ZAPI EPS-AC manual.pdf

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Indice

Page Page Int Introroduductctioionn ... 33 1

1 System System compcomponentsonents ... 44 1.1

1.1 SteSteeriering ng serservo vo motmotor or concontrol trol uniunitt ... 44 1.2

1.2 SteSteer er angangle le posposition ition popotententiotiometmeterer... 55 1.3

1.3 OpeOperatrator or conconsolsolee... 55 1.4

1.4 AC AC stesteeriering ng serservo vo motmotoror... 55 1.5

1.5 SteSteeriering ng hanhandledle... 55 1.6

1.6 MotMotor or shashaft ft encencodeoderr ... 66 2

2 ElectricElectrical al specifspecificatioicationsns... 77 2.1

2.1 BatBattertery y volvoltagtage e ranrangege... 77 2.2

2.2 SteSteer er motmotor or curcurrenrent t ranrangege ... 77 2.3

2.3 ComCommanmand d devdevice ice spespecifcificaicatiotionsns... 77 2.3.1 Tach

2.3.1 Tacho generator or stepper motoro generator or stepper motor... 77 2.3.2

2.3.2 AutomAutomatic atic centecentering ring potenpotentiomettiometerer... 88 3

3 MeMechanical chanical specifspecificatioicationsns ... 99 4

4 System System descripdescriptiotionn ... 1010 4.1

4.1 ManManual ual stesteeriering ng witwith h tactacho-ho-gengeneraerator tor or or stesteppepper r motmotoror... 1010 4.2

4.2 AutAutomaomatic ctic cententeriering...ng... 1010 5

5 JumJumpers pers descridescriptiptionon ... 1111 6

6 Power Power connconnection ection diagramdiagram... 1313 6.1

6.1 EleElectrctricaical l dradrawinwingg ...1414 6.1.1

6.1.1 TachTacho-geno-generatoerator r steersteeringing... 1414 6.1.2 Stepper motor steering

6.1.2 Stepper motor steering... 1515 6.1.3 Tac

6.1.3 Tacho-geho-generanerator steeritor steering with automng with automatic centeatic centeringring ... 1616 6.1.4 Ste

6.1.4 Stepper motopper motor steerinr steering with automag with automatic centetic centeringring... 1717 6.1.5 Interface

6.1.5 Interface descdescriptioriptionn... 1818 7

7 One One shot instshot installation procedurallation proceduree ... 2020 8

8 DeDescriscriptiption of on of connconnectorsectors ... 2121 8.1

8.1 CNB CNB conconnecnectortor...2121 8.2

8.2 CNA CNA conconnecnectortor...2323 9

9 SeSettitting ng the the steeringsteering ... 2525 9.1

9.1 TacTacho-ho-gengeneraerator tor or or stesteppepper r motmotor or concontrotrollelled d stesteerieringng... 2525 9.2

9.2 AutAutomaomatic ctic cententeriering...ng... 2525 9.3

9.3 SteSteer er angangle le indindicaicator tor gaugaugege ... 2626 10

10 Zapi Zapi hand set hand set descdescririptptioionn ... 2727 10.

10.11 ManManual mual mode ode stesteeriering ong optiption - hon - hand and set fset funcunctiotion man mapp ... 2828 10.2

10.2 ManuaManual modl mode stee steering ering optiooption ann and aud automattomatic cic centerentering -ing -hand set function map

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 2 of 51Page 2 of 51 SIGNATURES TABLE SIGNATURES TABLE S S E E C C I I V V R R E E S S . . T T P P E E D D Y Y N N A A P P M M O O C

C MM A ANN A AGGEEMMEENNTT EEXXEECCUUTTIIVVEE

E E V V I I T T U U C C E E X X E E N N O O I I T T C C E E S S G G N N I I R R E E E E N N I I G G N N E E R R E E G G A A N N A A M M T T R R O O P P X X E E Publications N°:

Publications N°: ADCZP0A ADCZP0ABB Edition:

Edition:July 2006July 2006 10.

10.88 ConConfig menufig menu: : "Ad"Adjusjustmetmentsnts" " funfunctictions listons list... 3737 10.

10.99 ConConfig menufig menu: : "Se"Set t modmodel"el" ... 4040 10.10 Maxim

10.10 Maximum current adjustmum current adjustmentent ... 4040 11

11 EPSEPS-AC -AC alarm alarm lilistst ... 4141 11.1

11.1 AnalyAnalysis sis of of alarmalarms s dispdisplayed layed on on consoconsolele... 4141 11.1.

11.1.1 One blink ala1 One blink alarmsrms ... 4141 11.1.

11.1.2 2 Two Two blinkblinks s alarms...alarms... 4444 11.1.

11.1.3 Three 3 Three blinkblinks s alarmsalarms... 4545 11.1.

11.1.4 Four 4 Four blinkblinks alarmss alarms... 4646 11.1.

11.1.5 5 Five blinks Five blinks alarms...alarms... 4646 11.1.

11.1.6 Six blink6 Six blinks alarmss alarms ... 4747 12

12 SaSafety fety contcontrolrols s and and their their useuse ... 4949 12.

12.11 SafSafety cety contontrolrols in ts in tachacho-go-geneeneratorator and autr and automaomatic ctic cententeriering sng steeteerinringg .. 4949 12.

12.22 SafSafety on ety on motmotor or wirwires es brobroken...ken... 4949 12.

12.33 SafSafety on faety on failuilure of the stre of the steereering taing tachocho-ge-generneratoatorr ... 4949 12.3.

12.3.1 Safety on failur1 Safety on failures of the steering stepes of the steering stepper motorper motor... 4949 12.

12.44 SafSafety oety on thn the pree presensence oce of cuf currerrent when thnt when the ste steereering ing motmotor ior is at rs at restest .. 4949 12.5

12.5 SafetSafety on y on the pthe presenresence of phasce of phase vole voltage wtage when then the sthe steerineeringg motor is

motor is at at restrest... 5050 12.

12.66 SafSafety oety on pot win pot wires bres brokroken (foen (for autor automatmatic ceic cententerinring opeg operatrationion))... 5050 12.

12.77 CroCross diss diagnagnosiosis bets betweeween masn master ater and sund superpervisvisor mior microcroconcontrotrollellerr ... 5050 13

13 PeriodPeriodic ic mainmaintenanctenancee ... 5151 13.

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INTRODUCTION

This equipment enables

This equipment enables manuamanually lly controlcontrolled power steering and automaticled power steering and automatic centering.

centering. Manually controlled steering may use either a tacho-generator or, in Manually controlled steering may use either a tacho-generator or, in a later a later version, an inexpensive stepper motor fixed to the steering wheel.

version, an inexpensive stepper motor fixed to the steering wheel. The automaticThe automatic centering operation requires a potentiometer mechanically fixed on the MDU (Motor centering operation requires a potentiometer mechanically fixed on the MDU (Motor Drive Unit).

Drive Unit). The M

The MDU useDU uses an ins an inexpensive, robusexpensive, robust and mt and maintenance free three phases ACaintenance free three phases AC induction motor.

induction motor. Also,

Also, our pour pateatented system makes optional the adoption nted system makes optional the adoption of an encoder of an encoder mounted on mounted on the steering motor shaft.

the steering motor shaft.

The on board CAN interface

The on board CAN interface makes the communication exchange between our EPS makes the communication exchange between our EPS and other controllers placed on the truck

and other controllers placed on the truck rapid and simple, so potentially extending therapid and simple, so potentially extending the steering performance to steer equalization for traction speed, CAN management of steering performance to steer equalization for traction speed, CAN management of aa wire guidance application and so on.

wire guidance application and so on. Configuration opt

Configuration options, steering adjustment, meaions, steering adjustment, measuremesurement fnt functionunctions, ands, and toubleshooting

toubleshooting operaoperations tions are inteare integrally supgrally supported by ported by the ZAPthe ZAPI hand heldI hand held controller

controller equipped with Eprom release number CKULTRA ZP3.01 or later. equipped with Eprom release number CKULTRA ZP3.01 or later. Improved safety and operation are provided

Improved safety and operation are provided by having two microprocessor:by having two microprocessor: the first the first of them performs operations and a

of them performs operations and a second one executes supervisor functions.second one executes supervisor functions.

The microprocessors combined with the ZAPI hand held controller make servicing easy The microprocessors combined with the ZAPI hand held controller make servicing easy and direct, reducing adjustment and troubleshooting time. Increased steering motor and direct, reducing adjustment and troubleshooting time. Increased steering motor performance and reduced noise levels are

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 4 of 51Page 4 of 51

1 SYSTEM COMPONENTS

The EPS_AC equipment consists of the following parts: The EPS_AC equipment consists of the following parts:

1.1 STEERING SERVO MOTOR CONTROL UNIT 1.1 STEERING SERVO MOTOR CONTROL UNIT It consists of a

It consists of a control unit using the logic control unit using the logic marked ADCZPA0H which operates the ACmarked ADCZPA0H which operates the AC motor for both manual and automatic centering steering. There are three different control motor for both manual and automatic centering steering. There are three different control units available:

units available: 1)

1) A 24/A 24/36Vb36Vbatt unatt unit proit providevides a mas a maximum ximum currecurrent of 7nt of 70Amps0Amps.. 2)

2) A 48A 48Vbatt Vbatt unit unit proviprovides des a maxa maximum imum currecurrent of nt of 70Am70Amps.ps. 3)

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1.2 STEER ANGLE POSITION POTENTIOMETER 1.2 STEER ANGLE POSITION POTENTIOMETER To execute an automatic centering operation, a multiturn

To execute an automatic centering operation, a multiturn 5K potentiometer must be5K potentiometer must be mounted directly on the end of

mounted directly on the end of the output shaft of the the output shaft of the steering gear reduction box. Thissteering gear reduction box. This potentiometer measures the angle of the MDU directly. The

potentiometer measures the angle of the MDU directly. The full range of possible outputfull range of possible output is approximately 0÷5Vdc. This potentiometer also provides information for the steer is approximately 0÷5Vdc. This potentiometer also provides information for the steer angle indicator gauge mounted on the operator

angle indicator gauge mounted on the operator console.console. 1.3 OPERATOR CONSOLE 1.3 OPERATOR CONSOLE

The control unit can support the following devices typically fixed on

The control unit can support the following devices typically fixed on the operator conso-the operator conso-le.

le. 1

1)) KKeey sy swwiittcchh 2)

2) ManuaManual/autol/automatic matic centecentering selecring selection tion switcswitch (AUh (AUTOSETOSEL).L). 3)

3) A stA statatus dus devevicice (Be (BUZUZZEZER)R).. 4)

4) A sA steeteer ar anglngle ie indindicatcator or gaugauge.ge.

1.4 AC STEERING SERVO MOTOR 1.4 AC STEERING SERVO MOTOR

The steering system includes a three phase AC induction motor with a

The steering system includes a three phase AC induction motor with a maximum ratedmaximum rated power of:

power of: 1)

1) 40A cur40A current ratirent rating (Imang (Imax=70Ax=70A) if the batte) if the battery voltary voltage is 36Vge is 36Vdc or lessdc or less. (about 1. (about 1KWKW rated power motor at Vbatt=36V).

rated power motor at Vbatt=36V). 2)

2) 30A cu30A current rarrent rating (Iting (Imax=7max=70A) if th0A) if the battee battery voltry voltage is 4age is 48Vdc8Vdc. (abou. (about 1KW ratet 1KW ratedd power motor).

power motor). 3)

3) 22A cur22A current ratirent rating (Imaxng (Imax=50A) if th=50A) if the battere battery voltay voltage is greage is greater than 4ter than 48Vdc8Vdc. (about. (about 1.2KW rated power motor at

1.2KW rated power motor at Vbatt=80V).Vbatt=80V).

The gear box should be chosen so that the complete 180° MDU

The gear box should be chosen so that the complete 180° MDU rotation takes 3 to 6rotation takes 3 to 6 seconds at the maximum steer speed.

seconds at the maximum steer speed.

1.5 STEERING HANDLE 1.5 STEERING HANDLE This is a multi-turn steering handle or

This is a multi-turn steering handle or wheel attacched to a command device. There arewheel attacched to a command device. There are two option:

two option: 1)

1) tacho-generator.tacho-generator. This solution requires just a two This solution requires just a two wire connection. Thewire connection. The recommended tacho-gene

recommended tacho-generator is AIRPAX Part rator is AIRPAX Part N° 24Vdc - 9904 -120 - N° 24Vdc - 9904 -120 - 16206.16206. 2)

2) steppestepper motorr motor.. This solution requires either a six wire This solution requires either a six wire connection or an optionalconnection or an optional three wire connection. The recommended stepper motor model is Minebea type three wire connection. The recommended stepper motor model is Minebea type code

code AA23KM-K227-T20VAA23KM-K227-T20V.. This last device requ

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 6 of 51Page 6 of 51 1.6 MOTOR SHAFT ENCODER

1.6 MOTOR SHAFT ENCODER

This device is optional (not necessary). The Eps-Ac can receive an

This device is optional (not necessary). The Eps-Ac can receive an encoder (CNA #6,encoder (CNA #6, #16, #17 and #7) directly connected to the

#16, #17 and #7) directly connected to the steering motor shaft. This is an steering motor shaft. This is an option for aoption for a special application. E.g. fine steering speed control, safety

special application. E.g. fine steering speed control, safety improvement etc. A typicalimprovement etc. A typical manual controlled steering with automatic centering does not require an

manual controlled steering with automatic centering does not require an encoder; it justencoder; it just requires a feedback pot.

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2 EL

ECTR

ECTRICAL

ICAL

SPEC

IFICATIONS

2.1 BATTERY VOLTAGE RANGE 2.1 BATTERY VOLTAGE RANGE Battery voltage input ranges for different

Battery voltage input ranges for different releases of the control unit:releases of the control unit: 2 244//3366 2244--336 6 VVddcc 4 488 4488 VVddcc 4 488//8800 4488--880 0 VVddcc

2.2 STEER MOTOR CURRENT RANGE 2.2 STEER MOTOR CURRENT RANGE 2

244//3366 IImmaaxx ≤≤70Aac. Adjustable with the hand held controller (HARDWARE70Aac. Adjustable with the hand held controller (HARDWARE SETTING)

SETTING) 4

488 IImmaaxx ≤≤70Aac. Adjustable with the hand held controller (HARDWARE70Aac. Adjustable with the hand held controller (HARDWARE SETTING)

SETTING) 4

488//8800 IImmaaxx ≤≤50Aac. Adjustable with the hand held controller (HARDWARE50Aac. Adjustable with the hand held controller (HARDWARE SETTING)

SETTING)

2.3 COMMAND DEVICE SPECIFICATIONS 2.3 COMMAND DEVICE SPECIFICATIONS 2.

2.3.3.1 T1 Tacho generator or acho generator or stepper mostepper motor tor

We supply two command device solutions: Tacho-generator and Stepper motor. We supply two command device solutions: Tacho-generator and Stepper motor. Tacho-generator is to be AIRPAX 24VDC - part

Tacho-generator is to be AIRPAX 24VDC - part No. 9904-120-16206. Use of any other No. 9904-120-16206. Use of any other device may provide non-optimum performance.

device may provide non-optimum performance. Stepper motor is to be

Stepper motor is to be Minebea type code AA23KM-K227-T20V. Use of any other Minebea type code AA23KM-K227-T20V. Use of any other device may provide non-optimum performance.

device may provide non-optimum performance. Ste

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 8 of 51Page 8 of 51 Tacho generator - mechanical specification

Tacho generator - mechanical specification

2.3.2 Automatic centering potentiometer

The potentiometer fixed on the steering gear box

The potentiometer fixed on the steering gear box output shaft should be a 5Koutput shaft should be a 5K conductive plastic potentiometer. A multi-turn potentiometer is suggested to

conductive plastic potentiometer. A multi-turn potentiometer is suggested to ensureensure negligible mechanical play.

negligible mechanical play.

The feedback angle potentiometer should rotate approximately ensure 80% of its The feedback angle potentiometer should rotate approximately ensure 80% of its totaltotal travel, corresponding to 180 degrees of steering angle. The greater

travel, corresponding to 180 degrees of steering angle. The greater the travel, the better the travel, the better the resolution and accuracy.

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3 MECHANICAL

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ADCZP0AB

4 SYSTEM DESCRIPTION

4.1 MANUAL STEERING WITH TACHO-GENERATOR OR STEPPER MOTOR 4.1 MANUAL STEERING WITH TACHO-GENERATOR OR STEPPER MOTOR This option uses a tacho-generator (or a stepper motor)

This option uses a tacho-generator (or a stepper motor) attached to the steering wheelattached to the steering wheel to convert the steering wheel rotation into

to convert the steering wheel rotation into an electrical signal. The control logic sets thean electrical signal. The control logic sets the steer servo-motor in motion at a

steer servo-motor in motion at a speed that increases with the speed of the steeringspeed that increases with the speed of the steering wheel. Steering sensitivity and maximum speed are adjustable by using the

wheel. Steering sensitivity and maximum speed are adjustable by using the ZAPI handZAPI hand held controller.

held controller.

4.2 AUTOMATIC CENTERING 4.2 AUTOMATIC CENTERING Through the AUTOSEL input request it is possible to

Through the AUTOSEL input request it is possible to turn the steering state fromturn the steering state from manual mode to automatic centering. The automatic centering request should be

manual mode to automatic centering. The automatic centering request should be edgeedge or level conditioned (see option AUT INP

or level conditioned (see option AUT INP ACTIVE 10.7.7). As soon as an automaticACTIVE 10.7.7). As soon as an automatic centering request is recognized, the steering control will start

centering request is recognized, the steering control will start to automatically rotate theto automatically rotate the MDU until it is straight ahead.

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5 JUMPERS DESCRIPTION

Three are three jumpers it is

Three are three jumpers it is possible to configure.possible to configure. J7:

J7: This jumper selects the This jumper selects the active level on the traveactive level on the travel demand inputs. Travel dl demand inputs. Travel demandsemands are connected in the CNA #5 and CNA

are connected in the CNA #5 and CNA #15 positions. They are used in the#15 positions. They are used in the automatic centering to restart steering always when the truck is

automatic centering to restart steering always when the truck is moving. When J7 ismoving. When J7 is closed between pins No. 1 and 2, tr

closed between pins No. 1 and 2, travel demands are expected active low (fig. 5.1);avel demands are expected active low (fig. 5.1); when closed between pins No. 2 and 3,

when closed between pins No. 2 and 3, travel demands are expected active hightravel demands are expected active high (fig. 5.2).

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 12 of 51Page 12 of 51 J8:

J8: This jumper selects the oThis jumper selects the optional encoder suppptional encoder supply voltage. When J8 is closly voltage. When J8 is closeded between pins No. 1 and 2,

between pins No. 1 and 2, the encoder supply is 16Vdc; when closed between pinsthe encoder supply is 16Vdc; when closed between pins No. 2 and 3, the

No. 2 and 3, the encoder supply is 5Vdc.encoder supply is 5Vdc. J2:

J2: This is a two pin jumper. WheThis is a two pin jumper. When closed the safety con closed the safety contact is internally groundedntact is internally grounded.. When open the safety contact is floating

When open the safety contact is floating and should be externally polarized (seeand should be externally polarized (see 8.1).

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6 POWER CONNECTION DIAGRAM

Note: Note:

Reversing Battery positive and negative will damage the unit. Reversing Battery positive and negative will damage the unit.

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 14 of 51Page 14 of 51 6.1 ELECTRIC

6.1 ELECTRICAL AL DRAWINGDRAWING 6.1.1 Tacho-generator steering

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6.

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 16 of 51Page 16 of 51 6.

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6.1.4 Stepper motor steering with automatic centering

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 18 of 51Page 18 of 51 6.

6.1.1.5 Interface descri5 Interface descriptiptionon

a)

a) The 5K steThe 5K steer angle feer angle feedbacedback potenk potentiometiometer shouter should be rigidld be rigidly mounly mounted to the steted to the steeringering linkage with no play. The pot wiper

linkage with no play. The pot wiper is connected to Pin #11 of is connected to Pin #11 of CNA connector. TheCNA connector. The ends of the pot are connected to Pins #1 and #2 of CNA connector. This feedback pot ends of the pot are connected to Pins #1 and #2 of CNA connector. This feedback pot is necessary when either a direction gauge or the

is necessary when either a direction gauge or the automatic centering operation isautomatic centering operation is required.

required. b)

b) Pin 5 on coPin 5 on connecnnector CNA is ctor CNA is conneonnected to thcted to the FWD (drie FWD (drive unit sve unit side) traide) travel demvel demand. Piand. Pinn 15 on connector CNA is connected to REV (load wheels side) travel demand. Travel 15 on connector CNA is connected to REV (load wheels side) travel demand. Travel demands may be active high (plus battery) or

demands may be active high (plus battery) or low (minus battery). Specify the modelow (minus battery). Specify the mode you want by configuring the Jumper J7 (see 5).

you want by configuring the Jumper J7 (see 5). The tra

The travel demavel demands nds are only required to are only required to maintain the steemaintain the steering ring control control activeactive afte

after alignment when the truck is movir alignment when the truck is moving.ng. c)

c) The staThe status devtus device is an opice is an optionational extra (1l extra (12Vdc ma2Vdc max 40mA Bux 40mA Buzzer or Lzzer or Lamp) suamp) supplyipplyingng an audible or visible warning when a steering alarm

an audible or visible warning when a steering alarm occurs. It should be connectedoccurs. It should be connected between connector CNB Pin #2 (16Vdc supply) and CNB Pin #8 (device driver between connector CNB Pin #2 (16Vdc supply) and CNB Pin #8 (device driver collector).

collector). d)

d) The EpsThe Eps-Ac prov-Ac provides an inides an internaternal safety col safety contact acntact accesscessible throible through conugh connectnector CNBor CNB pin #7 and CNB pin #

pin #7 and CNB pin # 1. It should be used to 1. It should be used to stop the traction and to enable anstop the traction and to enable an electromechanica

electromechanical brake when a steering alarm l brake when a steering alarm occurs. This safety contact is closedoccurs. This safety contact is closed when the key switch is turned on. The contact opens where there

when the key switch is turned on. The contact opens where there is a steeringis a steering alarm.This safety contact is floating, that means it's

alarm.This safety contact is floating, that means it's possible to connect it either topossible to connect it either to the plus battery or to the minus battery.

the plus battery or to the minus battery. Ensure that the pin #7 is connected to anEnsure that the pin #7 is connected to an equal or high

equal or higher voltage than pin #1.er voltage than pin #1.

For safety two cascaded safety switches are internally connected between pin # 7 For safety two cascaded safety switches are internally connected between pin # 7 and pin #1. The first is

and pin #1. The first is managed by the Main processor, the second is managed bymanaged by the Main processor, the second is managed by the supervisor processor.

the supervisor processor. Note:

Note:

If the safe

If the safety swity switch itch is connected in s connected in serieseries wits with externah external swil switches (setches (seat switch,at switch, tiller swit

tiller switch or sich or similar) it's recommendemilar) it's recommended that the steed that the steering safety switchring safety switch should be directly connected to the supply sour

should be directly connected to the supply source (ce (plus battery or minusplus battery or minus batte

battery) with no ry) with no interposed switches. (interposed switches. (it shouit should be the first ld be the first the chain: see the chain: see fig.fig. 6.1.5.1).

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e)

e) The autThe automatiomatic centec centering reqring request musuest must have an NPN ot have an NPN open colpen collectolector output (sr output (see fig.ee fig. 6.1.5.2). So it should assume the model of

6.1.5.2). So it should assume the model of an open or closed switch with respect toan open or closed switch with respect to GND. External pull-up is not required.

GND. External pull-up is not required. The automatic centering request may be levelThe automatic centering request may be level or edge triggered depending on the AUT

or edge triggered depending on the AUT INP ACTIVE setting (see 10.7.7).INP ACTIVE setting (see 10.7.7).

An edge is detected if the level before or after the edge remains for at least 30msec. An edge is detected if the level before or after the edge remains for at least 30msec.

f)

f) Pin #Pin #18 of 18 of CNA cCNA conneonnector pctor providrovides 0 tes 0 to 4.5Vo 4.5Vdc oudc output ttput to cono control ttrol the stehe steering ering anglanglee indicator gauge Leds. Pin # 8

indicator gauge Leds. Pin # 8 of CNA connector provides negative to the steeringof CNA connector provides negative to the steering indicator.

indicator. g)

g) Pin #12 oPin #12 of CNA connf CNA connector (cector (centeentering ackring acknowlenowledgmendgment) provit) provides a max 2des a max 2Amps NPAmps NPNN open collector driver normally GND connected that opens when an automatic centering open collector driver normally GND connected that opens when an automatic centering operation is finished.

operation is finished. h

h)) The CAThe CAN conneN connectionctions are pros are provided ovided on the Pin #3 an the Pin #3 and Pin#nd Pin#4 CNA con4 CNA connectonector for ther for the High reference and on Pin #13 and Pin

High reference and on Pin #13 and Pin #14 for the Low reference. They are #14 for the Low reference. They are twotwo because our CAN should be externally loaded with a 120 ohms resistance to t

because our CAN should be externally loaded with a 120 ohms resistance to termi- ermi-nate the transmission line.

nate the transmission line. i)

i) The EpThe Eps_ac s_ac proviprovides ades an encon encoder inder interfacterface. It wae. It was fores foreseen seen for spefor special acial applicpplicationationss like accurate speed control or safety improvement. Normally it's not

like accurate speed control or safety improvement. Normally it's not required. Therequired. The encoder channels are connected on Pin #16 and Pin #17 of

encoder channels are connected on Pin #16 and Pin #17 of connector CNA. Theconnector CNA. The encoder supply is provided through the Pin #6 of

encoder supply is provided through the Pin #6 of connector CNA (choose the supplyconnector CNA (choose the supply you want through the jumper J8-see 5) and a

you want through the jumper J8-see 5) and a Gnd reference on the Pin #7 of Gnd reference on the Pin #7 of connector CNA (see fig. 6.1.5.3).

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ADCZP0AB

7 ONE SHOT INSTALLATION PROCEDURE

This section of the manual describes the connection procedure for t

This section of the manual describes the connection procedure for the tacho-generator,he tacho-generator, the potentiometer and the motor.

the potentiometer and the motor.

Step 1 - STEERING WHEEL (COMMAND) DEVICE CONNECTIONS Step 1 - STEERING WHEEL (COMMAND) DEVICE CONNECTIONS Connect the two wires from the tacho-generator (or t

Connect the two wires from the tacho-generator (or the two stepper motor lines) so thathe two stepper motor lines) so that clockwise rotation of the steering wheel produces an increasing (higher positive)

clockwise rotation of the steering wheel produces an increasing (higher positive) command value. This may be measured in two ways. Using the ZAPI

command value. This may be measured in two ways. Using the ZAPI hand heldhand held controller see the TESTER MENU' (see 10.6.1). The second way, (valid only controller see the TESTER MENU' (see 10.6.1). The second way, (valid only for afor a tacho-generator applica

tacho-generator application) is tion) is to use a DC voltmeter on to use a DC voltmeter on the +DT (Pin #9 of CNBthe +DT (Pin #9 of CNB connector) and the minus terminal on the

connector) and the minus terminal on the battery.battery. Step

Step 2 - STEERING ANGLE FEEDBACK 2 - STEERING ANGLE FEEDBACK POT. CONPOT. CONNECTINECTIONON a) The steer angle feedback pot. has 3 wires:

a) The steer angle feedback pot. has 3 wires: two end wires and a wiper wire. two end wires and a wiper wire. If theIf the truck has a not leading MDU (Motor

truck has a not leading MDU (Motor Drive Unit - see figure 7.1)* Drive Unit - see figure 7.1)* connect the two endconnect the two end wires to Pin #1 and #2

wires to Pin #1 and #2 of connector CNA so when the Drive Unit of connector CNA so when the Drive Unit is turned Counter-is turned Counter-Clockwise (Counter-Clockwise for a truck with a leading MDU) the value on

Clockwise (Clockwise for a truck with a leading MDU) the value on the wiper isthe wiper is increasing. This value may be measured in two ways. Use the

increasing. This value may be measured in two ways. Use the Zapi hand held controller Zapi hand held controller through the TESTER MENU' (see 10.6.3). The second way is to

through the TESTER MENU' (see 10.6.3). The second way is to use a DC voltmeter use a DC voltmeter connected to the steering angle feedback pot. wiper

connected to the steering angle feedback pot. wiper and battery negative. The wiper and battery negative. The wiper should be connected to Pin # 11

should be connected to Pin # 11 of connector CNA.of connector CNA.

*

* NNo t o t l el eaad id in g n g MMDDUU : means the steering-traction wheel is opposite to the driving seat. : means the steering-traction wheel is opposite to the driving seat. When the steering handle is turned clockwise, the MDU turns counterclockwise. When the steering handle is turned clockwise, the MDU turns counterclockwise. Leading

Leading MDMDUU : means the steering traction wheel is on the same side of the driving seat. When the steering : means the steering traction wheel is on the same side of the driving seat. When the steering handle is turned clockwise, the MDU turns clockwise too.

handle is turned clockwise, the MDU turns clockwise too.

b) Physically adjust the steering angle feedback potentiometer so with the Drive b) Physically adjust the steering angle feedback potentiometer so with the Drive UnitUnit straight ahead, the wiper voltage is 2.5Vdc. The

straight ahead, the wiper voltage is 2.5Vdc. The Zero Point for the Zero Point for the steering anglesteering angle feedback pot. can be adjusted using the ZAPI hand

feedback pot. can be adjusted using the ZAPI hand held controller. See the CONFIGheld controller. See the CONFIG MENU' (see. 10.8.1).

MENU' (see. 10.8.1).

Step 3 - STEER MOTOR CONNECTIONS Step 3 - STEER MOTOR CONNECTIONS Connect the three steering motor wires so that

Connect the three steering motor wires so that a Clockwise steering wheel movementa Clockwise steering wheel movement causes a Counter-Clockwise steer movement, for a not leading MDU truck, or a

causes a Counter-Clockwise steer movement, for a not leading MDU truck, or a Clockwise steer movement, for a leading MDU truck. If

Clockwise steer movement, for a leading MDU truck. If this operation is carried outthis operation is carried out correctly, the truck will turn

correctly, the truck will turn Clockwise when the steering wheel is moved ClockwiseClockwise when the steering wheel is moved Clockwise while the truck is travelling in

while the truck is travelling in frontal direction (with respect to the frontal direction (with respect to the driving seat).driving seat). Step 4 - LIMIT SWITCHES CONNECTION

Step 4 - LIMIT SWITCHES CONNECTION

After completing Steps 1 - 3, check that the limit switch connected to Pin #12 of After completing Steps 1 - 3, check that the limit switch connected to Pin #12 of

connector CNB stops steering in the handwheel clockwise direction. Then, check that connector CNB stops steering in the handwheel clockwise direction. Then, check that the limit switch connected to Pin

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8 DESCRIPTION OF CONNECTORS

8.1 CNB CONNECTOR 8.1 CNB CONNECTOR 1 1 NNKK11 TThhiis s iis s tthhe e seseccoonnd d ((lloowweer r ppootteennttiiaall) ) ssaaffeetty y sswwiittcch h ccoonnnneeccttiioonn..TThhe e ffiirrsstt connection is on Pin #7. If

connection is on Pin #7. If jumper J2 is closed, the Pin # jumper J2 is closed, the Pin # 1 is ground1 is ground referenced and NK1 is at ground (GND) potential. I

referenced and NK1 is at ground (GND) potential. If jumper J2 isf jumper J2 is open, NK1 is floating. (I

open, NK1 is floating. (It assumes an externally applied potential).t assumes an externally applied potential). NK1 must be connected to an equal or

NK1 must be connected to an equal or lower potential than K1 (Pinlower potential than K1 (Pin #7 of CNB).

#7 of CNB). 2

2 ++1166 OOuuttppuut t ffoor r iinntteerrnnaalllly y pprroovviiddeed d ++1166VVddc c ssttaabbiilliizzeed d ssuuppppllyy. . It It mmaay y bbee used for the status device supply. The maximum rated output is used for the status device supply. The maximum rated output is 40mAmps. Warning: do not short circuit this

40mAmps. Warning: do not short circuit this pin because it ispin because it is common with the Electric Power Steering card supply.

common with the Electric Power Steering card supply. 3

3 DDTT--//DDLL FFoor tr thhe te taacchhoo--ggeenneerraattoor ar apppplliiccaattiioon tn thhiis is is a s a ttaacchhoo--ggeenneerraattoor r connection. It is internally connected to battery negative (GND). connection. It is internally connected to battery negative (GND). For For the stepper motor application this is a

the stepper motor application this is a stepper motor line (called Dstepper motor line (called D line).

line). 4

4 GGNNDD TThhiis s iis s iinntteerrnnaalllly y ccoonnnneecctteed d tto o ggrroouunnd d ((bbaatttteerry y mmiinnuuss) ) rreeffeerreennccee. I. Itt may be used for the GND

may be used for the GND reference of the Automatic Centeringreference of the Automatic Centering request switch and for the stepper motor

request switch and for the stepper motor GND connection.GND connection. 5

5 GGNNDD TThhiis s iis s iinntteerrnnaalllly y ccoonnnneecctteed d tto o ggrroouunnd d ((bbaatttteerry y mmiinnuuss) ) rreeffeerreennccee. I. Itt may be used for the GND reference of

may be used for the GND reference of the limit switches.the limit switches. 6

6 LLLLSS LLeefft t ((CCCCWW) ) LLiimmiit t SSwwiittcchh. . IItt''s s ppoossssiibblle e tto o ssttoop p sstteeeerriinng g iin n tthhe e didirreeccttiioonn that causes negative signal from the tacho-generator by closing the that causes negative signal from the tacho-generator by closing the connection between LLS (Pin #6) and negative (GND Pin#5).

connection between LLS (Pin #6) and negative (GND Pin#5). Therefore, connection of a normally open switch between Pin #6 Therefore, connection of a normally open switch between Pin #6 andand Pin #5 acts as a Counter-Clockwise steering limit switch.

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 22 of 51Page 22 of 51 7

7 KK11 TThhiis s iis s tthhe e fifirrsst t ((hhiigghheer r ppootteennttiiaall) ) ssaaffeetty y sswwiittcch h ccoonnnneeccttiioonn..TThhee second connection is on Pin #1. This normally open contact is

second connection is on Pin #1. This normally open contact is closedclosed by switching on the key. When the key switch

by switching on the key. When the key switch is On, the contactis On, the contact opens in case of steering alarm. If

opens in case of steering alarm. If Jumper J2 is closed, ground isJumper J2 is closed, ground is provided on pin 7 whenever the key switch is on

provided on pin 7 whenever the key switch is on and there is noand there is no alarm. If jumper J2

alarm. If jumper J2 is open, the safety contact between NK1 and K1is open, the safety contact between NK1 and K1 is floating and may be referenced either

is floating and may be referenced either to the plus batteryto the plus battery (connecting K1 to a plus battery voltage reference) or

(connecting K1 to a plus battery voltage reference) or to the minusto the minus battery (connecting NK1 to a minus battery

battery (connecting NK1 to a minus battery voltage reference).voltage reference). 8

8 BBUUZZZZ TThhiis s ccoonnnneeccttiioon n pprroovviiddees s a a ggrroouunnd d lliinne e tto o sswwiittcch h oon n tthhe e ssttaattuus s ddeevviiccee (it could be a 12Vdc buzzer device). It

(it could be a 12Vdc buzzer device). It can sink up to 40mAmps. Thiscan sink up to 40mAmps. This status device encodes steering alarm

status device encodes steering alarm conditions.conditions. 9 9 DDTT++//QQLL TThhiis is is a s a tatacchhoo--ggeenneerarattoor cr coonnnneeccttiioon on or a r a sstteeppppeer mr moottoor lr liinne (e (ccaalllleedd Q line). Q line). 1 100 AAUUTT TThhiis s iis s tthhe e aauuttoommaattiic c rreeqquueesst t iinnppuutt. . IIt t ccaan n be be eeiitthheer r an an aaccttiivve e lleevveel l oor r edge detection depending by the AUTO INP ACTIVE

edge detection depending by the AUTO INP ACTIVE setting (seesetting (see 10.7.7). When the selected event happens an

10.7.7). When the selected event happens an automatic centeringautomatic centering request will immediately start. This input pin

request will immediately start. This input pin may be connected to:may be connected to: 1. An external ground through a

1. An external ground through a switch.switch. 2. An internal ground (Pin #4)

2. An internal ground (Pin #4) through a switch.through a switch. 3. An external open collector transistor (For

3. An external open collector transistor (For example an output of aexample an output of a photocell circuit).

photocell circuit).

To recognize an automatic request each level should remain for at To recognize an automatic request each level should remain for at least 30msec. least 30msec. 1 111 KKEEYY TThhiis s iis s tthhe e kkeey y sswwiittcch h vvoollttaagge e iinnppuutt.. 1 122 RRLLSS RRiigghht t ((CCWW) ) LLiimmiit t SSwwiittcchh. . IItt''s s ppoossssiibblle e tto o ssttoop p sstteeeerriinng g iin n tthhe e ddiirreeccttiioonn that causes positive signal from the tacho-generator by closing the that causes positive signal from the tacho-generator by closing the connection between RLS (Pin #12) and negative (GND Pin#5). connection between RLS (Pin #12) and negative (GND Pin#5). Therefore, connection of a normally open switch between Pin Therefore, connection of a normally open switch between Pin #12#12 and Pin #5 acts as a Clockwise steering limit

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8.2 CNA CONNECTOR 8.2 CNA CONNECTOR

1

1 NNPPOOTT TThhiis s iis s tthhe e lloowweer r vvoollttaagge e coconnnneeccttiioon n ffoor r tthhe e sstteeeer r ffeeeeddbbaacckk potentiometer.

potentiometer. It's It's internally internally connected connected to Gto GND thND through rough a 4a 47070 Ohms resistance.

Ohms resistance. 2

2 PPPPOOTT TThhiis s iis s tthhe e hhiigghheer r vvoollttaagge e ccoonnnneeccttiioon n ffoor r tthhe e sstteeeer r ffeeeeddbbaacckk potentiometer. It's internally connected to a

potentiometer. It's internally connected to a 5Vdc reference through a5Vdc reference through a 470 Ohms resistance . 470 Ohms resistance . 3 3 CCAANNHH TThhiis s iis s tthhe e hhiiggh h rreeffeerreenncce e oof f tthhe e CACAN N iinntteerrffaaccee.. 4 4 CCAANNHH SSaamme e oof f ppiin n ##33. . PPiin n ##3 3 aannd d ##4 4 aarre e iinntteerrnnaalllly y ccoonnnneecctteed d ttooggeetthheerr.. 5 5 FFWWDD A A rreeqquueesst t tto o ttrraavveel l iin n tthhe e DDrriivve e UUnniit t ddiirreeccttiioon n mmuusst t pprroovviidde e a a ssiiggnnaall on this input, either at battery positive or battery negative. Either level on this input, either at battery positive or battery negative. Either level may be selected configuring Jumper J2.

may be selected configuring Jumper J2. 6

6 VVCCCC OOppttiioonnaal l enenccooddeer r ssuuppppllyy. . WhWheen n aan n eennccooddeer r iis s uusseed d iit t mmaay y bbee supplied through this pin. The output voltage

supplied through this pin. The output voltage is selected through theis selected through the jumper J8 (see. 5).

jumper J8 (see. 5). 7

may be used for the GND reference of the optional encoder or for thereference of the optional encoder or for the stepper motor (manual command device).

stepper motor (manual command device). 8

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ADCZP0AB

100 QQLLSS TThhe e sstteeppppeer r mmoottoor r hhaas s ffoouur r cchhaannnneells s DDLL, , QQLL, , DDLLSS, , QQLLSS. . DDL L aannd d QQLL are already assigned on the connector CNB. DLS and QLS

are already assigned on the connector CNB. DLS and QLS are theare the stepper motor channels for the Supervisor microprocessor. This pin stepper motor channels for the Supervisor microprocessor. This pin is the QLS input. is the QLS input. 1 111 CCPPOOTT TThhiis s is is tthhe e wwiippeer r ccoonnnneeccttiioon n ffoor r tthhe e sstteeeer r fefeeeddbbaacck k ppootteennttiioommeetteerr.. 1 122 KK33 PPiin n # # 112 2 of of CCNNA A ccoonnnneeccttoor r pprroovviiddees s a a mmaax x 22AAmmpps s NNPPN N ooppeenn collector driver. GND is applied by switching on the key and

collector driver. GND is applied by switching on the key and GND isGND is removed when an automatic centering operation is finished.

removed when an automatic centering operation is finished. 1 133 CCAANNLL TThhiis s is is tthhe e lloow w rreeffeerreenncce e oof f tthhe e CACAN N iinntteerrffaaccee.. 1 144 CCAANNLL SSaamme e oof f ppiin n ##1133. . PPiin n ##113 3 aannd d ##114 4 aarre e iinntteernrnaalllly y ccoonnnneecctteed d ttooggeetthheerr.. 1 155 RREEVV A A rreeqquueesst t to to ttrraavveel l iin n tthhe e LLooaad d WWhheeeells s ddiirreeccttiioon n mmuusst t pprroovviidde e aa signal on this input, either

signal on this input, either at battery positive or battery at battery positive or battery negative.negative. Either level may be selected by configuring Jumper J2.

Either level may be selected by configuring Jumper J2. 1 166 CCHHAA TThhiis s iis s tthhe e ffiirrsst t cchhaannnneel l iinnppuut t ffoor r tthhe e ooppttiioonnaal l eennccooddeerr.. 1 177 CCHHBB TThhiis s iis s ththe e sseeccoonnd d cchhaannnneel l iinnppuut t ffoor r tthhe e opopttiioonnaal l eennccooddeerr.. 1 188 IINNDDIICC OOuuttppuutts a s a ssccaalleed ad annd cd coonnvveerrtteed 0 d 0 tto 4o 4..55VVddc sc stteeeer ar anngglle fe feeeeddbbaacckk potentiometer position for the steer

potentiometer position for the steer angle indicator gauge LEDs.angle indicator gauge LEDs. 0Vdc corresponds to the steer angle feedback pot voltage that 0Vdc corresponds to the steer angle feedback pot voltage that waswas memorized using the ZAPI hand control for SET MAX

memorized using the ZAPI hand control for SET MAX FB POT.FB POT. 4.5Vdc corresponds to the steer angle feedback pot voltage that 4.5Vdc corresponds to the steer angle feedback pot voltage that waswas memorized using the ZAPI hand control for SET MIN

memorized using the ZAPI hand control for SET MIN FB POT . SeeFB POT . See 10.7.6 to reverse the turning

10.7.6 to reverse the turning direction displayed.direction displayed. 1

199 PPPPOOCC22 NNoot Ut Usesedd. T. Thhiis is is s ththe he higighheer vr voollttaagge ce coonnnneeccttiioon n fofor a r a sseeccoonndd handwheel set point potentiometer. To improve the safety a

handwheel set point potentiometer. To improve the safety a secondsecond optional command pot is foreseen. While the first

optional command pot is foreseen. While the first set point pot isset point pot is Master microprocessor processed, this second set point pot is Master microprocessor processed, this second set point pot is Supervisor microprocessor processed. The wiper of this

Supervisor microprocessor processed. The wiper of this second setsecond set point pot should be connected to the

point pot should be connected to the Pin #9 of CNB connector. ThePin #9 of CNB connector. The lower voltage end should be connected to the Pin

lower voltage end should be connected to the Pin #3 of CNB#3 of CNB connector.

connector. This steThis steering option requires modificering option requires modifications on theations on the log

logic card and cannot be used when a ic card and cannot be used when a tacho-generator or atacho-generator or a steppe

stepper motor motor card is chosenr card is chosen. This pin is internally . This pin is internally connected to aconnected to a 5Vdc reference through a 470 Ohms resistance.

5Vdc reference through a 470 Ohms resistance. 2

200 DDLLSS TThhe e sstteeppppeer r mmoottoor r hhaas s ffoouur r chchaannnneells s DDLL, , QQLL, , DDLLSS, , QQLLSS. . DDL L aannd d QQLL are already assigned on the connector CNB. DLS and QLS

are already assigned on the connector CNB. DLS and QLS are theare the stepper motor channels for the Supervisor microprocessor. DLS stepper motor channels for the Supervisor microprocessor. DLS enters in this connection.

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9 SETTING THE STEERING

Use the ZAPI hand set to

Use the ZAPI hand set to adjust the manual steering settings.adjust the manual steering settings.

9.1 TACHO-GENERATOR OR STEPPER MOTOR CONTROLLED STEERING 9.1 TACHO-GENERATOR OR STEPPER MOTOR CONTROLLED STEERING The following procedure should be used only after "One

The following procedure should be used only after "One Shot Installation Procedure" inShot Installation Procedure" in Section 7 is completed. Carry out

Section 7 is completed. Carry out the procedure in the following sequence.the procedure in the following sequence. 1)

1) Use the haUse the hand set to spnd set to specify thecify the steere steering is taching is tacho-geno-generatoerator type usir type using the SETng the SET MODEL setting (see 10.9).

MODEL setting (see 10.9). 2)

2) AdjusAdjust SET BAt SET BATTERY TTERY TYPE to tTYPE to the batthe battery voery voltage iltage in the trucn the truck usink using the hag the hand setnd set (see 10.8.6).

(see 10.8.6). 3)

3) ReguRegulate the malate the maximuximum frequem frequency to the mncy to the motor rateotor rated frequed frequency. Usncy. Use the hand se the hand setet adjustment SET SATURATION FREQ (see 10.8.7).

adjustment SET SATURATION FREQ (see 10.8.7). 4)

4) ReguRegulate the late the SPEED LSPEED LIMIT for sIMIT for steerinteering on the hg on the hand seand set. Hight. Higher valuer values caues cause these the MDU to turn faster (see 10.4.1).

MDU to turn faster (see 10.4.1). 5)

5) AdjusAdjust the slow stt the slow steerineering respog responce usince using the SENng the SENSIBILSIBILITY settiITY setting on the hang on the hand set.nd set. A higher value causes faster responce (see 10.4.2).

A higher value causes faster responce (see 10.4.2). Note:

Note:

Low settings of the SPEED LIMIT

Low settings of the SPEED LIMIT result in almost no steering responce when turningresult in almost no steering responce when turning the steering wheel al low speed. To

the steering wheel al low speed. To avoid this problem increase the SENSIBILITYavoid this problem increase the SENSIBILITY setting.

setting.

9.2 AUTOMATIC CENTERING 9.2 AUTOMATIC CENTERING 1)

1) For autoFor automatic cematic centerinntering operag operation it is nection it is necessaessary to adjury to adjust SET MODst SET MODEL to leveEL to level 1.l 1. When an automatic centering request on the input Pin

When an automatic centering request on the input Pin #10 of CNB connector is#10 of CNB connector is recognized an automatic MDU alignment will start.

recognized an automatic MDU alignment will start. 2)

2) AdjusAdjust the stet the steer angler angle cente centering pering precisrecision usion using KP aning KP and POSITd POSITION ACCION ACCURACURACYY parameters on the hand set. The first

parameters on the hand set. The first is for coarse regulation, the second is for is for coarse regulation, the second is for finefine regulation. Higher value of these parameters increase the precision, but make

regulation. Higher value of these parameters increase the precision, but make steering "busy" with dither.

steering "busy" with dither. 3)

3) Use the Use the hand shand set SET Set SET STEER 0TEER 0-POS (s-POS (see 10.8ee 10.8.11) to a.11) to adjust thdjust the steee steer angler angle feedback pot for straight steering MDU.The setting may be

feedback pot for straight steering MDU.The setting may be adjusted up and down inadjusted up and down in 5mV increments from the 2.5V default voltage. Test

5mV increments from the 2.5V default voltage. Test the results by driving the truckthe results by driving the truck forward

forward and reverse wand reverse with a centered ith a centered MDU. Watch for sMDU. Watch for straight travel.traight travel. 4)

4) Use PUUse PURSUIT RRSUIT RAMP on tAMP on the hanhe hand set to ad set to adjust tdjust the autohe automatic cmatic centeentering spring speed (seed (seeee 10.5.3).

10.5.3). 5)

5) Use DEUse DESENSISENSIBILIZBILIZAT on the hAT on the hand seand set to adjut to adjust the aust the automattomatic centic centering sering speedpeed closely the straight ahead MDU position (see 10.5.4).

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 26 of 51Page 26 of 51 9.3 STEER ANGLE INDICATOR GAUGE

9.3 STEER ANGLE INDICATOR GAUGE If a steer angle indicator gauge with

If a steer angle indicator gauge with Leds is applied then you will also Leds is applied then you will also need to performneed to perform the following steps for the

the following steps for the gauge to respond correctly:gauge to respond correctly: 1)

1) Use SEUse SET MIN FB PT MIN FB POT on thOT on the hand se hand set to memet to memorize torize the steehe steer angle r angle feedbfeedback poack pott voltage for maximum Clockwise rotation of the Drive Unit

voltage for maximum Clockwise rotation of the Drive Unit (see 10.8.12).(see 10.8.12). 2)

2) Use SEUse SET MAX FB T MAX FB POT on tPOT on the hanhe hand set to md set to memoriemorize the sze the steer anteer angle feegle feedbacdback potk pot voltage for maximum Counter-Clockwise rotation of the Drive Unit (see 10.8.13). voltage for maximum Counter-Clockwise rotation of the Drive Unit (see 10.8.13). 3)

3) Use thUse the hand se hand set SET Set SET STEER 0TEER 0-POS (s-POS (see 10.ee 10.8.11) to 8.11) to adjusadjust the stet the steer angler anglee feedback pot for straight steering MDU.The setting may be

feedback pot for straight steering MDU.The setting may be adjusted up and down inadjusted up and down in 5mV increments from the 2.5V default voltage. Test the

5mV increments from the 2.5V default voltage. Test the results by driving the truckresults by driving the truck forward

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10 ZAPI HAND SET DESCRIPTION

This section describes the ZAPI hand set functions. Numbers inside the

This section describes the ZAPI hand set functions. Numbers inside the trianglestriangles correspond to the same number on the hand set

correspond to the same number on the hand set keyboard buttons shown in the figurekeyboard buttons shown in the figure below. The orientation of the triangle

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 28 of 51Page 28 of 51 10.1 MANUAL MODE STEERING OPTION - HAND SET FUNCTION MAP 10.1 MANUAL MODE STEERING OPTION - HAND SET FUNCTION MAP

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10.2 MANUAL MODE STEERING OPTION AND AUTOMATIC CENTERING - HAND 10.2 MANUAL MODE STEERING OPTION AND AUTOMATIC CENTERING - HAND

SET FUNCTION MAP SET FUNCTION MAP

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 30 of 51Page 30 of 51 10.3 MAIN MEN

10.3 MAIN MENU "U "PARAMETERS LIST"PARAMETERS LIST" The parameters are slightly different between t

The parameters are slightly different between tacho-generator, tacho-generatoacho-generator, tacho-generator withr with automatic centering and pot steering option. (the

automatic centering and pot steering option. (the stepper motor application has thestepper motor application has the same hand set map as t

same hand set map as the tacho-generator configuration)he tacho-generator configuration)

After modifyng a parameter, memorize it with the hand set by pushing the "4" (OUT) After modifyng a parameter, memorize it with the hand set by pushing the "4" (OUT)

button and the "3" (

button and the "3" (IN) button. Double pushing the OUT button exits IN) button. Double pushing the OUT button exits without saving thewithout saving the modifications.

modifications.

10.4 PARAMETERS IN SET MODEL 0 (TACHO-GENERATOR OR STEPPER 10.4 PARAMETERS IN SET MODEL 0 (TACHO-GENERATOR OR STEPPER

MOTOR ONLY) MOTOR ONLY)

1

1)) SSPPEEEED LID LIMMIITT

Regulates the MDU maximum turning

Regulates the MDU maximum turning speed.speed. - Level 0 is for slow

- Level 0 is for slow turning.turning. - Level 9 is for fast turning. - Level 9 is for fast turning.

Intermediate levels are for proportionally increasing speed settings. Maximum MDU Intermediate levels are for proportionally increasing speed settings. Maximum MDU speed has to be regulated after SET BATTERY TYPE is

speed has to be regulated after SET BATTERY TYPE is done (see JJ)done (see JJ) 2

2)) SSEENNSSIIBIBILILITTYY

It provides a non-linear relationship between MDU steering speed and It provides a non-linear relationship between MDU steering speed and tach-generator voltage when low.

generator voltage when low. This parameter produces increasing steering sensitivityThis parameter produces increasing steering sensitivity with small changes in steering input.

with small changes in steering input. - Level 0 is for

- Level 0 is for steering response that is less sensitive to small steering wheelsteering response that is less sensitive to small steering wheel movements.

movements. - Level 9 is for

- Level 9 is for steering response that is very sensitive to small steering wheelsteering response that is very sensitive to small steering wheel movements.

movements.

Intermediate levels are for proportionally increasing speed setting. This parameter Intermediate levels are for proportionally increasing speed setting. This parameter does not influence the maximum MDU steering rate.

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3

3)) CCRREEEEP P SSPPEEEEDD

Provides an increased torque for slow turning steering wheel. It's

Provides an increased torque for slow turning steering wheel. It's used to compen-used to compen-sate the drop in V/f

sate the drop in V/f (flux) when the frequency applied to the motor (flux) when the frequency applied to the motor is low.is low. - Level 0 is f

- Level 0 is for no torque compensationor no torque compensation - Level 9 is for

- Level 9 is for a very strong torque compensationa very strong torque compensation

Intermediate levels are for proportionally increasing torque setting. This parameter Intermediate levels are for proportionally increasing torque setting. This parameter is useful in two ways. First

is useful in two ways. First of all it guarantees a large torque of all it guarantees a large torque for very slowly turnedfor very slowly turned handwheel. Secondly this large torque allows it to

handwheel. Secondly this large torque allows it to neutralize the elastic tire effectneutralize the elastic tire effect when the handwheel is close to being released it.

when the handwheel is close to being released it. 4

4)) CCOOMMPPEENNSSATATIIOONN

Provides stator flux compensation. The ideal motor control provides constant flux Provides stator flux compensation. The ideal motor control provides constant flux value for each working frequency. While CREEP SPEED provides low f

value for each working frequency. While CREEP SPEED provides low frequencyrequency feedforward flux compensation effect, COMPENSATION produces a feedback flux feedforward flux compensation effect, COMPENSATION produces a feedback flux compensation effect. This is a very important setting

compensation effect. This is a very important setting for an application without thefor an application without the shaft encoder be cause by turning compensation to a different

shaft encoder be cause by turning compensation to a different value than zero getsvalue than zero gets the motor flux (and torque)

the motor flux (and torque) indipendent from the battery voltage. So torque isindipendent from the battery voltage. So torque is guaranteed when the battery is low:

guaranteed when the battery is low: - Level 0 means no compensation but a

- Level 0 means no compensation but a flux degradation when current is too highflux degradation when current is too high - Level 1 compensate the drop on power

- Level 1 compensate the drop on power mosfets and cablesmosfets and cables - Level 2 compensate the drop on power

- Level 2 compensate the drop on power mosfets, cables and stator resistancemosfets, cables and stator resistance - Level 3 means no compensation.

- Level 3 means no compensation. This should normally be set to Level 2

This should normally be set to Level 2 as a strong compensation reduces the slipas a strong compensation reduces the slip (difference between the speed and the frequency applied to the

(difference between the speed and the frequency applied to the motor). Anmotor). An exception can be a smaller motor (small torque required) in which a

exception can be a smaller motor (small torque required) in which a strong flux (andstrong flux (and a greater magnetization current) is not necessary (Level 0).

a greater magnetization current) is not necessary (Level 0). 5

5)) ANANTTIIRROOLLBLLBACACKK

Adjusts the stand still torque value with a released handwheel. This setting is a Adjusts the stand still torque value with a released handwheel. This setting is a

percentage of Imax. The stand still torque i

percentage of Imax. The stand still torque is used to neutralize the elastic tire s used to neutralize the elastic tire effecteffect which would move the MDU an angle back in the direction it

which would move the MDU an angle back in the direction it was coming from. Thiswas coming from. This parameter is specified as a percentage of the maximum current.

parameter is specified as a percentage of the maximum current. 6

6)) AUAUXXILILIIARARY TY TIIMMEE

Defines the time, after the

Defines the time, after the handwheel is released, for which the stand still handwheel is released, for which the stand still torque istorque is applied.

applied.

- Level 0 is for no stand still torque - Level 0 is for no stand still torque - Level 1 is for

- Level 1 is for a short application of a stand still a short application of a stand still torque (about 6sec)torque (about 6sec) - Level 9 is for

- Level 9 is for a long application of a stand still a long application of a stand still torque (about 90sec)torque (about 90sec) Intermediate levels are for proportionally increasing auxiliary time. Intermediate levels are for proportionally increasing auxiliary time. 7

7)) AUAUX FX FUUNNCCTTIIOON 3N 3

Through the Can comunication, the traction chopper supplies the truck speed Through the Can comunication, the traction chopper supplies the truck speed information to the EPS-AC. The EPS-AC

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ADCZP0AB

8)) AUAUX X FFUNUNCCTITION ON 44

Has the same purpose as the previous parameter. The only difference is the Has the same purpose as the previous parameter. The only difference is the auxaux function 4 varies the value of t

function 4 varies the value of the steering speed when the hand-wheel is turninghe steering speed when the hand-wheel is turning slowly.

slowly.

10.5 PARAMETERS IN SET MODEL 1 (TACHO-GENERATOR OR STEPPER 10.5 PARAMETERS IN SET MODEL 1 (TACHO-GENERATOR OR STEPPER

MOTOR AND AUTOMATIC CENTERING) MOTOR AND AUTOMATIC CENTERING)

All the parameters in the section 10.3 are adopted also for the tacho-generator (or All the parameters in the section 10.3 are adopted also for the tacho-generator (or

stepper motor) and automatic centering model. To this previous list

stepper motor) and automatic centering model. To this previous list here we have tohere we have to add the following parameters:

add the following parameters: 1

1)) KKPP

Used for the automatic centering set up. It

Used for the automatic centering set up. It modifies the static precision of themodifies the static precision of the position control loop. To obtain precise centering increase the KP

position control loop. To obtain precise centering increase the KP value. If value. If overshoot becomes evident, try to lower the KP

overshoot becomes evident, try to lower the KP value.value. - Level 0 is for

- Level 0 is for less precise centering.less precise centering. - Level 9 is for very precise steering (but

- Level 9 is for very precise steering (but "busy")."busy").

Intermediate levels are for proportionally increasing centering precision. Intermediate levels are for proportionally increasing centering precision. 2

2)) PPOOSS. AC. ACCCUURRACACYY

Used for automatic centering set up. It

Used for automatic centering set up. It has the same KP function but it has the same KP function but it waswas introduced to increase the resolution of the static

introduced to increase the resolution of the static precision. To obtain preciseprecision. To obtain precise

centering increase the POS. ACCURACY value. If overshoot becomes evident, try centering increase the POS. ACCURACY value. If overshoot becomes evident, try to lower the POS.

to lower the POS. ACCURACY value.ACCURACY value. - Level 0 is for

- Level 0 is for less precise centering.less precise centering.

- Level 9 is for very precise centering (but "

- Level 9 is for very precise centering (but "busy").busy").

Intermediate levels are for proportionally increasing centering precision. Intermediate levels are for proportionally increasing centering precision. 3

3)) PPUURRSSUUIIT T RRAMAMPP

Used for automatic centering set up. It

Used for automatic centering set up. It decreases the amount of time it decreases the amount of time it takes totakes to complete an automatic centering operation.

complete an automatic centering operation. - Level 0 is for

- Level 0 is for an automatic centering carried out with a motor an automatic centering carried out with a motor frequency of frequency of SAT.FREQ/5.

SAT.FREQ/5. - Level 9 is for

- Level 9 is for an automatic centering carried out with a motor an automatic centering carried out with a motor frequency of frequency of SAT.FREQ.

SAT.FREQ.

Intermediate levels are for proportional frequency changes. Intermediate levels are for proportional frequency changes. 4)

4) DEDESESENNSISIBILIBILIZAZATT

Used for automatic centering set up. It slows

Used for automatic centering set up. It slows down the MDU in the region close todown the MDU in the region close to the straight ahead position.

the straight ahead position. - Level 0 is for

- Level 0 is for a large slowing down quasi-centered MDU.a large slowing down quasi-centered MDU. - Level 9 is for

- Level 9 is for a no slowing down quasi-centered MDU.a no slowing down quasi-centered MDU.

Intermediate levels are for proportionally slowing down changes. The close to Intermediate levels are for proportionally slowing down changes. The close to straight position slowing down should reduce the MDU overshoot in an automatic straight position slowing down should reduce the MDU overshoot in an automatic centering operation.

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10.6 MAIN MEN

10.6 MAIN MENU: "U: "TESTETESTER" R" FUNCTFUNCTIONS LISTIONS LIST The TESTER functions list is common for applications with or

The TESTER functions list is common for applications with or without the automaticwithout the automatic centering model. Each TESTER function provides the measurement, executed by the centering model. Each TESTER function provides the measurement, executed by the software, of the specified parameter. Descriptions of each TESTER function are

software, of the specified parameter. Descriptions of each TESTER function are givengiven below.

below. 1

1)) DDTT

Provides the value of the tacho-generator (or stepper motor)

Provides the value of the tacho-generator (or stepper motor) input from the steeringinput from the steering wheel with its sign in real

wheel with its sign in real time. The value is scaled for the time. The value is scaled for the CPU A/D converter CPU A/D converter (range 0±5Vdc). The value measured directly on the tacho-generator output is (range 0±5Vdc). The value measured directly on the tacho-generator output is sometimes higher than measured on the hand set.

sometimes higher than measured on the hand set. 2

2)) SSEET PT POOININT PT POOTT

Not used. Pot steering only. I

Not used. Pot steering only. It provides the steering handle command potentiometer t provides the steering handle command potentiometer voltage in real time (i.e. the voltage on the Pin #20 of CNA connector)(for two pots voltage in real time (i.e. the voltage on the Pin #20 of CNA connector)(for two pots closed loop position control only).

closed loop position control only). 3

3)) FFEEEEDDBACBACK PK POOTT

Provides the MDU steer angle feedback potentiometer voltage in real time.

Provides the MDU steer angle feedback potentiometer voltage in real time. A steer A steer angle straight ahead corresponds to about 2.5Vdc.

angle straight ahead corresponds to about 2.5Vdc. 4

4)) TTEEMMPPEERRATATUURREE

Provides in real time the c

Provides in real time the control unit plate temperature in ontrol unit plate temperature in celsius degrees. An celsius degrees. An alarmalarm occurs when the temperature is above 76 degrees Celsius.

occurs when the temperature is above 76 degrees Celsius. 5

5)) FFRREEQQUUEENNCCYY

Provides in real time the f

Provides in real time the frequency applied to the steering motor with its requency applied to the steering motor with its sign.sign. 6

6)) MMOOTTOOR VR VOOLTLTAGAGEE Provides in real time the

Provides in real time the voltage applied to the steering motor as a voltage applied to the steering motor as a percentage of percentage of the battery voltage.

the battery voltage. 7)

7) MOMOTTOR OR CUCURRRREENTNT

Provides in real time the phase motor current (Rms). Provides in real time the phase motor current (Rms). 8

8)) EENNCC

Not used. It's for the optional encoder. Not used. It's for the optional encoder. 9

9)) EENNC C SSPPEEEEDD Not used. It's for

Not used. It's for the optional encoder. This reading (and the previous) wasthe optional encoder. This reading (and the previous) was introduced to read the optional encoder speed and position. At

introduced to read the optional encoder speed and position. At present it's notpresent it's not managed.

managed. 10)

10)ENDENDSTRSTROKE CWOKE CW

Provides in real time the active state (ON)

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ADCZP0AB

ADCZP0AB EPS-AC EPS-AC OPERATING OPERATING AND AND USER USER MANUALMANUAL Page 34 of 51Page 34 of 51 12)

12)CW LIMICW LIMIT LEVELT LEVEL

Provides in real time the

Provides in real time the information that the steer angle feedback potentiometer information that the steer angle feedback potentiometer has overcome the SET MAX FB POT value (see 10.8.13).

has overcome the SET MAX FB POT value (see 10.8.13). 13)

13)ACW LIMIT ACW LIMIT LEVELLEVEL Provides in real time the

Provides in real time the information that the steer angle feedback potentiometer information that the steer angle feedback potentiometer has overcome the SET MIN FB POT value (see 10.8.12).

has overcome the SET MIN FB POT value (see 10.8.12). 14)

14)AUTOMAUTOMATIC REQATIC REQ..

Provides in real time the steering state:

Provides in real time the steering state: manual or automatic. Note: this reading ismanual or automatic. Note: this reading is not the AUTOSEL (Pin #10 of CNB

not the AUTOSEL (Pin #10 of CNB connector) level but the steering state the SW connector) level but the steering state the SW isis recognizing. This information coincides with the AUTOSEL input level when this recognizing. This information coincides with the AUTOSEL input level when this input is level triggered.

input is level triggered. 15)

15)DIRECDIRECTION INPTION INPUTSUTS

Provides in real time the information of

Provides in real time the information of an active travel demand. It turns ON an active travel demand. It turns ON whenwhen either a FWD or a REV

either a FWD or a REV travel demand is present.travel demand is present. 16)

16)MM ALARM SWMM ALARM SWITCITCHH

Provides in real time the state (closed or

Provides in real time the state (closed or not) of the Master Microprocessor not) of the Master Microprocessor controlled safety switch.

controlled safety switch. 17)

17)SM ALARM SWSM ALARM SWITCITCHH

Provides in real time the state (

Provides in real time the state (closed or not) of the Slave Microprocessor controlledclosed or not) of the Slave Microprocessor controlled safety switch.

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10.7 CON

10.7 CONFIG MENU: "FIG MENU: "SET OPTIOSET OPTIONS" NS" FUNCTFUNCTIONS LISTIONS LIST The SET OPTIONS functions list is used for

The SET OPTIONS functions list is used for all the steering options. These optionsall the steering options. These options modify the system configuration on user request. A description of

modify the system configuration on user request. A description of each option follows ineach option follows in the list below.