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Zapi EPS-AC, Operating And Users Manual, Page: 4 / 52

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Page 4

1 SYSTEM COMPONENTS

The EPS_AC equipment consists of the following parts:

1.1 STEERING SERVO MOTOR CONTROL UNIT

It consists of a control unit using the logic marked ADCZPA0D which operates the AC
motor for both manual and automatic centering steering. There are three different
control units available:
1) A 24/36Vbatt unit provides a maximum current of 70Amps.

2) A 48Vbatt unit provides a maximum current of 70Amps.

3) A 48/80Vbatt unit provides a maximum current of 50Amps.

Summary of Contents for EPS-AC

Page 1: ...ng 14 6 1 2 Stepper motor steering 15 6 1 3 Tacho generator steering with automatic centering 16 6 1 4 Stepper motor steering with automatic centering 17 6 1 5 Interface description 18 7 One shot inst...

Page 2: ...ks alarms 46 11 1 5 Five blinks alarms 46 11 1 6 Six blinks alarms 47 12 Safety controls and their use 49 12 1 Safety controls in tacho generator and automatic centering steering 49 12 2 Safety on mot...

Page 3: ...and other controllers placed on the truck rapid and simple so potentially extending the steering performance to steer equalization for traction speed CAN management of a wire guidance application and...

Page 4: ...ntrol unit using the logic marked ADCZPA0D which operates the AC motor for both manual and automatic centering steering There are three different control units available 1 A 24 36Vbatt unit provides a...

Page 5: ...t 36V 2 30A current rating Imax 70A if the battery voltage is 48Vdc about 1KW rated power motor 3 22A current rating Imax 50A if the battery voltage is greater than 48Vdc about 1 2KW rated power motor...

Page 6: ...encoder CNA 6 16 17 and 7 directly connected to the steering motor shaft This is an option for a special application E g fine steering speed control safety improvement etc A typical manual controlled...

Page 7: ...ontroller HARDWARE SETTING 48 80 Imax 50Aac Adjustable with the hand held controller HARDWARE SETTING 2 3 COMMAND DEVICE SPECIFICATIONS 2 3 1 Tacho generator or stepper motor We supply two command dev...

Page 8: ...output shaft should be a 5K conductive plastic potentiometer A multi turn potentiometer is suggested to ensure negligible mechanical play The feedback angle potentiometer should rotate approximately e...

Page 9: ...Page 9 3 MECHANICAL SPECIFICATIONS...

Page 10: ...with the speed of the steering wheel Steering sensitivity and maximum speed are adjustable by using the ZAPI hand held controller 4 2 AUTOMATIC CENTERING Through the AUTOSEL input request it is possib...

Page 11: ...and inputs Travel demands are connected in the CNA 5 and CNA 15 positions They are used in the automatic centering to restart steering always when the truck is moving When J7 is closed between pins No...

Page 12: ...d between pins No 1 and 2 the encoder supply is 16Vdc when closed between pins No 2 and 3 the encoder supply is 5Vdc J2 This is a two pin jumper When closed the safety contact is internally grounded W...

Page 13: ...Page 13 6 POWER CONNECTION DIAGRAM Note Reversing Battery positive and negative will damage the unit...

Page 14: ...Page 14 6 1 ELECTRICAL DRAWING 6 1 1 Tacho generator steering...

Page 15: ...Page 15 6 1 2 Stepper motor steering...

Page 16: ...Page 16 6 1 3 Tacho generator steering with automatic centering...

Page 17: ...Page 17 6 1 4 Stepper motor steering with automatic centering...

Page 18: ...should be connected between connector CNB Pin 2 16Vdc supply and CNB Pin 8 device driver collector d The Eps Ac provides an internal safety contact accessible through connector CNB pin 7 and CNB pin 1...

Page 19: ...ledgment provides a max 2Amps NPN open collector driver normally GND connected that opens when an automatic centering operation is finished h The CAN connections are provided on the Pin 3 and Pin 4 CN...

Page 20: ...le feedback pot wiper and battery negative The wiper should be connected to Pin 11 of connector CNA Not leading MDU means the steering traction wheel is opposite to the driving seat When the steering...

Page 21: ...DT DL For the tacho generator application this is a tacho generator connection It is internally connected to battery negative GND For the stepper motor application this is a stepper motor line called...

Page 22: ...m conditions 9 DT QL This is a tacho generator connection or a stepper motor line called Q line 10 AUT This is the automatic request input It can be either an active level or edge detection depending...

Page 23: ...configuring Jumper J2 6 VCC Optional encoder supply When an encoder is used it may be supplied through this pin The output voltage is selected through the jumper J8 see 5 7 GND This is internally con...

Page 24: ...steer angle indicator gauge LEDs 0Vdc corresponds to the steer angle feedback pot voltage that was memorized using the ZAPI hand control for SET MAX FB POT 4 5Vdc corresponds to the steer angle feedb...

Page 25: ...ring responce when turning the steering wheel al low speed To avoid this problem increase the SENSIBILITY setting 9 2 AUTOMATIC CENTERING 1 For automatic centering operation it is necessary to adjust...

Page 26: ...ation of the Drive Unit see 10 8 12 2 Use SET MAX FB POT on the hand set to memorize the steer angle feedback pot voltage for maximum Counter Clockwise rotation of the Drive Unit see 10 8 13 3 Use the...

Page 27: ...his section describes the ZAPI hand set functions Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the figure below The orientation of the triangle...

Page 28: ...Page 28 10 1 MANUAL MODE STEERING OPTION HAND SET FUNCTION MAP...

Page 29: ...Page 29 10 2 MANUAL MODE STEERING OPTION AND AUTOMATIC CENTERING HAND SET FUNCTION MAP...

Page 30: ...mum turning speed Level 0 is for slow turning Level 9 is for fast turning Intermediate levels are for proportionally increasing speed settings Maximum MDU speed has to be regulated after SET BATTERY T...

Page 31: ...mpensate the drop on power mosfets cables and stator resistance Level 3 means no compensation This should normally be set to Level 2 as a strong compensation reduces the slip difference between the sp...

Page 32: ...was introduced to increase the resolution of the static precision To obtain precise centering increase the POS ACCURACY value If overshoot becomes evident try to lower the POS ACCURACY value Level 0...

Page 33: ...EDBACK POT Provides the MDU steer angle feedback potentiometer voltage in real time A steer angle straight ahead corresponds to about 2 5Vdc 4 TEMPERATURE Provides in real time the control unit plate...

Page 34: ...ote this reading is not the AUTOSEL Pin 10 of CNB connector level but the steering state the SW is recognizing This information coincides with the AUTOSEL input level when this input is level triggere...

Page 35: ...G MENU SET OPTIONS FUNCTIONS LIST The SET OPTIONS functions list is used for all the steering options These options modify the system configuration on user request A description of each option follows...

Page 36: ...motor control it could be a valid support to make steering control easier in a closed loop application steering position control 5 LIMIT DEVICE When this option is set ON the steer angle feedback pot...

Page 37: ...both stator resistance and current gain amplifiers acquisition procedure is enabled As soon as this adjustment is turned to a Level different from 0 a DATA ACQUISITION alarm will immediately occurs 2...

Page 38: ...constant voltage Vbatt for higher than saturation frequency values weakening region 8 OVERSAT FREQ The limit frequency for the constant voltage control law degraded flux and torque is set through this...

Page 39: ...3 button The display changes to the present feedback pot value Push the OUT 4 and the ENTER 3 button to save this new reading 13 SET MAX FB POT Is used to adjust the scaling of the clockwise 90 degre...

Page 40: ...w SET MODEL value will be acquired only after the key is switched off 10 10 MAXIMUM CURRENT ADJUSTMENT With the hand set is possible to modify the maximum current setting In order to modify it Enter t...

Page 41: ...lse every 16msec to run an interrupt service routine reading the command on the SM When this synchronisation pulse is missing for more than 100msec this alarm occur Remedy If the alarm occurs permanen...

Page 42: ...occurs permanently it is necessary to substitute the logic 9 KM CLOSED Cause It occurs when the MM has detected its safety contact closed prior to being commanded Remedy The alarm can be due to a wro...

Page 43: ...alarm occurs So we recommend the safety switch should be directly connected to the supply source plus battery or minus battery with no interposed switches If the alarm does not occur for the wrong wir...

Page 44: ...If the alarm occurs permanently it is necessary to substitute the logic 5 MAIN CONT OPEN Cause It occurs during init by Can Bus synchronisation with traction module if main contactor doesn t close Re...

Page 45: ...e problem is not due to wiring replace the stepper motor 3 Q LINE SENSOR KO Cause It occurs when the stepper motor channel on CNB pin 9 is open Remedy check the stepper motor wires and measure the ste...

Page 46: ...on the hand set display Push twice the Enter button If the alarm occurs permanently it is necessary to substitute the logic Note each time the Eprom release is changed this alarm could occur So we sug...

Page 47: ...M2 settings to try a logic substitution 2 VMN NOT OK Cause It occurs when in the initial rest state at least one of the phases of the motor voltage is high that means the voltage between D47 and D48 a...

Page 48: ...when in the rest state the Vu Vw phase motor voltage is high that means the voltage between D48 anode and gnd is not in the window Vu Vw 0 0 25Vdc see Fig 11 1 6 2 Remedy If the alarm occurs permanent...

Page 49: ...eady state motor current is less than 6Aac this alarm could unwillingly occur 12 3 SAFETY ON FAILURE OF THE STEERING TACHO GENERATOR The safety on tacho generator failure detects the presence on the l...

Page 50: ...wiper pin of the steer angle feedback pot In fact the 5K pot is connected with two resistances that confine its center point inside the two limits specified above if the pot is correctly connected see...

Page 51: ...nt that could lead to additional vehicle damage must be communicated to ZAPI technical staff or the technical sales network so that corrective action and an appropriate decision regarding continued op...

Page 52: ...STRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI COSTRUZIONE APPARECCHIATURE ELETTRONICHE OLEODINAMICHE INDUSTRIALI 4...

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