Zapi EPS-ACW User Manual
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Zapi EPS-ACW 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 N°: AF9ZP0BA
Edition: October 2014
User Manual
EPS-ACW
REACH
TRUCK

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Summary of Contents for Zapi EPS-ACW

  • 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-ACW REACH TRUCK Publication N°: AF9ZP0BA...
  • Page 2 Under no circumstances will Zapi S.p.A. 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 spa reserves the right to make changes or improvements to its products at any time and without notice.

  • Page 3: Table Of Contents

    13.3.3  Config menu “ADJUSTMENTS” functions list ..........39  13.3.4  Config menu “SET MODEL” functions list ........... 42  13.3.5  Main menu “PARAMETER CHANGE” functions list ........44  13.3.6  Zapi menu “HARDWARE SETTINGS” functions list ........47  AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 3/90...
  • Page 4 13.3.7  Zapi menu “SPECIAL ADJUSTMENT” functions list ........50  13.3.8  Main menu “TESTER” functions list ............52  14  TROUBLESHOOTING ......................57  14.1  STATUS #1: selfcheck of the Motor and of the Power Drives ........57  14.2  STATUS #2: selfcheck of the Encoder and Transmission ........59 ...

  • Page 5: Introduction

    ISO13849 category # 3 and PLd requirements. On demand, and particularly suited for closed loop application (position control mode), the same system may be supplied with two internal encoders in the motor. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 5/90...

  • Page 6: Features

    Operating frequency: ..........8 kHz with center aligned PWM External temperature range: ............. -30 °C ÷ 40 °C Maximum inverter temperature: ..............80 °C International protection: ..................IP65 Figure 2–1 Page - 6/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 7: Mechanical Specifications

    Tightening Torque on the Epsacw_small_cover (Ref 5):………...1,5 +/- 0,2 Nm Tightening Torque on the Motor_encoder_cover (Ref 6):………..1,5 +/- 0,2 Nm Ref 6 Ref 3 Ref 5 Ref 2 Ref 1 Figure 3–1 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 7/90...

  • Page 8: Mechanical Drawing

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

  • Page 9: Motor And Gear Box

    Total gears ratio (about):................1:200 Encoder resolution*..……..……………………………..….....4 pulses/rev Thermal sensor: ..................KTY84-130 * Note: on demand, particularly suited for closed loop applications, version with two encoders same resolution is available too AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 9/90...

  • Page 10: Electrical Specifications

    Maximum current (36/48 V): ..........2’ (alarm after 5secs) Logic Supply current: .............. max 200 mA @ 24 V Minimum Input (key) Supply Voltage after start-up: .......... 12 V Power Fuse Rated Data.................40A 58V Page - 10/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 11: Blocks Diagram

    This is the one implemented in the current application and dealt in this manual. Figure 7.1-1 – Open Loop Mode Blocks Diagram AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 11/90...

  • Page 12: Position Control Mode (Closed Loop)

    In a Steer Assist Mode (Torque Assisted), the steering motor speed is proportional to the torque of the operator on the steering handle bar. Figure 7.3–1 – Steer Assist Blocks Diagram Page - 12/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 13: Functions Of The Eps-Acw

    (see Figure 8.1-1). Then the control will turn the steering motor moving at a speed proportional to the stepper motor speed (Open loop Mode). Stepper Motor Figure 8.1-1 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 13/90...

  • Page 14: System Components

    (see parameter MAXIMUM CURRENT) preserving the motor from overheating in case a fault (e.g. locking the gear box), turns the controller in its maximum current limitation. Figure 9.3–1 Page - 14/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 15: Sensor In The Steering Wheel

    (or two) straight ahead toggle switch. This manual deals with above configuration (one incremental encoder in the motor shaft together with one or two toggle switches on the steered AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 15/90...

  • Page 16: Prox Switches And Cam: Mounting Specification

    (STEER ANGLE) is positive in the direction with positive speed (ENC SPEED >0); it is negative in the moving direction with negative speed (ENC SPEED <0). Page - 16/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 17 2) The cam should be mounted with an offset vs. the straight ahead switch (SW1). This offset must be the difference between 90° - max CW (or CCW) angle. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 17/90...
  • Page 18 Figure 9.5.1.1–1 Figure 9.5.1.1–2 Page - 18/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 19 An hardware setting AUX FUNCTION 11 (see 12.4) is used to specify the toggle switches configuration (one or two toggle switches and their succession vs. angle steered wheel). Figure 9.5.1.2-2 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 19/90...
  • Page 20 (encoder transitions) within 180° of the steered angle. So the angle measurement is determined with quanta of 180/1600=0.112 degrees. Following this statement, we have developed, together with the Zapi AC-motors- manufacturer, a 4 pulses/rev discrete encoder. It is an external device (not integrated in the ball bearing) mounted in the backside of the motor (see Figure 9.5.1.3-1).
  • Page 21 1 pole pairs (2poles) 2 pole pairs (4poles) Ninth letter specifies the encoder resolution in the following list: 4 pulses/rev 6 pulses/rev 8 pulses/rev 16 pulses/rev 32 pulses/rev 48 pulses/rev 64 pulses/rev AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 21/90...

  • Page 22: Connecting Drawing

    (arrangement with two encoders is strongly recommended for closed loop application => position control mode with twin pot as a command or automatic functions like automatic centering into an aisle). Page - 22/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 23: Connector Assignment For A Configuration With 1Enc, 2Sws & 2Cans

    NOTE 2: For closed loop applications (i.e. position control loop with a twin pot analog command or automatic functions like automatic centering into an aisle, release with two encoders in the motor is strongly recommended AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 23/90...

  • Page 24: Installation Procedure

    PULSE FOR 180DEG and AUX FUNCTION 11 (see below). Step6 Set special adjustment AUX FUNCTION 11 to level 0 or 1 if only one Page - 24/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 25 Step12 Procedure is finished. Don’t forget to turn the special adjustment DEBUG OUTPUT to level 15 if never done before. Step13 Carry out the complete set-up description (see 12.1). AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 25/90...

  • Page 26: Setting The Eps-Acw

    The complete set-up changes vs. the truck configuration. Seek your own configuration below: 12.1.1 Manual mode with the Stepper Motor Step1 With Zapi’s support, set the correct motor parameters (see HARDWARE SETTINGS menu). Step2 Set the steer sensitivity. Use parameters SPEED LIMIT and SENSITIVITY (see 13.3.5.1 and 13.3.5.2).

  • Page 27: Stepper Motor With Mechanical Angle Limitation

    There are mainly 4 mounting arrangements for the prox switches (see figure 12.3.1-1 and 12.3.2-1 below). Two cases are considered: ENC SPEED > 0 in CCW or in CW direction. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 27/90...

  • Page 28: Sectors When Enc Speed Is Positive In Counterclockwise (Ccw) Direction

    12.3.1 Sectors when ENC SPEED is positive in CounterClockWise (CCW) direction Figure 12.3.1-1: ENC SPEED > 0 in CCW direction Page - 28/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 29: Sectors When Enc Speed Is Positive In Clockwise (Cw) Direction

    AUX FUNCTION 11 manual setting below. 12.4 AUX FUNCTION 11 manual setting AUX FUNCTION 11 specifies the toggle switches arrangement (number of toggle AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 29/90...

  • Page 30: Pulse In 180 Deg Manual Setting

    180 degrees wheel revolution onto the data at the right side of the display (X=..). This value may be calculated after knowing: 1) Encoder resolution (resol = pulses per revolution) Page - 30/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 31: Autoteaching

    PULSE IN 180 DEG and PLS IN HALF MOON 9) Recycle the key to finish the autoteaching procedure (setting AUTOTEACHING will be automatically turned OFF). AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 31/90...
  • Page 32 During AUTOTEACHING procedure, the steered wheel pivots for more than 360 degrees and so take care there is not any mechanical limitation on the steered wheel side before launching the AUTOTEACHING procedure. Page - 32/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 33: Programming & Adjustments Using Digital Console

    Adjustment of Parameters and changes to the inverter’s configuration are made using the Digital Console. The Console is connected to the CNC connector of the inverter. 13.2 Description of console (hand set) & connection Figure 13.2–1 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 33/90...

  • Page 34: Description Of Standard Console Menu

    Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02". The section describes the Zapi hand set functions. Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the Figure 13.2-1.

  • Page 35: Settings In Stepper Motor With Encoder And Two Toggles Switches

    13.3.1 Settings in Stepper motor with Encoder and Two Toggles Switches Figure 13.3.1–1 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 35/90...

  • Page 36: Config Menu "Set Options" Functions List

    The Display will show : SET OPTIONS SET OPTIONS Press OUT again. Display now will show the - ' ' ' ' % ' opening Zapi menu Figure 13.3.2-1 Page - 36/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 37 OFF: No steered wheel angle limitation, based on the feedback sensor value, occurs. OPTION#1 when set to option #1 the limit of the side to side steered AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 37/90...
  • Page 38 When it is set ON, the steered wheel angle will be limited when two conditions occur: a) the encoder counting reaches the 1ST (2ND) ANGLE GAIN b) the 90 degrees switch (SW2) toggles. Page - 38/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 39: Config Menu "Adjustments" Functions List

    ' % ' ' % ' 12) Press ENTER to confirm ' ' ' 13) Repeat the same from 5 to 12 points for the other adjustments Figure 13.3.3-1 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 39/90...
  • Page 40 Motor resistance in milliohms. This is the resistance of the motor measured between two motor terminals. The motor resistance may be either self- acquired (Zapi adjusted) or may be set by rolling up or down this adjustment. 4) ADJUSTMENT #03 (Factory adjusted).
  • Page 41 (Factory adjusted). This is the self-acquired offset value of the stepper motor line connected to CNA#17. The default value is 2.500 mV and can be re- acquired by rolling the DEBUG OUTPUT to 0 (see 13.3.7.3). AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 41/90...

  • Page 42: Config Menu "Set Model" Functions List

    ' % ' ' % ' 10) Press ENTER to confirm ' ' ' 11) Repeat the same from 5 to 10 points for the other adjustments Figure 13.3.4-1 Page - 42/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 43 It assumes a number between 0 to 255. This setting is used to (virtually) connect the hand-set to a remote unit CAN Bus connected. With the hand-set connected to the epsacw it is possible to communicate with a remote Zapi unit. Every Zapi unit has its own identification number (e.g. epsacw master uC is 6;...

  • Page 44: Main Menu "Parameter Change" Functions List

    12) Press ENTER to accept the changes, or press ' ' ' ' % ' OUT to discard them MAIN MENU 13) The Display will show PARAMETER CHANGE Figure 13.3.5-1 Page - 44/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 45 The derivative (lead) contribution generates dither that is possible to reduce by increasing this adjustment. Obviously lag and lead regulations influence the stability of the closed loop and so different setting must be empirically tried to avoid oscillations. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 45/90...
  • Page 46 SENSITIVI VS TRC does that but only when the steering wheel is slow turning. This attenuation must be proportional to the drive Page - 46/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 47: Zapi Menu "Hardware Settings" Functions List

    TRAC, epsacw considers the traction speed is full speed. 13.3.6 Zapi menu “HARDWARE SETTINGS” functions list To enter this Zapi hidden menu a special procedure is required. Ask this procedure directly to a Zapi technician. Here we have the parameters for the motor control.
  • Page 48 When the frequency in the steering motor is FREQMAX FOR IMAX + INC FREQ1, the quadrature current is limited to IQMAX1 below. Factory adjusted. 12) IQMAX1 Maximum quadrature current at a motor frequency of FREQMAX FOR Page - 48/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 49 This is just an evidence of the HW release is aboard. This is protected against being written. 20) CONSOLE This adjustment enables/disable the communication with the Zapi hand set. 21) AUX SPEED #1 This adjustment sets the max steering motor speed in hertz.

  • Page 50: Zapi Menu "Special Adjustment" Functions List

    (AUX SPEED #1) are safety relevant and only authorized technicians are admitted to change the default settings 13.3.7 Zapi menu “SPECIAL ADJUSTMENT” functions list To enter this Zapi hidden menu a special procedure is required. Ask this procedure directly to a Zapi technician. 1) SET TEMPERATURE Factory adjusted.
  • Page 51 OFF when the STEER ANGLE is in the window 0 to 90 degrees). LEVEL 5: two toggle switches in the straight ahead and 90 degrees position. PROX SWITCH #1 (corresponding to CNA#12) and PROX SWITCH #2 (corresponding to CNA#11) are AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 51/90...

  • Page 52: Main Menu "Tester" Functions List

    FEEDBACK SECTOR shows the current sector (i.e. configuration of the toggle switches within a steered wheel revolution). The steered wheel revolution is divided into 4 quadrants (sectors) corresponding to 4 different toggle switches configurations: Page - 52/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 53 3nd reading: Short duration reading (about 500msec): it is the superior limit of the current sector (in degrees: STEER ANGLE is expected to be lower than this limit. POSITION ERROR AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 53/90...
  • Page 54 Provides real time the state of the CCW toggle switch (connected to CNA#11). It is On (active) when CNA#11 is low. 14) CW LIMIT LEVEL When the maximum angle limitation via feedback sensors is enabled (see Page - 54/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 55 An alarm SELFCHECK #1 occurs and STATUS #1 in the TESTER menu collect the data (see 14.1). Selfcheck #1 provides a check-up response on the functionality of motor and power drives (see 14.1). AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 55/90...
  • Page 56 WHEEL DIRECTION the sign sent on the CAN Bus (and collected by the display) will be reversed. 23) TRUCK SPEED This reading supplies the traction speed in percentage of the MAX SPEED TRAC (see 13.3.5.12) Page - 56/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 57: Troubleshooting

    Zapi DUT reports -14. 4. 4 VALUE: 180 to 380 => [milliohms] resistance between V and W. Zapi DUT reports 280. 5. 1 VALUE: 3. Injection involves W and U. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 57/90...
  • Page 58 SELCK 1.7 STA #1: occurs in case none of the above conditions has been detected. So reading and deepen analysis of STATUS#1 information is needed for deciding the proceeding. Page - 58/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 59: Status #2: Selfcheck Of The Encoder And Transmission

    So, if you launch the STATUS #2 closed loop selfchecking routine with a steered wheel lifted up, following data collection is an example of the correct sequence: 1. 1 VALUE: lower than 6.50 [Aac]. Zapi DUT reports 3.6 [Aac]. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 59/90...
  • Page 60 WHEEL IS LIFTED UP, it reports a situation that could be of high friction. When the steered wheel is lifted up, lower than 6.5Aac are expected. Anyway, even for a Page - 60/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 61: Status #5: Measure Of The Insulation Of The Motor And Battery

    (INIT VMN NOT OK or CAPACITOR CHARGE alarms). VALUE: first short duration value (about 500msecs): it is the voltage at the rail capacitors when the 1 VALUE has been picked on. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 61/90...
  • Page 62 Figure 14.3–1 ALARMS recalling STATUS #5: 1) INIT VMN NOT OK Alarm 0xFFFB Group #0:. 2) CAPACITOR CHARGE Alarm 0xFF3C Group #0: Figure 14.3–2 Page - 62/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 63: Epsacw Alarms

    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. So the Lifttruck Manufacturer is responsible for...

  • Page 64: Epsacw Alarms List

    Node #18 (CAN Consolle) and #6 (remote Zapi hand-set) is the Master Microcontroller (MuC) Node #19 (CAN Consolle) and #38 (remote Zapi hand set) is the Slave Microcontroller (supervisor-SuC). Letteres inside square brackets refers to the Master and Slave nodes.
  • Page 65 Otherwise the problem can be a failure in the power three phase bridge or in terminal V motor connection. 6) POWER FAILURE #3 Alarm 0xFF47=71 Group #2 [M]: AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 65/90...
  • Page 66 Check the continuity of the stepper motor connections. In particular the resistance between CNA#17 and the minus battery (with the stepper motor at rest) is expected being very low (close to 30 ohms). Page - 66/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 67 This alarm occurs with steer at rest in case the amplifier on the linked voltage Vv-Vu is not in a narrow window of +/- 250mV around Vvu_zero 96msec long (sampling time 8msec for 12 consecutive samples. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 67/90...
  • Page 68 A/D conversion every 250usec. In case no new conversion is successfully ended within 1.25msec this alarm occurs (i.e. 5 consecutive conversions failed). - Remedy: Recycle the key. If problem persists replace the controller. 19) M/S PAR CHK MISM Page - 68/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 69 MuC has detected the condition for the max angle limitation and the SuC has not (or viceversa). YY = 02h 3. When in closed loop for a recovery at rest, a mismatch AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 69/90...
  • Page 70 This warning occurs when the steered wheel reaches the maximum angle. - Remedy: turns the steering wheel in the opposite direction. 27) BAD STEER 0-SET Warning with eps on 0xFF51=81 [M,S]: Page - 70/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 71 When SuC raises an alarm it cuts off the power stage and steering motor cannot be actuated anymore. Then MuC raises this warning. In the Zapi console, MuC specifies the LSByte of the SuC alarm code on the XX position. For instances: 1.
  • Page 72 2. Short circuit on the DC rail and –B on another unit in the truck. 33) POSITION ERROR Alarm 0xFFE4=228 Group #2 [M]: - Cause: This alarm occurs for an error in the redundant test of the Page - 72/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 73 (the sensor bearing has two rings: one is connected to the rotor shaft; the other is connected to the motor frame). Check these two rings are strictly AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 73/90...
  • Page 74 5. In case the peak value of one stepper motor channel (DL or QL) is lower than 0.61V meanwhile the peak value of the second channel is higher than 2V longer than 120msec (it Page - 74/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 75 Alarm 0xFFD1=209 Group #0 [S]: - Cause: Every 32 detections of the Inputs (analog and digital) (i.e. every 4msec) MuC generates a falling edge on an input of the SuC AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 75/90...
  • Page 76 In case it isn’t this alarm occurs. - Remedy: It reports either a short circuit to GND of the load connected to CNA#9 or a problem in the controller (on safety switch Q3). Page - 76/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...

  • Page 77: Alarms In Selfcheck Routines

    2) CHECK #1 OK Warning 0xFE0F=205 [M] : - Cause: This alarm occurs only as a response of the SELFCHECK #1. It occurs in case the selfcheck #1 has passed. Condition for AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 77/90...
  • Page 78 W or U. 8) SELCK 1.6 CTL KO Alarm 0xFE06=205 [M] : - Cause: This alarm occurs only as a response of the SELFCHECK #1. It Page - 78/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 79 This alarm occurs only as a response of the SELFCHECK #2. It occurs in case the minimum encoder increment in 16msec has been detected lower than 2 (valley detection) and the average AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 79/90...
  • Page 80 (e.g. failure in the ball bearings or transmission) and not for an external physiological condition (e.g. hard floor or wheel Page - 80/90 AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual...
  • Page 81 #2 has not been passed but none of the above failure conditions has been detected. - Remedy: Only deepen analysis and interpretation of STATUS#2 (see TESTER menu) may help to finalize the troubleshooting AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 81/90...

  • Page 82: Can Bus "Alarms" List

    15.4 CAN BUS “ALARMS” List The Alarm Code List supplied by the Master Microcontroller (MuC) in the epsacW (Source Device Code #18 for the CAN Console and #06 for the remote Zapi hand set) is the following: WATCH DOG EEPROM KO...
  • Page 83 (Source Device Code #19 for the CAN Console and #38 for the remote Zapi hand set) is the following: WATCH DOG EEPROM KO LOGIC FAILURE #4 LOGIC FAILURE #3 VMN NOT OK MAIN CONT. OPEN STBY I HIGH HIGH CURRENT...

  • Page 84: 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 85: Straight Ahead Switch (Sw1)

    POSITION ERROR when SW2 toggles (real angle is +90°) and the measured angle is only (+90°-30°=) + 60°; in the other direction, the steered wheel angle will be limited to a (real) steered wheel angle of -60° AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 85/90...

  • Page 86: Safety Function To Stop The Traction Following An Epsacw Alarm

    To enable this handling, turn option SW2 LIMITING to ON. 16.2 Safety Function to stop the Traction following an epsacW alarm In case of an alarm in the steering system, the job in the Zapi steering assembly finishes when the STOP TRACTION REQUEST info (Bit in a PDO) and the alarm code (EMERGENCY or PDO frame) has been released on the CAN BUS (ask the object dictionary to the Zapi technicians).The procedure...

  • Page 87: Closed Loop Mode

    Besides only skill and well trained technicians are allowed to change these safety relevant parameters. 1) Zapi is available for supporting the lift truck manufacturer to list the safety relevant parameters. 2) Zapi is also available for limiting the rights to change these safety relevant parameters on the user demand.

  • Page 88: Safety Relevant Notes

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

  • Page 89: Installation Requirements & Recommendations

    3. IMPORTANT 3: TAKE CARE YOUR FINGERS STAYS AWAY FROM THE PINS OF THE EPSACW CONNECTOR DURING INSTALLATION. The fingers can bend or contaminate the pins. AF9ZP0BA - EPS-ACW REACH TRUCK - User Manual Page - 89/90...

  • Page 90: Periodic Maintenance To Be Repeated At Times Indicated

    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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