Zapi EPS-BLI HYG User Manual
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Zapi EPS-BLI HYG User Manual

Zapi EPS-BLI HYG User Manual

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ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
E-mail: zapi@zapispa.it – web: www.zapispa.it
EN
Publication: AFMNA0AA
Edition: June 1, 2018
User Manual
EPS-BLI
HYG

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Summary of Contents for Zapi EPS-BLI HYG

  • Page 1 ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259 E-mail: zapi@zapispa.it – web: www.zapispa.it User Manual EPS-BLI Publication: AFMNA0AA Edition: June 1, 2018...
  • Page 2 Under no circumstances Zapi S.p.A. will be held responsible to third parties for damage caused by the improper use of the present publication and of the device/devices described in it. Zapi S.p.A. reserves the right to make changes or improvements to its products at any time and without notice.

  • Page 3: Table Of Contents

    Description of the parameter lists ................22  9.2.1  SET OPTIONS list ..................24  9.2.2  ADJUSTMENTS list ..................27  9.2.3  SET MODEL list ..................30  9.2.4  PARAMETER CHANGE list ............... 32  9.2.5  HARDWARE SETTINGS list ..............38  AFMNA0AA – EPS-BLI HYG – User Manual Page – 3/75...
  • Page 4 14.2  Upload sequence ..................... 69  15  PERIODIC MAINTENANCE ....................75  15.1  Testing the faulty detection circuitry ................. 75  APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Page – 4/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 5: Introduction

    INTRODUCTION About this document This manual provides important information about EPS BLI controller. It presents mechanical, electrical and functional features; installation and handling of the Zapi assembly. This user manual refers to Zapi part number F07267A. 1.1.1 Manual Acronyms VMC (or VCM): ..Vehicle Master Control TMC: ......

  • Page 6: About The Controller

    It is responsibility of the vehicle manufacturer to identify the correct standards and to ensure that the vehicle meets these standards. As a major electrical control component, the role of a Zapi motor controller should be carefully considered and relevant safety precautions taken. It has several features which can be configured to help the system integrator meeting vehicle safety standards.

  • Page 7: Specifications

     #1 Spare digital input (CNA#12) with inner 3.3 kΩ pull-up to 13.5 V.  #1 Embedded steering motor sensor (position sensor).  #1 Embedded motor thermal sensor: KTY84-130 analog sensor.  #1 Embedded steered-wheel home-position sensor. AFMNA0AA – EPS-BLI HYG – User Manual Page – 7/75...

  • Page 8: Technical Specifications

    Max motor torque @ Imax = 50 Arms: ........3.1 Nm @ Vbatt = 24V Gear box: ................ Sumitomo CNVMS-5087-43 Total gear box ratio: ....................1:43 Thermal sensor: ..................... PT-1000 Page – 8/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 9: Drawings

    DESCRIZIONE/Description: HYSTER YALE EPS-BLI + BOISE + SUMITOMO This drawing is a ZAPI s.p.a. property. Its reproduction is prohibited except for a written authorization. The only allowed use is that relative to the repairs of ZAPI products. Figure 3-1. AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 10: Block Diagram

    This manual deals with the steer-by-wire mode which implements a position-control loop. In a position-control loop the angle of the steered wheel is one-to- one matched with that of the steering handle. Figure 4.1-1. Closed loop mode. Page – 10/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 11: Coordination Between Scm And Other Modules In The Truck

    VCM as a gateway), only the TCM should be designed with a category #3 architecture to ensure the SCM error is received by the destination and the traction is taken to a safe state. AFMNA0AA – EPS-BLI HYG – User Manual Page – 11/75...

  • Page 12: Scm Has Its Own Contactor

    DC rail caps inside the SCM.  Power stage of the SCM is always supplied: OEM (and UL) approval is required.  See 4.2.1: Bringing TCM to a safe state. Page – 12/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 13: A Single Mc, Driven By The Vcm, Supplies Power Rail To All The Modules

     An error in the TCM or PCM causes the MC to open. As a consequence, steering is not allowed during the stopping interval.  See 4.2.1: Bringing TCM to a safe state. AFMNA0AA – EPS-BLI HYG – User Manual Page – 13/75...

  • Page 14: System Components

    Hall element array. The angular position of a simple two-pole magnet is translated into analogue output voltages and used by the controller to know the real- time steered wheel position. Page – 14/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 15: Straight Ahead Toggle Switch

    5% to 95% per revolution programmed with triangle wave shape 90° shifted (see figure 5.4.1-1). Quasi-redundant or fully-redundant set point sensors may be adopted. Figure 5.4.1-1. AFMNA0AA – EPS-BLI HYG – User Manual Page – 15/75...

  • Page 16: Force Feedback

    A force-feedback device must be installed on the steering command axle as to dynamically modify the force needed to act on it. The friction at the steering command will be real-time adjusted according to either a Zapi basic implementation or a customer’s requirement.

  • Page 17: Connection Drawing

    CONNECTION DRAWING Figure 10-1. AFMNA0AA – EPS-BLI HYG – User Manual Page – 17/75...

  • Page 18: Ampseal Connector

    Ground (negative reference). triangle wave shape PWM. CPOC1 5 V supply output. CAN bus channel LOW (No 120 termination CANL1 aboard). CAN bus channel HIGH (No 120 termination CANH1 aboard). Page – 18/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 19: Installation Procedure

    Step3 Move mechanically the steered wheel in the straight ahead orientation. Step4 Switch on the key and with the Zapi Can Console (or with the Zapi hand set in a remote mode from another unit in the truck) check the reading CENTER WHEEL SW in the tester menu is ON (meanwhile the steered wheel is straight ahead).

  • Page 20: Setting The E-Steering Motor Controller

    Zapi PC CAN Console (or with the Zapi hand set in a remote mode from another unit in the truck or with a customized VMC and its CAN bus supported object dictionary). Any new set-up for a parameter must be saved and the key re-cycled before re-testing it.

  • Page 21: Zero Sp Pot Self-Acquisition

    All the steps below are assumed to be performed with the Zapi PC CAN Console (or with the Zapi hand set in a remote mode from another unit in the truck). Save and re-cycle the key before re-testing the system. Procedure for self-acquiring ZERO SP POT is: 1) Keep the steering handle in its straight ahead direction 2) Turn on the key.

  • Page 22: Programming & Adjustments

    Adjustment of parameters and changes to the inverter configuration can be done by using either the Zapi PC CAN Console (by a PC connected to a CAN bus dongle) or the digital console (Zapi hand set, figure 13.1-1). The Zapi hand set can be connected to a remote Zapi unit in the truck (traction, pump, VMC, etc.) communicating via CAN bus...
  • Page 23 Figure 9.2-1. AFMNA0AA – EPS-BLI HYG – User Manual Page – 23/75...

  • Page 24: Set Options List

    9.2.1 SET OPTIONS list To enter and navigate the SET OPTION list by the Zapi hand set go down the following procedure. EPSHTM 6U NAx.xx Opening Zapi lines. 24 V 50 A 00000 Press ROLL UP + SET UP simultaneously to enter...
  • Page 25 MOTOR TEMPERAT alarm occurs. 4) FRICTION MODE This option sets the control mode of the force-feedback device at the steering handle (output CNA#10). Modes below are the basic Zapi implementations. LEVEL 0: NO FRICTION on the steering handle LEVEL 1: FIXED FRICTION.
  • Page 26 (alarmed or not operational). ABSENT: CNA#14 is always in open state. Above setting is not handled in the Zapi PN F07206. Zapi Standard 1 Gen and Universal 2.0: CNA#14 can be used to drive a line contactor to connect the battery positive to the E-steering motor controller (in this instance, AUX OUTPUT #2 must be set to PRESENT as the Mandatory default value).

  • Page 27: Adjustments List

    9.2.2 ADJUSTMENTS list To enter and navigate the ADJUSTMENT list by the Zapi hand set go down the following procedure. EPSHTM 6U NAx.xx Opening Zapi lines. 24 V 50 A 00000 Press ROLL UP + SET UP simultaneously to enter % ' % CONFIG MENU.
  • Page 28 This setting is factory adjusted to calibrate ADJUSTMENT #03 and #04 below. 10) ADJUSTMENT #02 Milliohms. This is the resistance of the motor measured between two motor terminals. It may Page – 28/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 29 (Zapi adjusted) or changed by setting up or down this adjustment. 11) ADJUSTMENT #03 (Factory adjusted). This adjustment defines the compensation for the gain of the current amplifier in phase W. 12) ADJUSTMENT #04 (Factory adjusted). This adjustment defines the compensation for the gain of the current amplifier in phase V.

  • Page 30: Set Model List

    9.2.3 SET MODEL list This menu is implemented in the Zapi hand set to make possible the remote connection but it is not implemented in the PC CAN Console. To enter and navigate the SET MODEL list by the Zapi hand set go down the following procedure.
  • Page 31 This setting is used to (virtually) connect the hand-set to a remote unit CAN bus connected. With the hand-set connected to the E-steering motor controller it is possible to communicate with a remote Zapi unit. Every Zapi unit has its own identification number (e.g. E-steering motor controller master uC typically is 6;...

  • Page 32: Parameter Change List

    9.2.4 PARAMETER CHANGE list To enter and navigate the ADJUSTMENT list by the Zapi hand set go down the following procedure. EPSHTM 6U NAx.xx Opening Zapi lines. 24 V 50 A 00000 ' % ' Press ENTER to go into the main menu.
  • Page 33 See figure 10.2.4-2 below. STATIC NUMBNESS values are reported on the right. 100% 100% Steering set point [span percentage] Figure 9.2.4-1. AFMNA0AA – EPS-BLI HYG – User Manual Page – 33/75...
  • Page 34 14) SET STEER MAX. Milliamps, 0 mA through 1200 mA. Default value is 500 mA. This parameter defines the maximum force-feedback value, applied at the maximum steering angles. See figure 10.2.4-3. Page – 34/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 35 When option FRICTION MODE is set to LEVEL = 2 through 4, this parameter defines the traction speed below which the minimum force-feedback value applied is defined by SET STEER MIN. See figure 10.2.4-4. AFMNA0AA – EPS-BLI HYG – User Manual Page – 35/75...
  • Page 36 The proportional contribution is applied to the difference between the set point and the real position of the steered wheel angle. The accuracy of the pursuing between commanded and real position increases if POS. ACCURACY increases. Page – 36/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 37 LEVEL 8: Steered wheel relaxes 45 degrees in 72 s. LEVEL 9: Steered wheel relaxes 45 degrees in 80 s. For example, on LEVEL 2 relaxing 15 degrees takes 8 s. AFMNA0AA – EPS-BLI HYG – User Manual Page – 37/75...

  • Page 38: Hardware Settings List

    9.2.5 HARDWARE SETTINGS list To enter this Zapi hidden menu a special procedure is required. Ask this procedure directly to a Zapi technician. Parameters in the HARDWARE SETTINGS list from 1 (ID RMS MAX) through 22 (AUX SPEED #1) are safety relevant and only well trained technicians are allowed to change the default settings.
  • Page 39 This parameter defines the maximum quadrature current at a motor frequency equal to FREQMAX FOR IMAX + INC FREQ1. Also, the direct current will be limited by the full motor voltage. Factory adjusted. AFMNA0AA – EPS-BLI HYG – User Manual Page – 39/75...
  • Page 40 This setting defines the type of set point sensor adopted. OFF: PWM sensor. Default setting. Analog sensor. 19) MICRO CHECK: ABSENT: Master uC can drive the steering motor without the software has Page – 40/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 41 When released on the field, this setting must be equal to PRESENT. 20) MST DEBUG MSG This setting enables the transmission of diagnostic messages over CAN bus by master uC. Every bit of this setting enables a certain message. Reserved for Zapi debug. 21) SLV_DEBUG_MSG This setting enables the transmission of diagnostic messages over CAN bus by supervisor uC.

  • Page 42: Special Adjustments List

    Switch the controller off and on again. 9.2.6 SPECIAL ADJUSTMENTS list To enter this Zapi hidden menu, a special procedure is required. Ask this procedure directly to a Zapi technician. Parameters in the SPECIAL ADJUSTMENTS list are safety relevant and only...
  • Page 43 (Mandatory default value). Supervisor uC is fully operational. Traction is enabled. 7) AUX FUNCTION 11 Not Used. When releasing on the field, SAFETY LEVEL must be set to LEVEL 3. AFMNA0AA – EPS-BLI HYG – User Manual Page – 43/75...

  • Page 44: Tester List

    Angle of the second set-point sensor. 3) SP DUTY CYCLE 1 Unit: percentage. Duty cycle of the PWM from the first set-point sensor. 4) SP DUTY CYCLE 2 Unit: percentage. Page – 44/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 45 Speed of the motor encoder (this is a virtual encoder digitally derived basing on the information from the analog feedback sensor). 14) FREQUENCY Units: Hertz. Frequency applied to the steering motor. 15) MOTOR VOLTAGE AFMNA0AA – EPS-BLI HYG – User Manual Page – 45/75...
  • Page 46 (see setting MAX SPEED TRAC in 9.2.4). 26) BATTERY VOLTAGE Unit: Volt. Battery voltage sensed by the E-steering controller. 27) KEY VOLTAGE MAX Unit: Volt. Maximum key voltage sensed by the E-steering controller. Page – 46/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 47 Real-time angular position of the rotor. 36) P SENS ERR REG Unit: number. Count of the feedback sensor errors. 37) P SENS AGC Unit: number. Real-time gain of the feedback sensor. AFMNA0AA – EPS-BLI HYG – User Manual Page – 47/75...

  • Page 48: Steering Motor Controller Alarms

    (from LOW to HIGH) a STOP TRACTION REQUEST bit in a PDO (STATUS WORD) continuously sent to the unit designated to stop the traction. The job in the Zapi steering system finishes when the STOP TRACTION REQUEST has been sent. After that, the lift truck Manufacturer is responsible...

  • Page 49: Alarm List

    EPS_MuC  TMC: MuC STOP TRACTION REQUEST EPS_SuC  TMC: SuC STOP TRACTION REQUEST The job of the Zapi steering system finishes when the STOP TRACTION REQUEST has been sent to the TMC. The position of the STOP TRACTION REQUEST flag is given by table 10.1-1 below.
  • Page 50 Two alarm codes are sent on the CAN bus: hexadecimal and decimal (see the numbers in the list below). Decimal number is a standard protocol for a Zapi VMC or display (sent via a PDO); hexadecimal is the extended alarm code (sent via an EMERGENCY frame).
  • Page 51 4 quadrants (0° to 90°, 90° to 180°, 180° to 270°, 270° to 360°). - Remedy: Check the connections of the sensor at the steering handle (CNA#20 and CNA#17). Check for noise or interference on the sensor. Figure 10.2-1 AFMNA0AA – EPS-BLI HYG – User Manual Page – 51/75...
  • Page 52 Vv-Vu and Vu-Vw is not in a narrow window of ± 300 mV around 2.4 V 10 ms long (sampling time 2 ms for 5 consecutive samples). Admitted output at rest is 2.1 V through 2.7 V. Page – 52/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 53 MuC only. MuC writes its own parameter and commands the SuC to do the same on its own parameter list. Execution of the write command in the SuC is protected by a password. This alarm is AFMNA0AA – EPS-BLI HYG – User Manual Page – 53/75...
  • Page 54 The problem can be that the resistance of the TFD coil is too high (coil broken), or the wires to the TFD coil broken, or a problem in the controller. Page – 54/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 55 If it is repetitive, it is a problem in the steering controller. 25) WATCHDOG Alarm 0xFF08 = 8 Group #0 [M,S]: - Cause: MuC and SuC communicate via a local CAN bus communication AFMNA0AA – EPS-BLI HYG – User Manual Page – 55/75...
  • Page 56 When SuC raises an alarm, steering motor cannot be actuated. MuC, by raising this warning, reports that SuC has cut off the power stage. In the Zapi console, MuC specifies the LSbyte of the SuC alarm code. For instance, in case of SuC alarm code FFD0 (OUTPUT MISMATCH), MuC raises SLAVE ALARM D0.
  • Page 57 Alarm 0xFFD1 = 209 Group #0 [M,S]: - Cause: SuC does not receive synchronization signal from MuC longer than 90 ms. - Remedy: Re-cycle the key. If the problem remains replace the controller. AFMNA0AA – EPS-BLI HYG – User Manual Page – 57/75...
  • Page 58 Check the continuity of the stepper motor connections. In particular the resistance between CNA#9 and the minus battery (with the stepper motor at rest) is expected being very low (close to 30 ohms). Page – 58/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 59 This alarm occurs when E-steering detects the high-side driver for safety steer and TFD is not working right. - Remedy: Check the contacts A4 and A1. Check the TFD device if present. If the alarm persists, replace the controller. AFMNA0AA – EPS-BLI HYG – User Manual Page – 59/75...
  • Page 60 Alarm 0XFFCA = 250 Group #3 [M,S]: - Cause: This alarm occurs when the auto-teaching procedure for the feedback sensor fails. - Remedy: Repeat the procedure PMSM AUTOTEACH (see 9.2.5). Page – 60/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 61 60. HW TYPE is not defined with a valid value (see 9.2.5). 61. HW TYPE is not defined with a valid value (see 9.2.5). 62. HW TYPE is not defined with a valid value (see 9.2.5). AFMNA0AA – EPS-BLI HYG – User Manual Page – 61/75...

  • Page 62: Can Bus Alarm List

    The alarm code list provided by the master microcontroller of the E-steering motor controller is the following. WATCHDOG 220: MOTOR LOCKED EEPROM KO 221: M/S PAR CHK MISM LOGIC FAILURE #3 225: CURRENT GAIN VMN NOT OK 226: FUSE PROTECTION Page – 62/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 63 250: INPUT MISMATCH 212: WRONG RAM MEM. 251: INIT VMN NOT OK 213: PARAM RESTORE 253: ANALOG 215: CAN BUS KO M/S 254: NO SP REFRESH 216: TFD WRONG RESIST AFMNA0AA – EPS-BLI HYG – User Manual Page – 63/75...

  • Page 64: Safety Requirements & Recommendations

    VERY IMPORTANT: among the components of the system that are not in charge of Zapi there is the unit in the truck designated to lead the traction to a safe state in case of an alarm in the steering system (typically a VMC = Vehicle Master Control;...

  • Page 65: Vehicle Master Control (Vmc) Safety Functions

    TRUCK MNUFACTURER that has to ensure this procedure is 100% effective. Furthermore, special care is recommended in case the module designated to lead the traction to a safe state (traction control module = TMC) IS NOT A ZAPI UNIT (see 10.1 for properly coordinating the communication between E- steering motor controller and TMC).

  • Page 66: Fault Exclusions

    The recommendations of this manual highlighted with an attention box like this one, are safety relevant and so the user is recommended to accurately read and take care of these paragraphs and notes and ask for the Zapi support in case something is not clear.

  • Page 67: Installation Requirements & Recommendations

    When the cap has been removed be careful that the pinion does not impact any metallic part during the installation. AFMNA0AA – EPS-BLI HYG – User Manual Page – 67/75...

  • Page 68: Esd Cautions

    (as an alternative, a lamp can be used) between +B (CNA#3,4,5) and -B (CNA#6,7,8) of the cable in the E-steering motor controller connector (if the DC link of the E-steering motor controller is common with the Zapi pump controller, connect the resistance between +B and -B power posts of the pump controller).

  • Page 69: Upload Firmware In E-Steering Motor Controller

    PEAK, IFAK and KVASAR device. 3) Driver for USB to CAN Converter already installed in your PC. 4) Zapi software tool for Firmware Download: ZpCanFlasher. 14.2 Upload sequence After launching the software ZpCanFlasher, it is necessary to configure the USB-to- CAN device: select ‘Config Can’...
  • Page 70 After the confirmation, a new window appears. Tick the ‘USE IXXAT CONFIGURATION’ box and Select CAN bus Speed (125 kbps). Then press ‘OK’: The new window confirms that all previous actions were successful. Press the ‘OK’ button to continue. Page – 70/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 71 ZpCanFlasher and a particular node of the CAN bus network. Select from the ‘File’ drop-down menu the ‘Load ConfigFlash’ option. All .cfi files are listed following the path shown in the example below.   AFMNA0AA – EPS-BLI HYG – User Manual Page – 71/75...
  • Page 72 Select in the ‘File’ sub-menu the ‘Load File” option. Page – 72/75 AFMNA0AA – EPS-BLI HYG – User Manual...
  • Page 73 ‘Clear’ from the main menu and wait for the confirmation to appear in the log window:   Now select Flash to download the software onto the device and wait. AFMNA0AA – EPS-BLI HYG – User Manual Page – 73/75...
  • Page 74 Connection’. The Connection status will change again from “Connected” to “Not Connected”. Switch off the controller. The operation is finished. Remember that this operations needs to be repeated twice. Once for master and once for slave microcontroller. Page – 74/75 AFMNA0AA – EPS-BLI HYG – User Manual...

  • Page 75: Periodic Maintenance

    The installation of this electronic controller should be made according to the diagrams included in this manual. Any variations or special requirements should be made after consulting a Zapi agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this manual.

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