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1.0 INTRODUCTION
This equipment enables manually controlled power steering and automatic centering. Manually controlled steering
may use either a tacho-generator or a stepper motor fixed to the steering wheel. The automatic centering
operation requires a device mechanically fixed on the MDU (Motor Drive Unit). This device could be a
potentiometer or an encoder, the system adopted by NACCO provides an encoder mounted on the steering motor
shaft.
The MDU uses an inexpensive, robust and maintenance free three phases AC induction motor.
The on board CAN interface makes the communication exchange between our EPS and other controllers placed on
the truck rapid and simple, so potentially extending the steering performance to steer equalization for traction
speed, CAN management of a wire guidance application and so on.
Configuration options, steering adjustment, measurement functions, and toubleshooting operations are integrally
supported by the hand held controller equipped with Eprom release number CKULTRA ZP3.01 or later.
Improved safety and operation are provided by having two microprocessor: the first of them performs operations
and a second one executes supervisor functions.
The microprocessors combined with the hand held controller make servicing easy and direct, reducing adjustment
and troubleshooting time. Increased steering motor performance and reduced noise levels are achieved by using
MOSFET technology.

2.0 SYSTEM COMPONENTS

The EPS_AC equipment consists of the following parts:

2.1 STEERING SERVO MOTOR CONTROL UNIT

It consists of a control unit using the logic marked ADCZPA0D which operates the AC motor for both manual and
automatic centering steering.

48Vbatt unit provides a maximum current of 50Amps (Reach Truck AC)

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2.2 OPERATOR CONSOLE

The control unit can support the following devices typically fixed on the operator console.

1) Key switch
2) Manual/automatic centering selection switch (AUTOSEL).
3) A status device (BUZZER).
4) A steer angle indicator gauge.The steering system includes a three phase AC induction motor with a
maximum rated power of:

2.3 AC STEERING SERVO MOTOR

- 30A current rating (Imax=70A) if the battery voltage is 48Vdc. (about 1KW rated power motor).

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

2.4 STEERING HANDLE

This is a multi-turn steering handle or wheel attacched to a command device. There are two option:
1) tacho-generator. This solution requires just a two wire connection.
2) stepper motor. This solution requires either a six wire connection or an optional three wire connection.
This last device has a frictional linkage because there is no gear box.
Mounting the command device to eliminate axial or radial loading on the input shaft is important for reliable
operation.

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NOTE: All trucks use only the stepper motor system- on the EPS AC, the tacho system is never
used.

2.5 MOTOR SHAFT ENCODER

For the EPS AC controller to function correctly, it is necessary to connect an encoder installed on the shaft of
the steering motor. The encoder is necessary to carry out the following functions:

1. To increase the safety level

2. To execute the automatic centering operation
3. To manage the steer indicator
4. To replace the limit switches

This encoder has a resolution of 64 pulses per rotation: it is connected to Pin #6 CNA (Supply Positive
Voltage = 5Vdc), Pin #7 CNA (Supply Negative Voltage = GND), Pin #16 CNA ( Channel A), Pin #17 CNA
(channel B).

The encoder is fundamental for the correct functioning of electronic controllers of asynchronous AC motors.
Its function is to supply the controller with information relative to intant speed, acceleration, motor braking
and direction of rotation (particularly important for the steering controller). For these reasons, the encoder
must be installed on the motor shaft. When the controller has this rotation signal, it can maintain constant
rotation speed for example with traction when the truck descends a ramp. To know the direction of rotation
is usefull to control the direction of travel, usefull when the 360° steering system is installed.

2.5.1 COMPONENT DESCRIPTION

The kind of encoder used is a 'sensorised bearing' installed in the upper parte of each motor (traction,
pump, steering) to guide the motor shaft (Ref.A Fig.2)

The inner (rotating) ring of the bearing, has a series of polarized north-south magnets fixed to it by means

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of a plastic ring.
On the inside of the external (fixed) ring of the bearing there is a sensor, when the inner ring (and also
the armature) rotates, the alternation of the magnetic polarity is read generating a sequence of on-off
signals (square wave form).
The number of impulses per revolution depends on th enumber of magnets present in the bearing.
The encoders used on our motors emit 64 impulses per revolution.
Each encoder has 2 outputs that are dephased by 90° to each other, this allows the electronic controller
to understand the direction of rotation of the motor by observing the sequence of the outputs - either
on-off or off-on.

ENCODER INPUT/OUTPUT

NOTE: The 12V encoders have a different Part Number than the 5V encoders.Make sure thay
are connected to the correct power supply to avoid damage.

CONNECTION TO THE CONTROL MODULE

See 'Electrical System' section of the service manuals relative to the models using this device.

INSTALLATION ON THE MOTOR

See 'Mechanical' section of the service manuals relative to the models using this device.

3.0 ELECTRICAL SPECIFICATIONS

3.1 BATTERY VOLTAGE RANGE

48 48 VDC

3.2 STEERING MOTOR CURRENT RANGE

48 IMAX 70AAC. ADJUSTABLE WITH THE HAND HELD CONTROLLER

3.3 COMMAND DEVICE SPECIFICATIONS

3.3.1 STEPPER MOTOR - MECHANICAL SPECIFICATION

The Stepper Motor is used as a command device. This Stepper Motor is three wires connected. For a
correct connection, the two COM terminals of the stepper motor have to be joined in the stepper motor
side before converging to their GND reference (Pin #4 CNB).

Stepper motors are different from normal electric motors in that they have a permanent magnet as

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armature. This means that at each input impulse to the stator, the armature turns in a very small
fraction of a second by a certain angle, this angle is determined by the constructive characteristics of
the motor. A nearly instant arrest follows with high torque keeping the armatureer in position.
Rotation is a result of a certain number of impulses, inertia following these impulses is nearly
inexistant, the motor becomes indispensable in commanding digital that substitute always more often
the analogical, continuous systems that are commanded by a switch that is inserted at the beginning
of operation and remains insertefd until the end. Rotation is CW or CCw depending on the pattern of
the impulses.
The stepper motor can be used both with Alternating and Direct Current. In our case, the motor is
used as a generator, manually turning the armature, the stepper motor behaves as an AC generator.
The rotation of the magnets that make up the armature induces a sinusoidal electromagnetic force on
the field 90° dephased. The amplitude and frequency are proportional to the rotation speed of the
armature. The logic analyses and transforms the signal in two opposed signals to differentiate
rotation direction.

4.0 MECHANICAL SPECIFICATIONS

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5.0 SYSTEM DESCRIPTION

5.1 MANUAL STEERING WITH STEPPER MOTOR

This option uses a stepper motor attached to the steering wheel to convert the steering wheel
rotation into an electrical signal. The control logic sets the steer servo-motor in motion at a speed
that increases with the speed of the steering wheel. Steering sensitivity and maximum speed are
adjustable by using the hand held controller.

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5.2 AUTOMATIC CENTERING

At key on, the EPS AC unit receives an input from the steering position induction sensor that
reads the 'cam' fitted inside the gear crown on the MDU unit (see Fig.5.2). When the sensor
reads the cam at key on, the EPS AC unit gives instruction to the steering motor to turn the
MDU in counterclockwise (CCW) direction until the sensor no longer reads the cam, a small
adjustment is then carried out using the settings given in the fine adjustment procedure (SET
STEER 0-POS) and the wheel is centered. Contrarily, when at key on the sensor does not read
the cam, the EPS AC unit gives instruction to the steering motor to turn the MDU in clockwise
(CW) direction until the sensor reads the cam, a small adjustment is then carried out using the
settings given in the fine adjustment procedure (SET STEER 0-POS) and the wheel is centered.

Fine adjustment procedure is laid out in paragraph 8.0 SETTING THE STEERING.

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