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