mode Blocks Diagram

Page - 12/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
7.2 Position Control Mode (Closed Loop)
In a Position Control Mode (Closed Loop), steered wheel angle is one to one
matched with the steering wheel angle.
Figure 7.2–1 –Closed Loop Mode Blocks Diagram
7.3 Steer Assist Mode (Torque Assisted)
In a Steer Assist Mode (Torque Assisted), the steering motor speed is
proportional to the torque of the operator on the steering handle bar.
Figure 7.3–1 – Steer Assist Blocks Diagram

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 13/90
8 FUNCTIONS OF THE EPS-ACW
The epsacW controls the steer function of a warehouse truck in manual mode
only.
8.1 Manual Mode Steering
Manual mode steering requires a command sensor in the steering wheel. This
manual deals with an Open Loop mode steering system. Open Loop mode
consists of a speed control: the steering motor is driven to a speed proportional
to the speed of the steering wheel. So it is necessary to use a multiturn steering
wheel without any mechanical limitation (no strokes).
With a Multiturn steering wheel, the sensor in the steering-wheel shall be a
stepper motor used as a tacho-generator (see Figure 8.1-1). Then the control will
turn the steering motor moving at a speed proportional to the stepper motor
speed (Open loop Mode).
Stepper Motor
Figure 8.1-1

Page - 14/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
9 SYSTEM COMPONENTS
The integrated steering system needs the following components in order to work.
The following list describes the complete equipment.
9.1 Steering Motor
The integrated steering system includes a three phase AC induction motor
(Pn=400W @ 3000rpm) with a low resolution encoder (4pulses/rev) in the motor
shaft.
9.2 Gear Box and total reduction ratio
The steering motor is coupled to a planetary three stages IMS SP81 low noise
gear box with a 1:51 gears ratio. Standard arrangement typically uses a total
gears ratio in the range 1:200 to 1:300. So two external gears are expected to
increase the total gears ratio with a 1:4 or 1:5 factor.
9.3 EpsacW controller
It consists of a control unit working with Vbatt in the range 36 to 48V and a
maximum current limitation to 70Arms.
As the maximum torque @ Imax=70Arms is oversized for a standard application
(like a reach truck), it is possible to reduce the maximum current limitation to a
lower value (see parameter MAXIMUM CURRENT) preserving the motor from
overheating in case a fault (e.g. locking the gear box), turns the controller in its
maximum current limitation.
Figure 9.3–1

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 15/90
9.4 Sensor in the steering wheel
Only Open Loop mode (Speed control) is admitted, leading to the following
configuration:
1) No limit, multiturn steering wheel. It asks for a command device being a
stepper motor used as a tachogenerator.
9.4.1 Stepper motor
The stepper motor is used as a tachogenerator. The following part numbers
resulted suited to work with epsacW:
1) MINEBEA Type code AA23KM-K227-T20V.
2) JAPAN SERVO Type Code KH56JM2X 1269 DC12V 30 ohm.
They have the same mechanical dimensions (see Figure 9.4.1-1 below).
Obviously, the above information states only these parts are suited for the
epsacW; no reliability evaluation is given here.
Other sources are possible on request, but must be tested for approval.
Figure 9.4.1–1
9.5 Feedback sensors
The Feedback sensors arrangement to work in Open Loop Manual mode only
consists of:
1) Low resolution incremental encoder in the motor shaft (4pulses/rev)
2) Two Toggle switches in the straight ahead orientation (SW1 on CNA#12)
and 90 degrees orientation (SW2 on CNA#11) of the steered wheel.
On request and with a different part number, epsacW may work also in the
closed loop mode with two encoders in the motor shaft together with one (or two)
straight ahead toggle switch.
UThis manual deals with above configuration (one incremental encoder in
the motor shaft together with one or two toggle switches on the steered

Page - 16/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
wheel) working Open Loop mode.
Figure 9.5–1
9.5.1 Prox switches and Cam: mounting specification
Position 0 degrees below must be meant as the orientation from the pivot point of
the Drive Unit and the cam terminal closest to SW1 (with the steered wheel in the
straight ahead direction) (see figure below).
On the other side, position 180 degrees must be meant as the orientation from
the pivot point of the Drive Unit and the cam terminal far away from SW1 (with
the steered wheel in the straight ahead direction).
Span of the steered wheel angle is in the range +/-180°. Starting from 0°, and
driving the steering motor, the sign of the steered wheel angle (STEER ANGLE)
is positive in the direction with positive speed (ENC SPEED >0); it is negative in
the moving direction with negative speed (ENC SPEED <0).

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 17/90
Figure 9.5.1–1
Tolerance of the SW1 (CNA#12) mounting position:...............................0°+/-20°
Tolerance of the SW2 (CNA#11) mounting position:(SW1+90°)or(SW1-90°) +/-5°
Tolerance of the cam length (see also 9.5.1.1. below) .......................180°+/-20°
9.5.1.1 Cam length and mounting criterion
When the 90 degrees switch (SW2) is involved to limit the wheel angle (option
SW2 LIMITING to ON: see 13.3.2.9), two rules should be applied when designing
the cam shape (see figures 9.5.1.1-1 and 9.5.1.1-2):
1) Length of the cam must be the sum between max CW and max CCW
angle (e.g. if the steered wheel angle must be limited to +/-82 degrees,
the cam length should be 164degrees).
2) The cam should be mounted with an offset vs. the straight ahead switch
(SW1). This offset must be the difference between 90° - max CW (or
CCW) angle.

Page - 18/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
Figure 9.5.1.1–1
Figure 9.5.1.1–2

AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 19/90
9.5.1.2 Straight ahead toggle switch
The straight ahead toggle switch must be of NPN type (i.e. it must connect a
minus battery to CNA#12).
A possible arrangement for the straight-ahead switch (proximity switch) is shown
in Figure 9.5.1.2-1 below. The proximity switch is connected to the truck frame;
the Iron plate (Cam) rotates together with the steered wheel.
Figure 9.5.1.2-1
It is handled this way:
1) At key-on, the epsacW turns the steering motor moving in either CW or CCW
side, according to whether the output level from the straight ahead switch is
high or low (in the above sketch a proximity sensor is used as a straight
ahead switch).
2) When the falling edge on the prox switch is detected, the encoder counting is
initialized to 0 and the steered wheel is centered.
3) Then the encoder counting is continuously updated to measure the steered
wheel angle.
At key on, the Iron plate (Cam with the shape shown in the sketch), provides the
correct direction in which the epsacW must turn the steering motor in order the
falling edge on the proximity switch is detected.
Together with the straight-ahead switch, a second toggle switch is adopted to
detect when the steered wheel is in the 90 degrees limiting position. This second
toggle switch must be connected to CNA#11 and GND (minus battery).
An hardware setting AUX FUNCTION 11 (see 12.4) is used to specify the toggle
switches configuration (one or two toggle switches and their succession vs. angle
steered wheel).
Figure 9.5.1.2-2

Page - 20/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual
9.5.1.3 Feedback Encoder
One big advantage of our epsacW controller is that it can work with a cost-
effective very low-resolution encoder. It consists of a multipole magnet (4 pole
pairs) engaging two digital hall sensors leading to a resolution of 4pulses/rev.
That is more than enough for the angle measurement: in fact, with a total
reduction ratio of 1:200 and a 4 pulses/revs resolution, we have 1600 events
(encoder transitions) within 180° of the steered angle. So the angle
measurement is determined with quanta of 180/1600=0.112 degrees.
Following this statement, we have developed, together with the Zapi AC-motors-
manufacturer, a 4 pulses/rev discrete encoder. It is an external device (not
integrated in the ball bearing) mounted in the backside of the motor (see Figure
9.5.1.3-1). The advantages of this solution are both, money saving and effective
time saving in case of encoder replacement.
Figure 9.5.1.3-1
4Note: The SW must know the encoder resolution together with the poles-pair
number. The encoder resolution and the motor pole pairs (the controller can
handle), will be specified in the headline of the handset showing something like:
EPSWSM 1Q NA4.98
That means:
EPSW = EpsacW steering controller
S= Open Loop Mode (Stepper motor).
M= Master Microcontroller
X= type of sensor in the TFD
1= poles pair number
Q= 4 pulses/rev encoder
NA= SW release type Nacco
4.98= SW release number 4.98
The command configuration is specified through the first two letter after EPS in
the following list:
WS= Open Loop (Stepper Motor) for Warehouse Trucks