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AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual

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chain involves the motor pinion, the gear box and the external gears. Never
this chain is allowed to loose its driving force. If the lift truck manufacturer
excludes a fault, a detailed justification shall be given in the documentation
(see ISO13849-1 topic 7).

16.1.2 Straight ahead switch (SW1)

U

Another single component is the straight ahead switch (SW1). In case it
toggles not in the straight direction, the steered wheel will be aligned at
key-on to a wrong direction. So a decision on the related risk must be taken
and eventually SW1 fault must be excluded.
In case the lift truck manufacturer considers not practicable to exclude
SW1 fault, it is possible to test the straight ahead switch at key-on with the
following handling (currently not implemented).

16.1.2.1 Diagnosis of the straight ahead switch at key-on

U

With software modifications, it could be possible to make a test at key-on
on the straight ahead switch by comparing the current detection of the
straight ahead position (at SW1 edge) with the straight ahead position
expected if the initial angle of the steered wheel at key-on is coincident with
the last angle before turning off the key (and recorded in EEPROM).
In case of a mismatch, the truck speed shall be reduced to a very low value
and the driver is called for a manoeuvre (like spinning the steering wheel
until SW2 toggles) to have confirmed SW1 toggled in the correct direction
before the truck is allowed to speed up. This handling involves more
modules in the truck and it can annoy the driver because the steered wheel
can move by itself when the key is off (and so th-driver will be asked for
spinning the steering wheel on SW2 at the next key-on). For that reason it
will be implemented only on lift truck manufacturer’s demand (Note: when
this manual has been compiled (SW NA4.98) this function was not
implemented).

16.1.2.2 Involving 90 degrees switch (SW2) for the max angle limitation

U

90 degrees switch (SW2) may be used to fight the following failure effect
analysis. If the straight ahead switch (SW1) toggles not in the straight
direction, the steered wheel will be aligned at key-on to a wrong direction.
This situation may affect the max angle limitation. For instance, in case the
straight ahead switch toggles at +30° (real angle) at key-on, the max angle
limitation via encoder counting occurs in the range +30°+/-90 degrees (i.e.
at -60° and +120°). On the +120° direction, the failure in SW1 will be
detected by the POSITION ERROR when SW2 toggles (real angle is +90°)
and the measured angle is only (+90°-30°=) + 60°; in the other direction, the
steered wheel angle will be limited to a (real) steered wheel angle of -60°

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Содержание EPS-ACW

Страница 1: ...RIAL 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 A...

Страница 2: ...ake 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 t...

Страница 3: ...2 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 Steppe...

Страница 4: ...ms 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...

Страница 5: ...ng 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...

Страница 6: ...t 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 u...

Страница 7: ...n 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_...

Страница 8: ...Page 8 90 AF9ZP0BA EPS ACW REACH TRUCK User Manual 4 MECHANICAL DRAWING Figure 4 1...

Страница 9: ...rpm 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 parti...

Страница 10: ...TIONS 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...

Страница 11: ...ree 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...

Страница 12: ...eered 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 stee...

Страница 13: ...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 mec...

Страница 14: ...ear 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...

Страница 15: ...tes 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 Fee...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ...Page 18 90 AF9ZP0BA EPS ACW REACH TRUCK User Manual Figure 9 5 1 1 1 Figure 9 5 1 1 2...

Страница 19: ...s 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...

Страница 20: ...s 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 e...

Страница 21: ...following list M Master Microcontroller S Slave Microcontroller Seventh letter specifies the type of sensor mounted in the steering wheel in Closed Loop applications void in Open Loop mode Eighth lett...

Страница 22: ...Open Loop multitun steering wheel with one encoder and two toggle switches at the Drive Unit On customer request release with two encoders in the motor is available too arrangement with two encoders...

Страница 23: ...straight ahead A13 GND NBATT logic reference A14 PCOIL2 short circuit protected positive breaker for a proportional coil Cascaded with A9 A14 is a PWMout 0 7Adc max Vbatt 48V A15 KEY IN Key input Logi...

Страница 24: ...ame for NBATT Total current rating for three 1 31mm2 PVC wires is about 36Adc Tamb 40 C Total current rating for two 1 31mm2 PVC wires is about 26 5Adc Tamb 40 C Total current rating for three pins of...

Страница 25: ...ng procedure does not get successfully ended steered wheel continues to turn and never stops In this case AUX FUNCTION 11 is inconsistent if it is set to level 2 or 5 change it to level 3 or 4 if it i...

Страница 26: ...ll up and down the adjustment STEER 0 POS DEG see 13 3 3 7 to get the truck straight travelling Step6 Save STEER 0 POS DEG and recycle the key to exit the BAD STEER 0 SET warning 12 2Quick set up This...

Страница 27: ...initial alignment a warning BAD STEER 0 SET occurs Release the stepper motor and turn the traction moving Roll up and down the adjustments STEER 0 POS DEG see 13 3 3 7 to get the truck straight travel...

Страница 28: ...Page 28 90 AF9ZP0BA EPS ACW REACH TRUCK User Manual 12 3 1 Sectors when ENC SPEED is positive in CounterClockWise CCW direction Figure 12 3 1 1 ENC SPEED 0 in CCW direction...

Страница 29: ...ning direction of the motor i e turning direction with ENC SPEED 0 in the TESTER menu if the motor turns positive speed in CounterClockwise Side refer to Figure 12 3 1 1 if the motor turns positive sp...

Страница 30: ...ected to CNA 12 0 degrees straight ahead switch SW1 and CNA 11 90 degrees toggle switch SW2 respectively 6 If they are equal both ON or both OFF the consistent pair is level 2 or 5 7 If they are diffe...

Страница 31: ...the simplest set up procedure when the correct setting for AUX FUNCTION 11 is known and the steered wheel has not mechanical limitation If AUX FUNCTION 11 is not correctly set the autoteaching sequenc...

Страница 32: ...ACH TRUCK User Manual U During AUTOTEACHING procedure the steered wheel pivots for more than 360 degrees and so take care there is not any mechanical limitation on the steered wheel side before launch...

Страница 33: ...USING DIGITAL CONSOLE 13 1Adjustments via console Adjustment of Parameters and changes to the inverter s configuration are made using the Digital Console The Console is connected to the CNC connector...

Страница 34: ...with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 The section describes the Zapi hand set functions Numbers inside the triangles correspond to the same number...

Страница 35: ...AF9ZP0BA EPS ACW REACH TRUCK User Manual Page 35 90 13 3 1 Settings in Stepper motor with Encoder and Two Toggles Switches Figure 13 3 1 1...

Страница 36: ...ill show SET MODEL CONFIG MENU SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear The Display will show SET OPTIONS CONFIG MENU SET OPTIONS Press ENTER to go in the SET OPTIONS...

Страница 37: ...CNG 6 CNG is an embedded connector 5 AUX OUTPUT 1 This option enables the handling of the output CNA 10 PRESENT ABSENT 6 AUX OUTPUT 2 This option enables the handling of the output CNA 14 PRESENT ABSE...

Страница 38: ...on to involve the 90 degrees switch SW2 to limit the max steered wheel angle When it is set to OFF the max steered wheel angle will be limited when the encoder counting reaches the 1ST 2ND ANGLE GAIN...

Страница 39: ...to enter CONFIG MENU 3 The Display will show SET MODEL CONFIG MENU SET MODEL 4 Press ROLL UP button until ADJUSTMENTS MENU appears 5 ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS 6 Press...

Страница 40: ...EACHING procedure to properly set STEER 0 POS DEG 8 PULSE IN 180DEG This adjustment shows the encoder counting corresponding to a half steered wheel revolution It is an important setting especially fo...

Страница 41: ...in the fan connected to CNA 10 13 A10 A14 PWM KHZ It sets the frequency of the PWM in the loads connected to CNA 10 and CNA 14 14 AUX VOLTAGE 1 Factory adjusted This is the self acquired offset value...

Страница 42: ...nu EPSWSM 1Q NA4 98 48V 70A 00000 2 Press Top Left Right Buttons to enter CONFIG MENU 3 The Display will show SET MODEL CONFIG MENU SET MODEL 4 Press ENTER to go into the SET MODEL MENU 5 The display...

Страница 43: ...e hand set In fact epsacw has two uCs aboard When MODEL TYPE is set to 0 the hand set is communicating with the main uC when MODEL TYPE is set to 1 the hand set is communicating with the slave uC 3 SY...

Страница 44: ...will show the first parameter SPEED LIMIT LEVEL 7 6 Press either ROLL UP and ROLL DOWN to display the next parameter 7 The names of the Parameters appear on the Display SENSITIVITY LEVEL 0 8 When des...

Страница 45: ...are performed at very slow motor speed in order they are not safety relevant functions The proportional contribution is applied to the difference between the commanded position and the real position s...

Страница 46: ...nitial stand still torque current down to zero with a delay specified with this setting 10 SPEED LIM VS TRC Percentage 10 to 100 This setting performs the Dynamic Numbness compensation it consists of...

Страница 47: ...and so the eps ac0 must be CAN Bus connected 12 MAX SPEED TRAC This parameter sets the frequency in Hertz corresponding to the 100 of the traction speed When the traction speed is higher equal than MA...

Страница 48: ...IVISOR VDSP Proportional divisor PI for the ID loop Factory adjusted 9 KI3 VDSP Integral factor PI for the ID loop Factory adjusted Figure 13 3 6 2 10 FREQMAX FOR IMAX Current in the steering motor is...

Страница 49: ...the B to the epsacw it must be set ON default value In case the epsacw is directly connected to the battery terminal B it must be set OFF 18 DEBUG MODE This adjustment enables the debug frames to be...

Страница 50: ...n automatic sequence to collect the PULSE IN 180 DEG see 13 3 3 8 and PLS IN HALF MOON see 13 3 3 9 If the collected couple is consistent PLS IN HALF MOON stays inside the window from 3 4 to 6 4 of PU...

Страница 51: ...specifies the toggle switches arrangement one or two toggle switches and their succession inside a complete steered wheel revolution see also 12 4 AUX FUNCTION 11 manual setting LEVEL 0 only one toggl...

Страница 52: ...EVEL 2 Alarms SP MISMATCH and OUPUT MISMATCH masked LEVEL 3 Alarm OUPUT MISMATCH masked LEVEL 4 SuC Fully operational U When releasing on the field SAFETY LEVEL mut be set to LEVEL 4 U Parameters in t...

Страница 53: ...e range 90 to 0 degrees With one toggle switch The steered wheel is in the 1ST sector FEEDBACK SECTOR is 1 when the configuration of the toggle switch is the one expected for a STEER ANGLE in the rang...

Страница 54: ...shaft 5 FREQUENCY Hertz value with 2 decimal digit This is the frequency applied to the steering motor 6 MOTOR VOLTAGE It is a percentage 100 means the sine waves in the motor have the maximum PWM amp...

Страница 55: ...500msec it is voltage between on the power rail capacitors battery plus ang GND when the 1st reading has been collected 1st reading provides a check up feedback on the integrity of the insulation betw...

Страница 56: ...AUX FUNCTION 11 see 13 3 6 6 and for the diagnosis of the correspondence between sector and encoder measurement POSITION ERROR alarm see 15 33 22 DISPLAY ANGLE This reading supplies the angle of the s...

Страница 57: ...alues 2 and 3 Value 2 means current injection involves terminals V and W Value 3 means current injection involves terminals U and W 2ND VALUE first short duration value about 500msec this is the curre...

Страница 58: ...r than 10Vdc It reports a failure with terminal W or terminal V of the motor interrupted SELCK 1 3 MOT WU occurs in case the linked voltages between terminal W and U Vwu and Vuw to get the expected cu...

Страница 59: ...minimum value valley detection of the encoder pulses counted in 16msec during this selfchecking routine fixed speed 25Hz 3RD VALUE second short duration value about 500msecs it is the average value of...

Страница 60: ...ncoder counting Reason could be a noise in the encoder two channels of the encode toggles in the same time no 90 degrees shift a bad encoder connection SELCK 2 4 IMAX occurs in case the 1ST value curr...

Страница 61: ...ituation reports to a probable short circuit between two motor terminals ALARMS recalling STATUS 2 1 FB SENSOR LOCKED Alarm 0xFFF1 Group 0 14 3 STATUS 5 measure of the insulation of the motor and batt...

Страница 62: ...Page 62 90 AF9ZP0BA EPS ACW REACH TRUCK User Manual Figure 14 3 1 ALARMS recalling STATUS 5 1 INIT VMN NOT OK Alarm 0xFFFB Group 0 2 CAPACITOR CHARGE Alarm 0xFF3C Group 0 Figure 14 3 2...

Страница 63: ...n the Zapi steering system finishes when the STOP TRACTION REQUEST has been sent So the Lifttruck Manufacturer is responsible for coordinating the communication between different units in the truck an...

Страница 64: ...secs and so when possible we keep the steering system operative up to 5secs traction is immediately DEMANDED TO STOP instead In the list below Node 18 CAN Consolle and 6 remote Zapi hand set is the Ma...

Страница 65: ...the controller 4 POWER FAILURE 1 Alarm 0xFF49 73 Group 2 M S Cause This alarm is raised by the MuC when the current in phase U of the motor lower than 5 4Arms 100msec long even if it is commanded high...

Страница 66: ...the voltage on every stepper motor line is a sine wave with null mean voltage Remedy Check the continuity of the stepper motor connections In particular the resistance between CNA 20 and the minus bat...

Страница 67: ...50msec long sampling time 10msec for 5 consecutive samples Admitted outputs of the current amplifiers at key on are from 2 2V to 2 8V When the diagnosis has been passed the offset of the current ampl...

Страница 68: ...back up copy with a correct checksum Remedy Make a Clear Eeprom If the problem persists replace controller 17 PARAM TRANSFER Alarm 0xFFF4 244 Group 0 M Cause Master uC and Slave uC has its own parame...

Страница 69: ...1 Mismatch on straight ahead or 90 degrees switch level SW1 on CNA 12 and SW2 on CNA 11 YY 83h 2 Mismatch in the quadrant of the MDU in the 360 degrees revolution SW1 vs SW2 vs AUX FUNCTION 11 settin...

Страница 70: ...et point torque currents have a displacement larger 3Aac and opposite sign YY 0Bh when 1 is concurring 0Dh when 2 is concurring 4 At least one between mismatches 1 and 2 is concurring Then actual and...

Страница 71: ...Bus analyzer 30 EPS NOT ALIGNED Warning 0xFFEE 238 with eps on and no drive M S Cause This warning occurs at key on in three ways 1 No edge on the straight ahead switch SW1 on CNA 12 longer than 3secs...

Страница 72: ...Remedy Some cases a if this alarm is only reported in the steering controller check the continuity of cables to CNA 3 4 5 from battery source and eps b if the cables to CNA 3 4 5 are OK measure the vo...

Страница 73: ...egrees no offset between SW1 and null angle and a cam 180 degrees long The real thresholds affected by SW1 offset and cam length are shown real time on the FEEDBACK SECTOR reading Remedy If the alarm...

Страница 74: ...A 17 and DL on CNA 20 longer than 128msec for MuC 224msec for SuC Remedy Check for a short circuit in the wires connected to CNA 20 and CNA 17 The short circuit likely is in the path from the stepper...

Страница 75: ...fy the new state redundancy in the state label This redundancy has been thought in order to avoid that a failure in the RAM memory leads to a wrong destination state for the DFAs In case the two state...

Страница 76: ...f the root of the problem needs a Can Bus analyzer 45 OUT1 STB I HIGH Warning with eps on 0xFFEC 236 M S Cause If the output of the amplifier to measure the current in the load connected to CNA 10 is...

Страница 77: ...s when the SELFCHECKING routine 1 is in progress and the check result has not been determined yet This selfchecking routine carries out a voltammeter measure of the motor resistances between phase V a...

Страница 78: ...U Alarm 0xFE03 205 M Cause This alarm occurs only as a response of the SELFCHECK 1 It occurs in case the linked voltages between terminal W and U Vwu and Vuw to get the expected current 14 7Adc are bo...

Страница 79: ...encoder and mechanical components trasmission sensor bearings gears pinion After the gathered data have been processed and an unexpected result occurred this warning message will turn in an alarm inf...

Страница 80: ...case the average encoder increment in 16msec has been detected lower than 4 motor doesn t reach commanded 25Hz speed and the average current in the motor has been detected higher than 40Arms Note at...

Страница 81: ...occurs with the steered wheel lifted up only very low Tamb could physiological affect significantly the friction in the transmission 18 SELCK 2 7 POWER Alarm 0xFE17 204 M Cause This alarm occurs only...

Страница 82: ...72 POWER FAILURE 2 73 POWER FAILURE 1 81 BAD STEER 0 SET 84 STEER SENSOR KO 85 STEER HAZARD 204 SELFCHECK 2 205 SELFCHECK 1 206 CAN BUS WARN 210 WRONG SLAVE VER 212 WRONG RAM MEMORY 213 PARAM RESTORE...

Страница 83: ...STBY I HIGH 70 HIGH CURRENT 81 BAD STEER 0 SET 84 STEER SENSOR KO 206 CAN BUS WARN 207 SP MISMATCH 208 OUTPUT MISMATCH 209 W D SYNCHRO 212 WRONG RAM MEMORY 213 PARAM RESTORE 215 CAN BUS KO M S 220 MOT...

Страница 84: ...agnosis shall not lead to a lost of safety no countermeasure required 2 The lift truck manufacturer according its own FMEA can conclude that a fault in a component that is not redundant and not covere...

Страница 85: ...se of a mismatch the truck speed shall be reduced to a very low value and the driver is called for a manoeuvre like spinning the steering wheel until SW2 toggles to have confirmed SW1 toggled in the c...

Страница 86: ...fe state Traction Control Module TMC IS NOT A ZAPI s UNIT ask to Zapi technicians for properly coordinating the communication between EpsacW and TMC 16 3 Vehicle Master Control VMC Safety Functions U...

Страница 87: ...two reasons 1 These secondary closed loop functions are executed with a very slow steering motor and only in case the steering wheel is released AND 2 As soon as the driver moves the steering wheel t...

Страница 88: ...relevant notes U The recommendations of this manual underlined with the attention symbol are safety relevant and so the user is recommended to accurately read and take care of these paragraphs and no...

Страница 89: ...AL connector will be used in the epsacW side the contacts in the counterpart must be gold plated too 2 IMPORTANT 2 DO NOT CONNECT A LIVE BATTERY TO THE EPSACW B and B CONNECTIONS A live battery genera...

Страница 90: ...al 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 information included in this Manual During...

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