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AFMNA0AA – EPS-BLI HYG – User Manual

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1 INTRODUCTION

1.1 About this document

This manual provides important information about EPS BLI controller. It presents
mechanical, electrical and functional features; installation and handling of the Zapi
assembly.

This user manual refers to Zapi part number

F07267A

.

1.1.1 Manual

Acronyms

VMC (or VCM):  ........ Vehicle Master Control
TMC:  ........................ Traction Control Module
MuC: ........................ Master microcontroller
SuC: ........................ Slave microcontroller
ACIM:  ...................... AC Induction Motor
PM: .......................... Permanent Magnet
BLAC:  ...................... Brushless AC Motor
ESD: ........................ Electrostatic Discharge
EPS: ........................ E-steering controller
CPOT:  ..................... Central Zero Potentiometer (Pos./Neg.)
CNA#i:  ..................... Connector A, pin i
PWM: ....................... Pulse-Width Modulation
PL: ........................... Performance Level
ENC: ........................ Encoder
CCW: ....................... Counterclockwise
FOC:  ........................ Field Oriented Control
PDO:  ........................ Project Data Object
DUT:  ........................ Device Under Test
FMEA:  ..................... Failure Mode and Effect Analysis
PCB:  ........................ Printed Circuit Board
BOM: ....................... Bill Of Material

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Summary of Contents for EPS-BLI HYG

Page 1: ...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 User Manual EPS BLI HYG Publication AFMNA0AA...

Page 2: ...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 there...

Page 3: ...2 5 A single MC driven by the SCM supplies power rail to all the modules 13 5 SYSTEM COMPONENTS 14 5 1 Steering motor and gear box 14 5 2 E steering motor controller 14 5 3 Feedback sensors 14 5 3 1...

Page 4: ...alarm 64 11 2 Vehicle master control VMC safety functions 65 11 3 Fault exclusions 66 11 3 1 Mechanical mounting of the magnet for the steered wheel sensor 66 11 4 Safety relevant parameters 66 11 5...

Page 5: ...r VCM Vehicle Master Control TMC Traction Control Module MuC Master microcontroller SuC Slave microcontroller ACIM AC Induction Motor PM Permanent Magnet BLAC Brushless AC Motor ESD Electrostatic Disc...

Page 6: ...scharge the DC link capacitors 1 2 2 OEM s responsibility Zapi motor controllers are intended for controlling motors in electric vehicles These controllers are supplied to original equipment manufactu...

Page 7: ...ens the door to an easy and flexible customization approach Redundancy in the microcontrollers and in the sensors make possible to fulfill ISO13849 Category 3 and PLd requirements Figure 2 1 1 The mai...

Page 8: ...voltage 12 5 V Maximum battery voltage 35 V Minimum input key supply voltage after start up 12 5 V Auxiliary circuits key input fuse rating max 6 3 A Power fuse rating proposal max 40 A CAN bus commu...

Page 9: ...MNANTS A C TIPO DI MATERIALE Material type This drawing is a ZAPI s p a property Its reproduction is prohibited except for a written authorization The only allowed use is that relative to the repairs...

Page 10: ...rol for brushless AC motors Figure 4 1 Motor control 4 1 Position control In general several steering modes are possible the main being steer by wire and steering assist This manual deals with the ste...

Page 11: ...as a proper redundancy MuC and SuC in the SCM check that the error information has been transmitted over CAN bus however the correct reception and the action of leading the TCM to a safe state are not...

Page 12: ...rectly on the DC Power rail Figure 4 2 3 1 SCM directly connected to the DC power rail This choice is similar to the 4 2 2 case Pros For turning operational SCM does not need synchronization with anot...

Page 13: ...function leading to a redundant and expensive VCM architecture U Chapter 14 2 deals about this safety function to be implemented in the VCM See 4 2 1 Bringing TCM to a safe state 4 2 5 A single MC dr...

Page 14: ...unit working with a nominal battery voltage in the range 12 5 through 35 V and a maximum current of 50 Arms With a parameter see MAXIMUM CURRENT it is possible to set the maximum current limitation to...

Page 15: ...o the E steering controller This solution implies mechanical hard stops and a rigid one to one relationship between steering command position and steered wheel position tiller is always aligned with t...

Page 16: ...t the steering command will be real time adjusted according to either a Zapi basic implementation or a customer s requirement For actuating this function a current controlled friction device is requir...

Page 17: ...AFMNA0AA EPS BLI HYG User Manual Page 17 75 6 CONNECTION DRAWING Figure 10 1...

Page 18: ...attery connection A9 PCOIL Positive terminal of the TFD coil 1 3 A max A10 NCOIL Negative terminal of the TFD coil 1 3 A max A11 Digital input general purpose redundant A12 SW1 Digital input for the h...

Page 19: ...10 1 except for the PBATT connections Up to three wires 1 5 mm2 for NBATT are foreseen same for PBATT Total current rating for three 1 31 mm2 PVC wires is about 36 A Tamb 40 C Total current rating for...

Page 20: ...options FRICTION MODE see 9 2 1 Step6 Set the minimum force feedback profile via parameters SET STEER MIN SET STEER HTS SET TFD LTS SET TFD HTS see 9 2 4 Step7 Set the maximum force feedback profile v...

Page 21: ...cycle and CPOC2 is 95 duty cycle see figure 5 4 1 1 4 Save the new setting 5 Switch off the key As an alternative this self calibration procedure may be executed on a VMC demand via CAN bus and follo...

Page 22: ...N bus with the E steering motor controller E steering motor controller supports also the function to adjust and configure the steering system on a VMC demand via CAN bus and its proper object dictiona...

Page 23: ...AFMNA0AA EPS BLI HYG User Manual Page 23 75 Figure 9 2 1...

Page 24: ...Press ENTER to go into the SET OPTIONS menu The display will show the first parameter and its actual setting HOURCOUNTER RUNNING Press ROLL UP or ROLL DOWN until the desired parameter appears The dis...

Page 25: ...below are the basic Zapi implementations LEVEL 0 NO FRICTION on the steering handle LEVEL 1 FIXED FRICTION At traction speeds below SET TFD LTS friction is defined by parameters SET STEER MIN At trac...

Page 26: ...utput CNA 14 is handled and diagnosed Default option CNA 14 supplies key voltage when E steering motor controller is ok CNA 14 is opened when E steering motor controller is not ok alarmed or not opera...

Page 27: ...NU ADJUSTMENTS Press ENTER to go into the ADJUSTMENTS menu The display will show the first parameter and its actual setting ADJUSTMENT 01 LEVEL 0 Press ROLL UP or ROLL DOWN to scroll the parameters Th...

Page 28: ...djustment defines the extreme positive value of the set point Acquire it by turning the steering handle to its positive limit 5 SP ZERO DEADZONE Percentage 0 through 100 Default value is 0 This adjust...

Page 29: ...he angle difference between the home switch and the physical straight ahead position of the steered wheel 15 PULSE IN 180 DEG Pulses 0 through 32767 Default value is 32761 This adjustment defines the...

Page 30: ...lines EPSHTM 6U NAx xx 24 V 50 A 00000 Press ROLL UP SET UP simultaneously to enter CONFIG MENU The display will show SET MODEL CONFIG MENU SET MODEL Press ENTER to go into the SET MODEL menu The dis...

Page 31: ...is 6 traction master uC typically is 2 By setting CONNECTED TO 2 the hand set will be virtually connected to the traction controller 2 MODEL TYPE Number 0 through 3 Default value is 0 This setting is...

Page 32: ...how the desired parameter and its actual setting FINAL NUMB SPEED 50 Press SET UP or SET DOWN to modify the setting The display will show the new setting FINAL NUMB SPEED 60 Press OUT to exit the menu...

Page 33: ...t the demanded position 5 OFFSET CENTER CORR Degrees 128 through 127 Default value is 0 This parameter defines the offset between the center position home position of the steered wheel and the home sw...

Page 34: ...as defined by parameter NUM 2 MAXSPEED 11 NUMB 1 MAXSPEED Percentage 40 through 100 Default value is 100 When the steering error between set point and feedback is smaller than parameter NUMB 1 ANG ERR...

Page 35: ...ET TFD HTS See figure 10 2 4 4 16 SET TFD LTS Percentage 0 through 100 Default value is 12 When option FRICTION MODE is set to LEVEL 2 through 4 this parameter defines the traction speed below which t...

Page 36: ...l of the force feedback device output CNA 10 21 PERCUSSION DUTY LEVEL 0 through 9 Default value is LEVEL 9 This parameter defines the time duration of the force feedback pulse put in place when the st...

Page 37: ...position are introduced Lag and lead regulations influence the stability of the closed loop and so different settings must be empirically tried as to avoid oscillations and instability LEVEL 0 Lowest...

Page 38: ...t value is 20 A Factory adjusted This setting defines the maximum direct current in Arms 2 MAX FLUX mWb 0 mWb through 200 mWb Default value is 83 mWb This setting defines the maximum linked flux peak...

Page 39: ...l factor of the d current control Factory adjusted Figure 9 2 5 2 9 FREQMAX FOR IMAX Hertz 0 Hz through 150 Hz Default value is 125 Hz Current in the steering motor is limited to the MAXIMUM CURRENT v...

Page 40: ...rk properly ABSENT Communication on the CAN bus is ignored and inconsistent Alarm CAN BUS KO is masked 16 MAIN CONTACTOR This setting defines the configuration of the system with respect to the main c...

Page 41: ...api adjusted It qualifies the hardware 8 24 V 50 A 23 HW TYPE2 Factory Zapi adjusted This settings qualifies the hardware 128 EPS BLI 24 BOM REVISION This parameter qualifies the hardware revision of...

Page 42: ...ibits some diagnosis to aid the troubleshooting Set DEBUG OUTPUT LEVEL 15 after the troubleshooting LEVEL 0 10 Zapi reserved LEVEL 11 Disables the following alarms diagnoses are disabled FB SENSOR LOC...

Page 43: ...Y LEVEL LEVEL 0 through 3 Default value is LEVEL 3 This adjustment defines a limitation to the supervisor uC diagnoses It has been foreseen for debug activity only When releasing on the field LEVEL 3...

Page 44: ...TESTER appears The display will show TESTER MAIN MENU TESTER Press ENTER to go into the TESTER menu The display will show the first readout SET POINT ONE 0 Press ROLL UP or ROLL DOWN to scroll the re...

Page 45: ...scaled in the range 2500 mV 2500 mV corresponding to a 0 180 of the steered wheel A steered wheel angle in the range 0 90 corresponds to a FEEDBACK ENC of 2500 mV 1250 mV i e from 1250 mV to 3750 mV...

Page 46: ...ure of the motor windings Not enabled 21 INPUT GP SENS 1 ON OFF State of the first digital general purpose redundant input pin CAN 1 22 INPUT GP SENS 2 ON OFF State of the second digital general purpo...

Page 47: ...E steering controller 31 CAP VOLTAGE MIN Unit Volt Minimum DC link capacitors voltage sensed by the E steering controller 32 PMSM TEACH STAT Unit number Status of the PMSM auto teaching 33 CPU TIME F...

Page 48: ...EST bit in a PDO STATUS WORD continuously sent to the unit designated to stop the traction The job in the Zapi steering system finishes when the STOP TRACTION REQUEST has been sent After that the lift...

Page 49: ...bring the steering system to a safe state Alarms E steering motor controller alarms are organized in four groups identified by the action taken on the steering system in case of an alarm detection Gr...

Page 50: ...to 1 At least one sensor channel is broken 2 Too much friction in the transmission gears 3 A failure in the power controller 4 A failure in the motor e g a sensor bearing locked or a motor phase brok...

Page 51: ...r disconnect CNA 3 4 5 and measure the voltage in the traction controller DC link B to B posts Replace the E steering motor controller in case DC link voltage of the traction controller goes higher th...

Page 52: ...x Remedy MuC If it is repetitive check if the battery is connected to the controller Otherwise the problem can be a failure in the power three phase bridge or in the motor SuC if the contactor on the...

Page 53: ...consecutive samples Admitted output at rest is 2 2 V through 2 8 V Remedy If it is repetitive it is necessary to replace the controller 13 HIGH TEMPERATURE Alarm 0xFF3D 61 Group 3 M S Cause This alar...

Page 54: ...troller it is an indication that the VCM has opened or not closed yet the line contactor 18 WRONG SLAVE VER Alarm 0xFFD2 210 Group 0 M S Cause This alarm is raised by MuC in case the software release...

Page 55: ...roup 3 S MAIN CONTACTOR other than OPTION 1 as to keep the motor controller on Cause There are two distinct circuits two distinct shunts and two distinct current amplifiers for MuC and SuC for measuri...

Page 56: ...those the MuC is reading SuC raises this alarm in case they are mismatched Remedy If it is repetitive it reports a problem in the controller 28 SP MISMATCH Alarm 0xFFCF 207 Group 0 S Cause MuC and Su...

Page 57: ...onfirmation that a CLEAR EEPROM action was correctly performed Remedy Re cycle the key 33 DATA ACQUISITION Warning with E steering motor controller off 0xFFF5 245 Group 4 M S Cause This alarm occurs d...

Page 58: ...of the stepper motor connections In particular the resistance between CNA 8 and the minus battery with the stepper motor at rest is expected being very low close to 30 ohms 40 CAN BUS WARNING Alarm 0X...

Page 59: ...ndle Verify the abovementioned parameters see 9 2 2 46 SP END ZONE Alarm 0XFFA8 232 Group 4 M S Cause This warning occurs when the steering handle is at its limiting position one way or the other and...

Page 60: ...e battery voltage by means of a voltmeter and compare it to that sensed by the E steering see 9 2 7 BATTERY VOLTAGE If they are considerably different 10 V or more replace the controller 52 SPI ANGLE...

Page 61: ...teered wheel as expected from its mechanical installation 58 VCAP TOO LOW Alarm 0XFFE5 229 Group 0 S Cause This alarm occurs when the DC link capacitors voltage is below 11 V longer than 500 ms Remedy...

Page 62: ...he SuC and verify which is the root problem 63 SLV STOP TRAC WR Alarm 0XFFED 237 Group 3 M Cause This alarm occurs when MuC detects SuC has stopped the traction because of some anomaly Remedy Re cycle...

Page 63: ...CONTROLLER MISM 254 NO SP REFRESH The alarm code of supervisor microcontroller is the following 8 WATCHDOG 217 SIN COS OFFS ACQ 13 EEPROM KO 218 CONTROLLER MISM 17 LOGIC FAILURE 3 220 MOTOR LOCKED 32...

Page 64: ...required 2 The lift truck manufacturer according its own FMEA can conclude that a fault in a component that is not redundant and not covered by the diagnosis shall lead to a loss of safety a failure...

Page 65: ...unicate on a PDO VMC E steering motor controller when the main contactor has been closed and the E steering motor controller turns Operational This function is Safety Relevant because the event with t...

Page 66: ...1 topic 7 11 4 Safety relevant parameters U Many of the parameters used in this application are safety relevant Despite of that it is a common practice the final lift truck manufacturer has its own to...

Page 67: ...nd B CONNECTIONS A live battery generates a conflict with the discharged caps rail inside the E steering motor controller a consequent spark will damage melt the pins of the connector Keep the battery...

Page 68: ...ir own cover In case whatever is the reason it is necessary to handle a Zapi electronics component without its own protection e g E steering motor controller without its cover the operator is obliged...

Page 69: ...erating system Win XP or later with at least one USB port available 2 USB to CAN Converter Suggested is IXXAT device Software can support also PEAK IFAK and KVASAR device 3 Driver for USB to CAN Conve...

Page 70: ...r Manual After the confirmation a new window appears Tick the USE IXXAT CONFIGURATION box and Select CAN bus Speed 125 kbps Then press OK The new window confirms that all previous actions were success...

Page 71: ...ation file must be set This file cfi allows the communication between the ZpCanFlasher and a particular node of the CAN bus network Select from the File drop down menu the Load ConfigFlash option All...

Page 72: ...ted successfully At this point the CAN bus communication is set Now the operator has to choose the correct software h86 file to be downloaded onto the controller typically the software to be downloade...

Page 73: ...tion must be started select from the main window Connection then Start Connection The status changes from Not connected to Connected At this point all is ready to download the software but first the m...

Page 74: ...lect from the Connection sub menu Stop Connection The Connection status will change again from Connected to Not Connected Switch off the controller The operation is finished Remember that this operati...

Page 75: ...ded in this manual Any variations or special requirements should be made after consulting a Zapi agent The supplier is not responsible for any problem that arises from wiring methods that differ from...

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