Zapi EPS-AC

Page 1
Indice
Page
Introduction .......................................................................................................... 3
1 System components ..................................................................................... 4
1.1 Steering servo motor control unit .......................................................... 4
1.2 Steer angle position potentiometer ....................................................... 5
1.3 Operator console................................................................................... 5
1.4 AC steering servo motor ....................................................................... 5
1.5 Steering handle ..................................................................................... 5
1.6 Motor shaft encoder .............................................................................. 6
2 Electrical specifications ............................................................................... 7
2.1 Battery voltage range ............................................................................ 7
2.2 Steer motor current range ..................................................................... 7
2.3 Command device specifications............................................................ 7
2.3.1 Tacho generator or stepper motor ............................................... 7
2.3.2 Automatic centering potentiometer .............................................. 8
3 Mechanical specifications............................................................................ 9
4 System description ..................................................................................... 10
4.1 Manual steering with tacho-generator or stepper motor ..................... 10
4.2 Automatic centering............................................................................. 10
5 Jumpers description ................................................................................... 11
6 Power connection diagram ........................................................................ 13
6.1 Electrical drawing ................................................................................ 14
6.1.1 Tacho-generator steering........................................................... 14
6.1.2 Stepper motor steering............................................................... 15
6.1.3 Tacho-generator steering with automatic centering ................... 16
6.1.4 Stepper motor steering with automatic centering ....................... 17
6.1.5 Interface description ................................................................... 18
7 One shot installation procedure ................................................................ 20
8 Description of connectors.......................................................................... 21
8.1 CNB connector .................................................................................... 21
8.2 CNA connector .................................................................................... 23
9 Setting the steering..................................................................................... 25
9.1 Tacho-generator or stepper motor controlled steering........................ 25
9.2 Automatic centering............................................................................. 25
9.3 Steer angle indicator gauge ................................................................ 26
10 Zapi hand set description........................................................................... 27
10.1 Manual mode steering option - hand set function map ....................... 28
10.2 Manual mode steering option and automatic centering -
hand set function map ......................................................................... 29
10.3 Main menu "Parameters list" ............................................................... 30
10.4 Parameters in set model 0 (tacho-generator or stepper motor only) .. 30
10.5 Parameters in set model 1 (tacho-generator or stepper motor and
automatic centering)............................................................................ 32
10.6 Main menu: "Tester" functions list ....................................................... 33
10.7 Config menu: "Set options" functions list............................................. 35

Zapi EPS-AC Specifications

General

Brand	Zapi
Model	EPS-AC
Category	Controller
Language	English

Summary

System Components

Steering Servo Motor Control Unit

Details the ADCZPA0D logic unit for AC motors in manual and automatic steering.

Steer Angle Position Potentiometer

Describes the multiturn 5K potentiometer used for measuring MDU angle in auto-centering.

Operator Console

Lists devices supported on the operator console: key switch, AUTOSEL, buzzer, gauge.

AC Steering Servo Motor

Specifies the three-phase AC induction motor's rated power and gearbox rotation time.

Steering Handle

Details options for steering input: tacho-generator or stepper motor.

Motor Shaft Encoder

Explains the optional encoder for special applications like speed control or safety.

Electrical Specifications

Battery Voltage Range

Defines the input voltage ranges for different control unit releases.

Steer Motor Current Range

Specifies maximum current limits for various battery voltage settings.

Command Device Specifications

Details specifications for tacho-generator and stepper motor command devices.

Mechanical Specifications

System Description

Manual Steering with Tacho-generator or Stepper Motor

Explains how the steering wheel rotation is converted to an electrical signal for motor control.

Automatic Centering

Describes the automatic MDU alignment process initiated by the AUTOSEL input.

Jumpers Description

Power Connection Diagram

Electrical Drawing

Provides schematic diagrams for various steering configurations.

Tacho-generator steering

Connection diagram for EPS-AC system with tacho-generator steering.

Stepper motor steering

Connection diagram for EPS-AC system with stepper motor steering.

Tacho-generator steering with automatic centering

Connection diagram for tacho-generator steering with auto-centering.

Stepper motor steering with automatic centering

Connection diagram for stepper motor steering with auto-centering.

Interface description

Details connections for feedback pot, travel demands, status device, and safety contacts.

One Shot Installation Procedure

Description of Connectors

CNB Connector

Describes the function and pinout of the CNB connector.

CNA Connector

Details the function and pin assignments for the CNA connector.

Setting the Steering

Tacho-generator or Stepper Motor Controlled Steering

Procedure for adjusting manual steering settings using the ZAPI hand set.

Automatic Centering

Steps to set up and adjust automatic centering precision and speed.

Steer Angle Indicator Gauge

Procedure for setting the steer angle feedback pot for correct gauge response.

Zapi Hand Set Description

Manual Mode Steering Option - Hand Set Function Map

Overview of hand set functions for manual steering mode.

Manual Mode Steering Option and Automatic Centering - Hand Set Function Map

Overview of hand set functions for manual and auto-centering steering modes.

Main Menu Parameters List

Lists and describes parameters available in the main menu for parameter adjustment.

Parameters in Set Model 0 (Tacho-generator or Stepper Motor Only)

Details specific parameters for tacho-generator or stepper motor configurations.

Parameters in Set Model 1 (Tacho-generator or Stepper Motor and Automatic Centering)

Details additional parameters for auto-centering configurations.

Main Menu: Tester Functions List

Describes the tester functions for real-time measurement of parameters.

Config Menu: Set Options Functions List

Lists configuration options to modify system settings.

Config Menu: Adjustments Functions List

Details adjustment functions for motor resistance, current amplifiers, and phase gains.

Config Menu: Set Model

Selects the steering configuration type (tacho-generator or stepper motor).

Maximum Current Adjustment

Procedure to modify the maximum current setting via the hidden Zapi menu.

EPS-AC Alarm List

Analysis of Alarms Displayed on Console

Detailed breakdown of alarm causes and remedies for various blink codes.

Safety Controls and Their Use

Safety Controls in Tacho-generator and Automatic Centering Steering

Lists malfunctioning conditions tested for manual steering operations.

Safety on Motor Wires Broken

Detects broken motor phases by monitoring current when motor frequency is non-zero.

Safety on Failure of the Steering Tacho-generator

Detects tacho-generator failure by impedance measurement and analyzes stepper motor phase failures.

Safety on the Presence of Current When the Steering Motor is at Rest

Checks current amplifier output at rest for deviations from expected voltage levels.

Safety on the Presence of Phase Voltage When the Steering Motor is at Rest

Tests phase voltage amplifier output at rest for deviations from specified voltage levels.

Safety on Pot Wires Broken (for Automatic Centering Operation)

Monitors feedback pot wiper voltage for open connections or out-of-range values.

Cross Diagnosis Between Master and Supervisor Microcontroller

Compares microcontroller readings to detect mismatches and trigger alarms.

Periodic Maintenance

Testing the Fault Detection Circuitry

Checks fault detection by simulating sensor disconnections to trigger alarms.