MOTOR CONTROLLER FOR ELECTRONIC POWER STEERING

FLY BY WIRE
INSTALLATION/OPERATION
MANUAL
for
FBW 4820

FBW 2440

Publication no 88Q020 Rev.C

Date:2000-05-04
54Q020PB
54Q020NB
54Q020RB
54Q020QB
TABLE OF CONTENTS
Content page

1. Overview ...................................................1

2. Specifications

2.1 General ..............................................2

2.2 Battery voltage ...................................2
2.3 Current capacity.................................3
2.4 Analog control inputs .........................3
2.5 Voltage outputs..................................3
2.6 Voltage input......................................3
2.7 Digital control inputs ..........................4
2.8 Safety relay output.............................4
2.9 Motor speed feedback .......................4
2.10 Safety system ....................................4
2.11 Indications..........................................5
2.12 Operating environment ......................6
2.13 Cooling and isolation .........................6
2.14 EMC...................................................6
2.15 Block diagram ....................................7
2.16 Mechanical dimensions .....................8

3. Installation instructions

3.1 Connections...................................... 9
3.2 Components required .......................10
3.2.1 Main contactor..........................10
3.2.2 Power fuse ...............................10
3.2.3 Control fuse ..............................10
3.2.4 Battery and motor cables .........10
3.2.5 Control wiring............................10
3.2.6 Limit switches ...........................10
3.2.7 Battery power supply ................11
3.2.8 Steering wheel tachometer.......11
3.2.9 Servo motor and gear...............11
3.3 Connectors .......................................12
3.3.1 Control connector .....................12
3.3.2 Power connector ......................12
3.4 Adjustments ......................................13
3.4.1 Current limit ..............................13
3.4.2 IR-compensation ......................13
3.4.3 Tachometer input scaling .........13
3.5 Indications.........................................14
3.5.1 LED ..........................................14
3.5.2 Output.......................................14
1. OVERVIEW
ELECTRONIC POWER STEERING FOR INDUSTRIAL BATTERY TRUCKS

FLY BY WIRE is the name of a series of controllers for electronic power

steerings, developed by Atlas Copco Controls in co-operation with manufacturers
of industrial battery trucks.

A complete steering system includes:

- electronic controller, FLY BY WIRE

- reference sensor (tachometer)
- DC-motor with gear
- contactors, fuses and cables

The electronic controller is designed to control a fully electric power steering

system. There is no mechanical connection between the steering wheel and the
traction wheel.

The FLY BY WIRE controller continuously monitors the entire steering system to
prevent any hazards. Any faults in the sensor, the cables, the controller or the
motor, will result in a fault condition and deenergized safety relay, diagnosed by
LED and optoisolated outputs.

When using a fully electric steering system the vehicle has to be stopped auto-
matically if any errors occurs.
This is achieved by connecting the safety relay, in the controller, to an electric
brake in the vehicle.

The safety system meets the European: Safety of machinery - Industrial trucks
prEN 1175-1 Part 1: Electrical requirements for battery powered trucks.

The power MOSFET transistors controlling the servo motor current provide high
efficiency, high reliability and long lifetime. The PWM switching frequency of
16kHz reduces motor losses and provides silent operation.

The controller has current and speed regulators and armature feedback with
compensation for motor voltage drop, I*R-compensation.

Cooling is achieved by mounting to a flat metal surface in the vehicle.

The right selection of sensors and servo motors is very important to guarantee
reliable operation. Atlas Copco Controls will assit in this matter.

....................................... 1
2. SPECIFICATIONS
2.1 GENERAL

Models 2440 ................. FBW 2440

........................ (24V battery voltage)

4820 ................. FBW 4820

........................ (48V battery voltage)

Part no 2440 ................. 54Q020PB

4820 ................. 54Q020NB / 54Q020RB / 54Q020QB

Motor type ........................ PM DC -motors

Motor inductance.................... min. 0,5mH

No. of quadrants ..................... 4Q

Modulation ........................ PWM (Puls Width Modulation)

Switching frequency............... 16kHz

2.2 BATTERY VOLTAGE

Nominal 2440 ................. 24VDC

4820 ................. 48VDC

Tolerances:

Continuous 2440 ................. 16-30VDC

4820 ................. 33-58VDC

Intermittent
<50ms 2440 ................. 12VDC (Start level > 20V)

4820 ................. 24VDC (Start level > 40V)

<100µs 2442 ................. 36VDC

4820 ................. 72VDC

........................ 2
2.3 CURRENT CAPACITY

Peak 2440 ................. 40A

4820 ................. 20A

Thermal average

2440 ................. 25A

........................ At +55oC environmental
4820 ................. 15A temperature

Adjustable current limits....... 50-100% of peak current.

........................ Adjustable in 4 steps with
dipswitches

2.4 ANALOG CONTROL INPUTS

From tachometer, put on the steering wheel:

Reference value ..................... +-1,3VDC up to +-5,9VDC

........................ Scaling adjustable in 16 steps with
dipswitches.
........................
........................ Progressive characteristic input,
........................ meaning increased sensitivity when
........................ faster rotation.

2.5 VOLTAGE OUTPUTS

+ ..................... +24VDC via 50 Ohm PTC

2.6 VOLTAGE INPUT

Internal supply
The same input as ....................
start/stopp 2440 ................. 24VDC

4820 ................. 48VDC

........................ 3
2.7 DIGITAL CONTROL INPUTS

Logic "0"=<4VDC
Logic "1"=>8VDC
max 58VDC

Start/stop ........................ Logic 1/logic 0

The same input as
internal supply

Positiv direction limiting ........ Logic 0: no limiting

........................ Logic 1: limiting

Negative direction limiting..... Logic 0: no limiting

........................ Logic 1: limiting

2.8 SAFETY RELAY OUTPUT

Safety relay 2440 ................. 24VDC (closed): ok

4820 ................. 48VDC (closed): ok

........................
........................ 0VDC (open): error
........................
........................ Relay data: max 48VDC, 3A

2.9 MOTOR SPEED FEEDBACK

Armature feedback with I*R-compensation.

I*R-compensation ................... Adjustable in 4 levels

........................ with dipswitches

2.10 SAFETY SYSTEM

When errors are detected the safety relay opens within 75ms and
the controller blocks power output.According to prEN 1175-1
The control is achived by a current pulse which is generated
by the safety system with frequency of 15Hz. The pulse passes
through the sensor, power electronics and motor circuit. If the pulse
disappears or changes shape beyond certain limits the safety system
will indicate error.
At every start up the safety system is checked by an error
simulation. It takes max 0,3 sec.
If the controller is stopped (turned off) it has to be >2 sec. before a
new start up.

........................ 4
Tachometer circuit ........................ Disconnections and short circuits
........................ are detected.

Electronic controller............... Motor output voltage above

........................ commanded values detected.

Motor circuit ........................ Disconnections and short circuit are

........................ detected.

Temperature protection ......... Linear reduction of current limit

........................ starting at 75oC .
........................
Short circuit protection .......... - Motor output+ to motor output-
........................ - Motor outputs to battery -

Power supply contactor ......... At every start-up: checking that

contactor is open

Emergency brake coil............. At every start-up: checking there is

no voltage on the coil

Direction limit switches ......... In direction limiting mode there is still

possible to get max 20-40% of supply
voltage on the motor output

2.11 INDICATIONS

LED-indications - Controller active

- Negative direction blocking active
- Positive direction blocking active
- Error in tacho sensor circuit
- Error in controller or motor circuit
- Error in controller
- Supply contactor closed or
voltage on emergency brake coil

Outputs indications - Controller active

- Error in sensor circuit
- Error in controller or motor circuit
- Error in controller
- Supply contactor closed or
voltage on emergency brake coil

5
2.12 OPERATION ENVIRONMENT

Temperature:

Operation ........................ -35oC - +55oC

Storage ........................ -40oC - +70oC

Humidity ........................ 100% condensing according to

IEC 68-2-30, Db

2.13 COOLING

External cooling ........ Contact cooling to metal plate or frame

Isolation ..................... 500VAC according to prEN 1175-1

2.14 EMC

Immunity: According to prEN50081-2

Emmission: According to prEN50082-2

6
 1
Start/Stopp
Safety relay 8

Temperatur sensor
Bat. +
2.15 BLOCK DIAGRAM

13
+12V
4 DC
Tachometer 0V
7 Voltage
-12V DC monitor
6
Tachometer
10 Blocking and PWM
Potentiometer
sensitivity Speed regulator Current regulator M1
11
Direction + + R C R C
- -
blocking - 5
+ +
- M2
Current limit

IR-sensitivity

Monitor puls
Bat.-
Error 3
signal 1 Sensors Current Voltage
monitor monitor monitor
Error 12
signal 2
Logic circuits monitor
9
Common

7
2.16 MECHANICAL DIMENSIONS

64

152
139

125

145 210

6.5

10

....................... 8
 Control fuse B+
Power fuse
Key switch
0
1
1 Start/Stop + Supply
3.1 CONNECTION

Battery + contactor
Internal supply
8
Safety circuit relay
13 Tachometer input
+24V scaling
4
0V Tachometer IxR-comp. adjust.
Steering wheel
tachometer 6 Current limit adjust. M1

.......................
Tachometer
Motor+
11
+ Direction limiting LED
Limit switches Steer
5 motor
- Direction limiting LED
M2
3 Motor-
Truck Error indication no 1,high LED
computer
10
Error indication no 1, low

12
Error indication no 2, high LED
9
Error indication no 2, low
-
3.INSTALLATION INSTRUCTIONS

Battery-

Safety brake
Controller

9
B-
3.2 COMPONENTS REQUIRED

3.2.1 POWER SUPPLY CONTACTOR

It must be controlled directly from the safety relay as shown in the

drawing.
Other connections may delay closing of main relay and cause error
condition.

Switching current
2440 ............. 50A

4820 ............ 25A

3.2.2 POWER FUSE

Current 2440 ............ 30A slow

4820 ............ 15A slow

3.2.3 CONTROL FUSE

Current ............... 6-10A slow

3.2.4 BATTERY AND MOTOR CABLES

Dimension 2440 ............ min. 4mm2

4820 ............ min. 2,5mm2

3.2.5 CONTROL WIRING

Dimension ............... min. 1mm2

3.2.6 LIMIT SWITCHES

Normal open (NO)

Operating at 5mA

............... 10
3.2.7 BATTERY POWER SUPPLY

Other power switching units on the same power supply cables may
affect the controllers internal capacitor. Please consult Atlas Copco
Controls in this case.

3.2.8 STEERING WHEEL TACHOMETER

Use only tachometers recommended by Atlas Copco Controls.

3.2.9 SERVO MOTOR AND GEAR

Use only motors and gears recommended by Atlas Copco Controls.

....................... 11
3.3 CONNECTORS

RE1
RELAY 1 ON

SW1 2 LIM-
OFF
K2 1 2 3 4 5 6 7 1
2
3 3 LIM+
4
5
M1 4
6 ERROR
7
8
5 ERROR

K1
M2 8 9 10 11 12 13

3.3.1 CONTROL CONNECTOR, 13-pin MIC, make: AMP

Pin no Function

1 Input: Start/stop and internal supply 24,48 V

2 Not connected
3 Output: Error indication no 1, high max 24 V, 5mA
(open collector)
4 Input: Tachometer 0V
5 Input: Negative direction limiting 15-48 V
6 Input: Reference value from tachometer +-[1,3-5,9] V
7 Not connected
8 Output: Safety circuit relay 24,48 V
9 Output: Error indication no 2, low
10 Error indication no 1, low
11 Input: Positive direction limiting 24,48 V
12 Output: Error indication no 2, high max 24 V, 5mA
(open collector)
13 Output: Supply for limit switches +24 V
(max 20 mA)

3.3.2 POWER CONNECTOR

4-pin POSITIV LOCK (5-pin with center pin excluded), make: AMP

Pin no. Function

+ Input: Battery voltage+ 24,48 V

- Input: Battery voltage- 0V
M1 Output: Motor connection +
M2 Output Motor connection -

12
 3.4 ADJUSTMENTS

RE1
RELAY 1 ON

SW1 2 LIM-
OFF
K2 1 2 3 4 5 6 7 1
2
3 3 LIM+
4
5
M1 4
6 ERROR
7
8
5 ERROR

K1
M2 8 9 10 11 12 13

3.4.1 CURRENT LIMIT

Dipswitch no 1 and 2:
4820 2440
Both switches open: 10A 20A
Switch no. 2 closed: 14A 28A
1: 17A 34A
1+2: 20A 40A

3.4.2 IR-COMPENSATION
Switch no 3 and 4:

Both switches open: No compensation

Switch no. 3 closed: 1/3
4: 2/3
3+4: Max compensation

3.4.3 TACHOMETER INPUT SCALING

Switch no. 5, 6, 7 and 8:
Switch no. 5+6+7+8 closed: +-1,3V
6+7+8: +-1,6V
5+7+8: +-1,9V
7+8: +-2,3V
5+6+8: +-2,6V
6+8: +-2,9V
5+8: +-3,2V
8: +-3,5V
5+6+7: +-3,8V
6+7: +-4,1V
5+7: +-4,4V
7: +-4,7V
5+6: +-5,0V
6: +-5,3V
5: +-5,6V
Switch no. 5+6+7+8 open: +-5,9V

13
3.5 INDICATIONS

RE1
RELAY 1 ON

SW1 2 LIM-
OFF
K2 1 2 3 4 5 6 7 1
2
3 3 LIM+
4
5
M1 4
6 ERROR
7
8
5 ERROR

K1
M2 8 9 10 11 12 13

3.5.1 LED:

LED 1 on (green): controller active

LED 2 on (red): negative direction limiting active
LED 3 on: positive direction limiting active
LED 4 on LED 5 off: error in sensor circuit
LED 4 off LED 5 on: error in controller or motor circuit
LED 4 on LED 5 on: error in controller
LED 1 on LED 4 off LED 5 off,
and controller is not starting up;
no output from safety circuit relay, 8: supply contactor closed or
voltage on emergency brake coil *

Outputs:

Error indication:
No 1 open no 2 open: controller active
No 1 active no 2 open: error in sensor circuit
No 1 open no 2 active: error in controller or motor circuit
No 1 active no 2 active: error in controller
No 1 open no 2 open,
and controller is not starting up;
no output from safety circuit relay, 8: supply contactor closed or
voltage on emergency brake coil *

* It has to be > 2 sec between a controller stop (turned off) and a new
start up. Otherwise this error may occur.

14