power amplifier for directional valves - w.e.st · pdf filepower amplifier for directional...

W.E.ST. Elektronik GmbH

Technical Documentation

PAM-195-P

PAM-195-L

Power amplifier for directional valves


of 30 PAM-195-*-1222 29.01.2014

CONTENTS

1 General Information ............................................................................................................................................. 4

1.1 Order number .............................................................................................................................................. 4

1.2 Scope of supply ........................................................................................................................................... 4

1.3 Accessories ................................................................................................................................................. 4

1.4 Symbols used .............................................................................................................................................. 5

1.5 Legal notice ................................................................................................................................................. 5

1.6 Safety instructions ....................................................................................................................................... 6

2 Characteristics ..................................................................................................................................................... 7

2.1 Device description ....................................................................................................................................... 8

3 Use and application ............................................................................................................................................. 9

3.1 Installation instructions ................................................................................................................................ 9

3.2 Typical system structure ............................................................................................................................ 10

3.3 Method of operation ................................................................................................................................... 10

3.4 Commissioning .......................................................................................................................................... 11

4 Technical description ......................................................................................................................................... 12

4.1 Input and output signals ............................................................................................................................. 12

4.2 LED definitions ........................................................................................................................................... 12

4.3 Circuit diagram ........................................................................................................................................... 13

4.4 Typical wiring ............................................................................................................................................. 14

4.5 Connection examples ................................................................................................................................ 14

4.6 Technical data ........................................................................................................................................... 15

5 Parameters ........................................................................................................................................................ 16

5.1 Parameterlist.............................................................................................................................................. 16

5.2 Parameter description ................................................................................................................................ 17

5.2.1 LG (Changing the language for the help texts) ................................................................................. 17

5.2.2 MODE (Switching between parametergroups) .................................................................................. 17

5.2.3 SOLENOIDS (One or two solenoids) ................................................................................................ 17

5.2.4 CCMODE (Activation of the characteristic linearization) ................................................................... 18

5.2.5 RCURR (Current input in mA) ........................................................................................................... 18

5.2.6 FUNC:IN (Choice of the additional function of S0/PIN 6) .................................................................. 18

5.2.7 S1 (Switchover of the output current) ................................................................................................ 19

5.2.8 LIM (Signal monitoring) ..................................................................................................................... 19

5.2.9 POL (Output polarity) ........................................................................................................................ 19

5.2.10 SENS (malfunction monitoring) ......................................................................................................... 20

5.2.11 AINA (Current- / Voltage input) ......................................................................................................... 21

5.2.12 AIN (Analogue input scaling) ............................................................................................................. 21

5.2.13 AA (Ramp function) ........................................................................................................................... 22

5.2.14 CC (Characteristic linearization) ....................................................................................................... 23

5.2.15 MIN (Overlap compensation) ............................................................................................................ 24

5.2.16 MAX (output scaling) ......................................................................................................................... 24

5.2.17 TRIGGER (threshold value of MIN function) ..................................................................................... 24

5.2.18 CURRENT (Current range switch) .................................................................................................... 25

5.2.19 DFREQ (Dither frequency) ................................................................................................................ 25

5.2.20 DAMPL (Dither amplitude) ................................................................................................................ 25

5.2.21 PWM (PWM frequency) .................................................................................................................... 25

5.2.22 PPWM (Solenoid current controller P gain) ....................................................................................... 26

5.2.23 IPWM (Solenoid current controller I gain) ......................................................................................... 26

5.2.24 PROCESS DATA (Monitoring) .......................................................................................................... 26

6 Appendix ............................................................................................................................................................ 27

6.1 Failure monitoring ...................................................................................................................................... 27


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6.2 Troubleshooting ......................................................................................................................................... 27

6.3 Special versions ......................................................................................................................................... 28

6.4 Description of the command structure ........................................................................................................ 28

7 Remarks ............................................................................................................................................................. 29


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1 General Information

1.1 Order number

PAM-195-P-12221 - for directional valves (max output current: 1,0 A, 1,6 A and 2,6 A)

PAM-195-L-1222 - for directional valves (max output current: 0,5 A, 0,8 A and 1,3 A)

Alternative products

PAM-195-P-GL - special version with GL approval

PAM-196-P - two independent channels for pressure or throttle valves

PAM-193-P - power amplifier for control, throttle and pressure valves, adjustment via potentiometer

1.2 Scope of supply

The scope of supply includes the moduleplus the terminal blocks which are a part of the housing.

The Profibus plug, interface cables and further parts which may be required should be ordered separately.

This documentation can be downloaded as a PDF file from www.w-e-st.de.

1.3 Accessories

RS232-SO - Programming cable with RS232C interface

USB-SO - Programming cable with USB interface

WPC-300 - Start-Up-Tool (downloadable from our homepage – products/software)

1 The number of the version consists of the hardware-version (first two digits) and the software-version (second two

digits). Because of the development of the products these numbers can vary. They are not strictly necessary for the order. We will always deliver the newest version.


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1.4 Symbols used

General information

Safety-related information

1.5 Legal notice

W.E.St. Elektronik GmbH

Gewerbering 31

D-41372 Niederkrüchten

Tel.: +49 (0)2163 577355-0

Fax.: +49 (0)2163 577355 -11

Homepage: www.w-e-st.de or www.west-electronics.com

EMAIL: [email protected]

Date: 29.01.2014

The data and characteristics described herein serve only to describe the product. The user is required to evaluate this data and to check suitability for the particular application. General suitability cannot be inferred from this document. We reserve the right to make technical modifications due to further development of the product described in this manual. The technical information and dimensions are non-binding. No claims may be made based on them.

This document is copyright.


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1.6 Safety instructions Please read this document and the safety instructions carefully. This document will help to define the product area of application and to put it into operation. Additional documents (WPC-300 for the start-up software) and knowledge of the application should be taken into account or be available. General regulations and laws (depending on the country: e.g. accident prevention and environmental pro-tection) must be complied with.

These modules are designed for hydraulic applications in open or closedloop control cir-cuits. Uncontrolled movements can be caused by device defects (in the hydraulic module orthe components), application errors and electricalfaults. Work on the drive or the elec-tronics must only be carried out whilst the equipment is switched off and not under pres-sure.

This handbook describes the functions and the electrical connections for this electronic assembly. All technical documents which pertain to the system must be complied with when commissioning.

This device may only be connected and put into operation by trained specialist staff. The instruction manual must be read with care. The installation instructions and the commis-sioning instructions must be followed. Guarantee and liability claims are invalid if the in-structions are not complied with and/or in case of incorrect installation or inappropriate use.

CAUTION! All electronic modules are manufactured to a high quality. Malfunctions due to the failure of components cannot, however, be excluded. Despite extensive testing the same also applies for the software. If these devices are deployed in safety-relevant applications, suitable external measures must be taken to guarantee the necessary safety.The same applies for faults which affect safety. No liability can be assumed for possible damage.

Further instructions

• The module may only be operated in compliance with the national EMC regulations. It is the user’s responsibility to adhere to these regulations.

• The device is only intended for use in the commercial sector.

• When not in use the module must be protected from the effects of the weather, con-tamination and mechanical damage.

• The module may not be used in an explosive environment.

• To ensure adequate cooling the ventilation slots must not be covered.

• The device must be disposed of in accordance with national statutory provisions.


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2 Characteristics

This module is used for the control of proportional valves.

The amplifier is controlled by a ±10 V (or 4... 20 mA) signal. The output current is closed loop controlled and therefore independent from the supply voltage and a varying solenoid resistance.

The universal input scaling enables the use of different input signals (e.g.: 0... 5... 10 V with 5 V for the centre position – joysticks –),

For monitoring (broken cable of the joystick) of the signal the boundary can be defined.

By the free parameterization of the power stage all typical proportional valves of the different manufac-

tures can be optimally adapted.

Typical applications: Control of proportional valves, current controlled adjustment of directional-, throttle

and pressure valves.

Features

• Power amplifier for proportional directional valves

• Compact housing

• Digital reproducible adjustments

• New: Free scaling of the input signal

• New: Monitoring of the signal range e.g.for joysticks

• Characteristic linearization via 10 XY-points per solenoid

• Free parameterization of ramps, MIN and MAX, DITHER (frequency and amplitude) and

PWM frequency

• MIN / MAX adjustment alternative in [mA]

• Output current up to 2,6A

• Adaptable to all standard proportional valves

• Fault diagnosis and extended function checking

• Simplified parameterization with WPC-300 software version 3.2


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2.1 Device description

V:ID:

Add.:Date:

Made in Germany

W.E.ST.

Ready

Status

1 2 3 4

5 6 7 8

9 10 11 12

14 15 1613

D-41372 NiederkrüchtenHomepage: http://www.w-e-st.de

W.E.ST. Elektronik

13 14 15

9 10 11 12

16

Klemmblöcke (steckbar)Terminals (removable)

LEDs

RS232 Interface

Typenschild und AnschlussbelegungType plate and terminal pin assignment

23,0000 mm99,0000 mm

114,0000 mm


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3 Use and application

3.1 Installation instructions

• This module is designed for installation in a shielded EMC housing (control cabinet). All cables which lead outside must be screened; complete screening is required. It is also a requirement that no strong electro-magnetic interference sources are installed nearby when using our open and closed loop control modules.

• Typical installation location: 24V control signal area (close to PLC) The devices must be arranged in the control cabinet so that the power section and the signal sec-tion are separate from each other. Experience shows that the installation space close to the PLC (24 V area) is most suitable. All digital and analogue inputs and outputs are fitted with filters and surge protection in the device.

• The module should be installed and wired in accordance with the documentation bearing in mind EMC principles. If other consumers are operated with the same power supply, a star-connected ground wiring scheme is recommended. The following points must be observed when wiring:

• The signal cables must be laid separately from power cables.

• Analogue signal cables must be screened.

• All other cables must be screened if there are powerful interference sources (frequen-cy converters, power contactors) and cable lengths > 3m. Inexpensive SMD ferrites can be used with high-frequency radiation.

• The screening should be connected to PE (PE terminal) as close to the module as possible. The local requirements for screening must be taken into account in all cases. The screening should be connected to at both ends. Equipotential bonding must be provided where there are differences between the connected electrical components.

• With longer lengths of cable (>10 m) the diameters and screening measures should be checked by specialists (e.g. for possible interference, noise sources and voltage drop). Particular care is required with cables of over 40 m in length – the manufacturer should be consulted if necessary.

• A low-resistance connection between PE and the mounting rail should be provided. Transient in-terference is transmitted from the module directly to the mounting rail and from there to the local earth.

• Power should be supplied by a regulated power supply unit (typically a PELV system complying with IEC364-4-4, secure low voltage). The low internal resistance of regulated power supplies gives better interference voltage dissipation, which improves the signal quality of high-resolution sensors in particular. Switched inductances (relays and valve coils) connected to the same power supply must always be provided with appropriate overvoltage protection directly at the coil.


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3.2 Typical system structure

This minimal system consists of the following components:

(*1) proportional valve

(*2) hydraulic cylinder

(*3) power amplifier PAM-195

(*4) interface to PLC with analogue and digital signals

3.3 Method of operation

This power amplifier will be controlled via an analogue signal (from the SPS, from a joystick or a potenti-ometer). An ENABLE signal (24V typical) activates the function and the READY output indicates the ac-tive module, if no internal or external error was detected.

The integrated standard functions will be configured via different parameters.

In case of a fault the power output stage will be deactivated and the fault will be indicated via deactivating the READY output and the flashing READY LED.

Three different modes can be used for the error management. SENS=ON: all faults have to be acknowl-edged by the ENABLE input. SENS=AUTO: automatic reset mode for all signal faults. SENS=OFF: fault detection is suppressed.

The output current is controlled whereby a high accuracy and a good dynamic will be obtained. All cus-tomary proportional valves (up to 2,6A) could be controlled with this power amplifier.


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3.4 Commissioning

Step Task

Installation Install the device in accordance with the circuit diagram. Ensure it is wired correct-ly and that the signals are well shielded. The device must be installed in a protec-tive housing (control cabinet or similar).

Switching on for the first time

Ensure that no unwanted movement is possible in the drive (e.g. switch off the hydraulics). Connect an ammeter and check the current consumed by the device. If it is higher than specified, there is an error in the wiring. Switch the device off immediately and check the wiring.

Setting up communication Once the power input is correct the PC (notebook) should be connected to the se-rial interface. Please see the WPC-300 program documentation for how to set up communication.

Further commissioning and diagnosis are supported by the operating software.

Pre-parameterization Now set up the following parameters (with reference to the system design and cir-cuit diagrams):

The output current and the typical valve parameter such as DITHER and MIN/MAX.

Pre-parameterization is necessary to minimize the risk of uncontrolled move-ments.

Control signal Check the control signal with a voltmeter. The control signal (the current of the solenoid) is within the range of 0... 2, 6A. In the actual status it should show ap-proximately 0A. CAUTION! You can monitor the current of the solenoids also in the WPC-300 program.

Switching on the hydraulics

The hydraulics can now be switched on. The module is not yet generating a sig-nal. Drives should be at a standstill or drift slightly (leave its position at a slow speed).

Activating ENABLE CAUTION! Drives can now leave their position and move to an end position at full speed. Take safety measures to prevent personal injury and damage.

The hydraulic axis can be moved over the analogue input value.

Optimize controller Now optimize the remaining parameters according to your application and your requirements.


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4 Technical description

4.1 Input and output signals

4.2 LED definitions

Connection Supply

PIN 7 Power supply (see technical data)

PIN 8 0 V (GND) Power supply (ground). Attention, PIN 8 is connected with PIN 11 internal. PIN 11 is used as the GND potential for the command and feedback signals.

Connection Analogue signals

PIN 9 / 10

PIN 13 / 14

Command (input) signal (W), range +/-100% corresponds with +/-10V or 4… 20 mA.

PIN 11 0 V (GND) for the signal inputs

PIN 12 Reference output voltage (8V).

PIN 1 / 2

PIN 3 / 4

Current controlled PWM outputs for solenoid A and B.

Connection Digital inputs and outputs

PIN 6 S0 input:

Function depends on parameter FUNC:IN (S1/RAMP).

OFF: Output current depending on the parameter S1 / ramp function is deactivated.

ON: 100% output current / ramp function is active.

PIN 5 READY output:

ON: No internal or external errors are detected.

OFF: ENABLE (PIN 15) is deactivated or an error is detected.

LEDs Description of the LED function

GREEN Identical to the READY output.

OFF: No power supply or ENABLE is not activated.

ON: System is ready for operation.

Flashing: Error detected (e.g. valve solenoid or 4… 20 mA).

Not active when SENS = OFF.

YELLOW The intensity is proportional to the output current.


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4.3 Circuit diagram

Example.: Hawe valves

Com

mands:

AIN

:WA

INA

LIM

Inp

ut

Sca

ling

PE

via

DIN

-RA

IL

3 4 1 515

Ready

Enable

S1

24 V

ou

tpu

t

3,5

mm

JIS

C-6

560 B

uch

se

PA

M-1

95

69 14

-10...1

0V

4... 20 m

A

0 V

10

13

Ou

tpu

t A

dap

tati

on

24 V

inp

ut

24 V

inp

ut

ws

u

Inte

rnal P

ow

er

7 80 V

Co

ntr

ol p

rog

ram

RS

232

C96

00 B

aud

1 S

topb

itno

par

ity

RA

MP

Gen

erat

or

Com

mands:

- A

A:1

...

AA

:4

Input

Lin

ear

isat

ion

Com

mands:

- C

CM

OD

E-

CC

Com

mands:

- M

IN:A

and :B

- M

AX

:A a

nd :B

- T

RIG

GE

R-

PO

L

DC

DC

24 V

0 V

PE

LV

w

Com

mands:

- LG

(Language

s)-

MO

DE

(E

xpert

or

Sta

ndard

)-

RC

UR

R-

SE

NS

Po

wer

Sta

ge

Com

mands:

- C

UR

RE

NT

- D

FR

EQ

- D

AM

PL

- P

WM

- P

PW

M-

IPW

M

ia ib2

A-S

ole

noid

B-S

ole

noid

Diff

ere

ntia

l input

Volta

ges

input

only

c

S1

11

Refe

rence

outp

ut (8

V)

12

3 4 12

A-S

ole

noid

B-S

ole

noid


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4.4 Typical wiring

4.5 Connection examples

AIN:W 2000 800 4000 V (für +/- 100%)

8V PIN 12

GND PIN 11

+In PIN 9

-In PIN 10

Potentiometer / Joystick

+In PIN 9

-In PIN 10

SPS / PLC 0... 10 V / +/- 10 V

8V PIN 12

GND PIN 11

+In PIN 9

-In PIN 10

Joystick

4... 20 mA input

+In PIN 9 + 13

-In PIN 10 + 14

GND PIN 11

AIN:W 2000 1600 2000 C ( für 0... 100%)AIN:W 2000 800 6000 C (für +/-100%)

AIN:W 1000 1000 0 V (für +/-100%) AIN:W 1000 800 0 V (für 0... 100%)AIN:W 2000 800 4000 V (für +/-100%)

0... 10 V to +/- 100% with external direction control

+In PIN 9

-In PIN 10

GND PIN 11

AIN:W 1000 1000 0 V (für 0... 100% plus Polaritätsumschaltung)

PIN 6 (24 V input) Parameter S1 = -10000

Enable

8765

16151413

1211109

Analoger Sollwert (-10... 10V)Analogue command signal (-10... 10V)

Magnet ASolenoid A

4321

0V

Schirm /Screen

PE

SpannungsversorgungPower Supply

0V

12 V / 24 V

Magnet BSolenoid B

+-

V ref.PE


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4.6 Technical data

Power supply

Power consumption max.

External fuse

[VDC]

[W]

[A]

12… 30 (incl. ripple)

60 (depending on solenoid type)

3 medium time lag

Reference voltage [V] 8 (maximum 10 mA)

Digital inputs

Input resistance

[V]

[V]

[kΩ]

logic 0: < 2

logic 1: > 10

25

Digital outputs [V]

[V]

logic 0: < 2

logic 1: > 12 (50 mA)

Analogue inputs

Resolution

[V]

[mA]

[%]

±10 / 0… 10; 90 kΩ

4...20; 390 Ω

< 0,1 (intern 0,02) incl. oversampling

PWM Output current

PWM frequency

[A]

[Hz]

1,0, 1,6 or 2,6 (per software selectable); broken wire and short circuit protected

50...2600

Sample time (pressure control)

Sample time (solenoid current control)

[ms]

[ms]

1

0,167

Interface

RS 232C, 9600 Baud, 1 stopbit, No parity, Echo Mode

Housing Snap-On Module EN 50022

Polyamide PA 6.6

Combustibility class V0 (UL94)

Protection class

Temperature range

Storage temperature

Humidity

Vibration

[°C]

[°C]

[%]

-

IP20

-20… 60

-20 …70

< 95 (not condensing)

IEC 60068-2-6 (category C)

Connections RS232C: 3,5mm JISC-6560

4 x 4pol. screw terminals

PE: direct via DIN rail

EMC EN 61000-6-2: 8/2002

EN 61000-6-3: 6/2005


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5 Parameters

5.1 Parameterlist

Command Default Unit Description

LG GB - Changing language help texts.

MODE STD - Mode parameter (standard or expert).

SOLENOIDS 2 - Switchover between one and two solenoids.

CCMODE OFF - Activation and deactivation of the characteristic linearization.

RCURR OFF - Parameterization of the MIN/MAX adjustment in mA.

FUNC:IN S1 - Switching function of the S0 input (PIN 6).

S1 10000 0,01% Switching over of the current output.

LIM 0 0,01% Range monitoring of the input signal (e.g. detecting failures of joy-sticks).

POL + - Changing of the output polarity.

SENS AUTO - Activation and deactivation of the monitoring functions.

AINA V - Simple input switchover between current (4...20 mA) and voltage (±10 V).

AIN:A A: 1000

B: 1000

C: 0

X: V

-

-

0,01 %

-

Scaling of the analogue input signal.

AA:1

AA:2

AA:3

AA:4

100

100

100

100

ms

ms

ms

ms

Four quadrant ramp times.

CC:-10… +10 X Y - Linearization function.

MIN:A

MIN:B

0

0

0,01%

0,01 %

Compensation of the deadband.

MAX:A

MAX:B

10000

10000

0,01%

0,01 %

Scaling of the current output.

TRIGGER 200 0,01% Trigger point for activating the MIN value.

CURRENT 0 - Selection of the rated current: 0 = 1 A; 1 = 1,6 A; 2 = 2,6 A

DFREQ 120 Hz Dither frequency

DAMPL 500 0,01% Dither amplitude.

PWM 2604 Hz PWM frequency

PPWM

IPWM

7

40

-

-

Control parameter for the current control loop.


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5.2 Parameter description

5.2.1 LG (Changing the language for the help texts)

Command Parameters Unit Group

LG X x= DE|GB - STD

Either German or English can be selected for the help texts in the WPC-300 program.

CAUTION: After changing the language settings the parameter list has to be updated by press-ing the “ID” Button in the menu bar of the WPC-300.

5.2.2 MODE (Switching between parametergroups)


MODE X x= STD|EXP - STD

This command changes the operating mode. Various commands (defined via STD/EXP) are blanked out in standard mode. The several commands in expert mode have more significant influence on the system performance. Therefore they should be changed with care.

Other group functions will change the parameter list depending on the settings in the corresponding commands. Only the relevant variation of the parameter is visible.

5.2.3 SOLENOIDS (One or two solenoids)


SOLENOIDS X x= 1|2 - STD

This parameter allows you to adapt the amplifier to valves with one solenoid (e.g. pressure valves) or to such with two solenoids (directional valves).

CAUTION: If using valves with two solenoids and 4…20mA input signal, solenoid A will be acti-vated by 12…4 mA and solenoid B by 12…20 mA. For valves with one solenoid and 4…20 mA input signal, the activation has to be parameterized via the AIN:A command in the expertmode.


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5.2.4 CCMODE (Activation of the characteristic linearization)


CCMODE X x= ON|OFF - EXP

This command will be used for activation or deactivation of the characteristic linearization. Because of the direct deactivating a simple and quick estimation of the linearization is possible.

5.2.5 RCURR (Current input in mA)


RCURR X x= ON|OFF - EXP

Switching on this parameter allows defining the MIN and MAX values directly in mA. Otherwise the MIN and MAX values are defined percentaged depending on the current parameter.

This parameter is activating the real current function for MIN and MAX input.

5.2.6 FUNC:IN (Choice of the additional function of S0/PIN 6)


FUNC:IN X x = S1|RAMP - EXP

This command offers two additional functions selectable by input S0/PIN 6.

S1: PIN 6 = active, output current range = 100% PIN 6 = inactive, output current range is scalable by the parameter S1.

RAMP: PIN 6 = active, the ramp function is activated. PIN 6 = inactive, the ramp function is deactivated (no ramp times).

In case of: FUNC:IN = RAMP, S1 should be always 10000 (default). In case of: FUNC:IN = S1, the ramp generator is always active.


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5.2.7 S1 (Switchover of the output current)


S1 X x= -10000… 10000 0,01% EXP

This parameter makes it possible to set a reduced or polarity switched output signal. It is active during it is chosen by the command parameter FUNC:IN and deactivation of S0 (PIN 6). In default settings there is no reduction (S1 is 10000 means 100%).

By setting S1 to -10000, the polarity can be switched via input S0 (PIN 6). So the power amplifier can be controlled by a simple 0…10 V signal from a plc. CAUTION: Switching will proceed without ramp times, so it should be made only with an input signal of 0 V.

5.2.8 LIM (Signal monitoring)


LIM X x= 0… 2000 0,01% EXP

The signal monitoring deactivates the output current and the READY output if the input signal leaves the permitted range after scaling. This function makes it possible to detect a short circuit or cable break of a joystick or potentiometer. Example:

LIM 500 (5% lower/upper limitation)

If the input signal gets higher than 95% or lower than -95% (with only one solenoid lower than 5 %), it leaves the permitted range and the outputs will switch of.

5.2.9 POL (Output polarity)


POL X x= +|- - STD

This command allows a switch over of the output polarity.

In case of SOLENOID=2 (directional valves), the polarity of the input signal will be switched over.

In case of SOLENOID=1 (throttle or pressure valve), the direction of the signal will be changed (“+“ = 0 % to 100 % and “-“ = 100 % to 0 %).


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5.2.10 SENS (malfunction monitoring)


SENS X x= ON|OFF|AUTO - STD

This command is used to activate/deactivate the monitoring functions (4… 20 mA sensors, output current, signal range and internalfailures) of the module.

ON: All monitoring functions are active. Detected failures can be reset by deactivating the ENABLE input.

OFF: No monitoring function is active.

AUTO: Auto reset mode. All monitoring functions are active. If the failure doesn’t exist anymore, the module automatically resumes to work.

Normally the monitoring functions are always active because otherwise no errors are detectable via the READY output. Deactivating is possible especially for troubleshooting.


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5.2.11 AINA (Current- / Voltage input)


AINA X x= V|C - STD

By the use of this command you can change the type of input signal between voltage (±10 V) and current (4…20mA). In case of current signal 12 mA is the neutral position

2. If choosing current, the shunt will be

activated automatically.

5.2.12 AIN (Analogue input scaling)


AIN:A A B C X a= -10000… 10000

b= -10000… 10000

c= -500… 10000

x= V|C

-

-

0.01%

-

EXP

This command offers an individual scalable input. It is available in EXPERT mode only and the AINA command is replaced.

The following linear equation is used for the scaling.

Output = A/B · (Input – C)

The “C” value is the offset (e.g. to compensate the 4 mA in case of a 4… 20 mA input signal).

The variables A and B are defining the gain factor.

e.g.: 2.345 correspond to: A = 2345, B =1000

The internal shunt for the current measuring (4… 20 mA) is activated via the x value.

Typical settings (examples):

Command Input Description

AIN:A 1000 1000 0 V ±10V

or

0… 10V

Working range: ±100%

for the control of two solenoids.

Output range: 0… 100%

for the control of one solenoid.

AIN:A 2 1 5000 V

ODER

AIN:A 2000 1000 5000 V

0… 10V Working range: ±100%

for the control of two solenoids, 5V is the neutral position

The offset will be set on 5000 (50% = 5V) and the gain on 2.

(0… 10V represent ±100%, working range = 200%).

AIN:A 20 8 5000 V ODER

AIN:A 2000 800 5000 V

1… 9V Working range: ±100%

for the activation of two solenoids, 5V is the neutral position

2 If the parameter SOLENOID is set to 1 and the input range 0…100% has to correspond to 4…20 mA instead of

12…20 mA, the AIN:A parameter has to be adapted in the EXPERT mode.


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Command Input Description

The offset will be set on 5000 (50% = 5V) and the gain on 2,5.

(1… 9V represent ±100%, working range = 200%).

AIN:A 20 4 2500 V ODER

AIN:A 2000 400 2500 V

0,5…

4,5V

Working range: ±100%

for the control of two solenoids, 2,5V is the neutral position (typi-cal for joysticks).

The offset will be set on 2500 (25% = 2,5V) and the gain on 5.

(0,5…4,5 V represent ±100 %, working range 200 %).

AIN:A 2016 2000 C ODER

AIN:A 1250 1000 2000 C

4… 20mA Working range: 0… 100%

The offset will be set on 20% (4 mA) and the signal (16 mA = 20mA – 4 mA) will be gained to 100% (20 mA), gaining factor is 1,25.

AIN:A 20 8 6000 C ODER

AIN:A 40 16 6000 C ODER

AIN:A 2500 1000 6000 C

4… 20mA Working range: ± 100%

The offset will be set on 60% (12 mA) and the signal (16 mA = 20mA – 4 mA) will be gained to±100%, gaining factor is 2,5.

5.2.13 AA (Ramp function)


AA:I X i = 1… 4

x = 1… 600000

-

ms

STD

Four quadrants ramp function.

The first quadrant means the acceleration ramp for solenoid A and the second one stands for the deceleration ramp of solenoid A. According to this the third quadrant represents the acceleration ramp for solenoid B so that the fourth quadrant remains for the deceleration ramp for solenoid B.

t

Ausg

ang/O

utp

ut A

Ausg

ang/O

utp

ut B

AA:1 AA:2

AA:3 AA:4


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5.2.14 CC (Characteristic linearization)


CC:I X Y i = -10… 10

x = -10000… 10000

y = -10000… 10000

-

0,01%

0,01%

CCMODE=ON

A user significant signal characteristic can be defined by this function. For activating the parameter CCMODE has to be switched to ON.

The positive indexes stand for the solenoid A, the negative ones represent the solenoid B. The curve il-lustration is calculated according to the equation of the linear interpolation:y=(x-x1)*(y1-y0)/x1-x0)+y1).

The influence of the linearization can be estimated via the process data on the monitor or on the oscillo-scope.

For the input of the characteristic linearization the WPC-300 program provides a tableand a graphic data input.The input signal is mapped on to the X-axis and the output signal is mapped on to the Y-axis.


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5.2.15 MIN (Overlap compensation)

5.2.16 MAX (output scaling)

5.2.17 TRIGGER (threshold value of MIN function)


MIN:I X

MAX:I X

TRIGGER X

i = A|B

x= 0… 6000

x = 300… 10000

x = 0… 3000

-

0,01% (mA)

0,01% (mA)

0,01%

STD

The output signal to the valve is adjusted by these commands. With the MAX value the output signal (the maximum valve current) will be defined. With the MIN value the overlap (dead band of the valve) will be compensated. Via the TRIGGER the activation point of the MIN function is set and so a non sensitive range around the zero-point

3 can be specified.

CAUTION: If the MIN value is set too high, it influences the minimal velocity, which can-not be adjusted any longer.

3 This dead band is necessary, in order to avoid unrequested activations caused by small variations of the input sig-

nal. If this module is used in position controls, the TRIGGER value should be reduced (typical: 1…10).

MAX:A

MIN:A

MIN:B

MAX:B

Input

Outp

ut

TRIGGER


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5.2.18 CURRENT (Current range switch)


CURRENT X x= 0 | 1 | 2 - RCURR=OFF

The nominal current range is set with this parameter. The DITHER and also the MIN/MAX parameter always refer to the selected current range.

0 = range of 1,0 A, 1 = range of 1,6 A, and 2 = range of 2,6 A.

In mode RCURR = ON this command is inactive and invisible and the current range is set automatically.

5.2.19 DFREQ (Dither frequency)

5.2.20 DAMPL (Dither amplitude)


DFREQ X x= 60… 400 Hz STD

DAMPL X x= 0… 3000 0.01% STD

The dither can be defined freely with this command. Different amplitudes or frequencies may be required depending on the respective valve.

The dither amplitude is defined in % of the nominal current range.

CAUTION: The PPWM and IPWM parameters influence the effect of the dither setting. These parameters should not be changed again after the dither has been optimized.

CAUTION: If the PWM frequency is less than 500 Hz, the dither amplitude should be set to zero.

5.2.21 PWM (PWM frequency)


PWM X x= 50… 2600 Hz STD

This parameter is entered in Hz. The optimum frequency depends on the valve.

CAUTION: The PPWM and PPWM parameters should be adapted when using low PWM fre-quencies because of the longer dead times which forces a reduced stability of the closed loop control (see 5.2.22 and 5.2.23).

The PWM frequency can only be set in defined steps. This means that there are deviations be-tween the specified and the actual frequency. It always will be selected the next higher step.


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5.2.22 PPWM (Solenoid current controller P gain)

5.2.23 IPWM (Solenoid current controller I gain)


PPWM X

IPWM X

x= 0… 30

x= 1… 100

-

-

EXP

The PI current controller for the solenoids is parameterized with these commands.

CAUTION: These settings are depending on the dynamic response of the solenoid (inductive reactance).

CAUTION: These parameters should not be changed without adequate measurement facilities and experiences.

If the PWM frequency is > 2500 Hz, the dynamic of the current controller can be increased.

Typical values are: PPWM = 7… 15 and IPWM = 20… 40.

If the PWM frequency is < 250 Hz, the dynamic of the current controller has to be reduced.

Typical values are: PPWM = 1… 3 and IPWM = 40… 80.

5.2.24 PROCESS DATA (Monitoring)

Command Parameter Unit

W

C

U

IA

IB

Command value after ramp

Control value after linearization

Output signal

Current to solenoid A

Current to solenoid B

%

%

%

mA

mA

The process data are the variable valueswhich can be continuously observed on the monitor or on the oscilloscope.


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6 Appendix

6.1 Failure monitoring

Following possible error sources are monitored continuously when SENS = ON/AUTO:

Source Fault Characteristic

Command signal PIN 9 / 10

4...20mA

Out of range The power stage is deactivated.

Command signal PIN 9 / 10

LIM function

Out of range The power stage is deactivated.

Solenoid A PIN 3 / 4

Solenoid B PIN 1 / 2

Broken wire The power stage is deactivated.

EEPROM (at switching on)

Data error The power stage is deactivated.

The module can be activated by saving new parameters (press-ing of the SAVE Button).

6.2 Troubleshooting Initial situation is an operable status of the device and existing communication between the module and the WPC-300 program. Furthermore, the parameterization of the valve control has to be done with the assistance of the valve data sheets.

The RC mode in monitor can be used to analyze faults.

CAUTION: If using the RC (Remote Control) mode, all safety aspects have to be checked solidly. In this mode the module is actuated directly and the machine control has no influence on the module.

FAULT CAUSE / SOLUTION

ENABLE is active, the module does not re-spond, and the READY LED is off.

Probably the power supply is disconnected or the ENABLE signal is not present.

If there is no power supply there is also no communication via our operating pro-gram. If the connection to the WPC-300 exists, the power supply is also available. In this case the availability of the ENABLE signal can be checked via the monitor.

ENABLE is active, the READY LED is flashing.

The flashing READY LED indicates that a fault is detected by the module. The fault could be:

• No signal at the input, if 4… 20 mA signal is chosen, or signal is out of range if the LIM monitoring is activated.

• A broken cable or incorrect wiring to the solenoids.

• Internal data error: execute the command/press the button SAVE, to delete the data error. The system reloads the DEFAULTdata.

With the WPC-300 operating program the failure can be localized directly via the monitor.


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6.3 Special versions

These special versions were realized for various applications and are available on request.

-S3 Module with integrated hydraulic power limiting function

-S4 has been replaced by th L-version

-S6 10V reference voltage instead of 8V

-S11 Output PIN 5 will be triggered by the active solenoid (identification of the direction)

6.4 Description of the command structure

The command structure:

[nnnn:i x] or

[nnnn x]

Meaning:

nnnn - used for an arbitrary command name

nnnn: - used for an arbitrary command name, expandable by an index.

Indexed commands are indicated by the sign “:”

i oder I - a dummy is for the index. E.g.an index can be „A“ or „B“, depending on the direction.

x - parameter value, in case of special commands more than one parameter is possible.

Examples:

MIN:A 2000 nnnn = “MIN”, i = “A” and x = “2000”

OFFSET 50 nnnn = „OFFSET“ and x = „50“

C:IC 2000 nnnn = “C”, i = “IC” and x = “2000”


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7 Remarks

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