Vickers(R) Accessories Power Amplifiers with PID Modules EEA-PAM-5**-D-32 Series General Description The EEA-PAM-5**-D-32 Eurocards are power amplifiers with integrated PID modules. Each of these cards replaces two conventional electronic cards. Features and Benefits Includes all features of "A" amplifiers (except gain) User configurable PID feed-forward, closed-loop operation Command input ramps Analog feedback sensor interface Automatic switch-over p/Q function Built-in test feature The design reduces the amount of external wiring, saves space in the rack enclosure and requires only one 24V supply The general purpose, integrated module can be configured using DIL switches (D1-D9) and potentiometers for the following applications: - Closed-loop pressure control using either proportional pressure valves or servo-performance proportional valves - Closed-loop velocity control - Closed-loop position control - p/Q control with internal or external switch-over from Q to p The DIL- switch and potentiometer settings can easily be reconfigured on different cards Front Panel LEDs [1] 24V power supply input, green [2] 15V control supply output, green [3] Drive (solenoid) enabled, yellow TEST VALVE LOOP [16] Test potentiometer AUTO 24/15 [4] Overload, red [5] LVDT failure, red 0 [6] Drive level to solenoid, yellow Potentiometers [7] Deadband compensation, flow P to B [8] Deadband compensation, flow P to A TEST [15] Mode switch - TEST VALVE setting - AUTO function setting - TEST LOOP setting - + [18] Integrator enabled, yellow [19] Feedback = command signal, green [20] Sensor failure, red P B A Potentiometers [21] Feed-forward signal scaling LED [9] Ramps enabled, yellow V Potentiometers P t t [10] Command ramp up [11] Command ramp down Monitor points I D 1 3 5 2 4 6 [12] MP1: Conditioned command signal [13] Common ground (0V) [14] MP2: LVDT (spool) position Number and function of potentiometers [7], [8], [7.2] vary according to model type as follows: [7.2] Offset For models -513/541/553- LEDs [17] PID-controller enabled, yellow [22] P-gain [23] I-gain [24] D-gain Monitor points [25] MP3: Command signal [26] MP5: PID-controller output [27] MP6: Integrator output [28] MP4: Feedback signal LED and symbol not on EEA-PAM-513/523/525 amplifiers. Solenoid current for EEA-PAM-523/525-D models. O2,0 mm (0.0787dia.) sockets. In the case of EEA-PAM-523/525-D models one of these relationships may not apply if two single solenoid valves are connected. This product has been designed and tested to meet specific standards outlined in the European Electromagnetic Compatibility Directive (EMC) 89/336/EEC, amended by 91/263/EEC, 92/31/EEC and 93/68/EEC, article 5. For instructions on installation requirements to achieve effective protection levels, see this leaflet and the Installation Wiring Practices for Vickers Electronic Products leaflet 2468. Wiring practices relevant to this Directive are indicated by Electromagnetic Compatibility (EMC) . January 1996 GB-2474 Model Codes Amplifier model For valves EEA-PAM-513-D-32 KCG-3, KCG-6/8 KX(C)G-6/8 With type "H" K*G4V-3, KDG5V-5/7/8 coils only K*G4V-5 KF*G4V-3 KF*G4V-5 KHDG5V-5/7/8 with zerolapped mainspool KSDG4V-3 KFDG5V-5/7 KFDG5V-8 CVU-**-EFP1 KHDG5V-5/7/8 EEA-PAM-523-D-32 EEA-PAM-525-D-32 EEA-PAM-533-D-32 EEA-PAM-535-D-32 EEA-PAM-541-D-32 EEA-PAM-553-D-32 EEA-PAM-561-D-32 EEA-PAM-568-D-32 EEA-PAM-571-D-32 EEA-PAM-581-D-32 } Operating Data Power (input) supply Control (output) supplies Reference voltages bz32 See appropriate base amplifier, e.g. for EEA-PAM-535-D-32 see EEA-PAM-535-A-32 z22 +15V for LVDTs only z2 +10V x 5 mA b2 -10V x 5 mA Analog inputs: Command inputs Direct-voltage inputs b6, b8, b10, z8 Inverting-voltage input z10 Voltage range Input impedance (voltage) Current input z6 Current range Input impedance (current) Feed-forward input d8 Input impedance Voltage range Input to ramp generator d28 Input impedance Voltage range Inputs from sensors Voltage input d2 Input impedance Voltage range Current input Input impedance Current range (See "DIL Switches" five pages on) Monitoring of sensor failure for sensors with a current outout only "10V 47 k "20 mA 100 6 k "10V 10 k "10V 1 M 0 to 10V, or "10V 100 4-20 mA or 0-20 mA The demand signal should have the same voltage range as the sensor feedback, i.e. 0 to 10V, or "10V. 2 Continued on next page Digital inputs: Drive enable (power available to solenoid) Ramps enable Integrator enable z24 b24 d14 Warning: In a power-up sequence, the integrator should not be enabled until all hydraulic, electric and control power and signals are applied and stable. Abrupt or unpredictable motion may occur if integrator is enabled during this transition time. PID-controller enable Enabled Disabled Load current Digital outputs: Sensor failure Sensor failure Sensor o.k. Load current (withstands a continuous short-circuit condition) This output may be used only in conjunction with sensors providing a current output (4-20 mA) Feedback = command signal Feedback matches demand Feedback does not match demand Load current (withstands a continuous short-circuit condition) The load at pin d18 and pin d10 has to be connected to ground Analog outputs: PID-controller output Error signal Feedback signal Load impedance Voltage range Output from ramp generator Load resistance Voltage range Alarm output (drive output status): Set alarm d12 17 to 40V 0 to 3,5V v10 mA d18 Vcc -2V <3V v100 mA d10 Vcc -2V <3V v100 mA d4 d22 d24 w10 k; short-circuit proof "10V d26 w5 k; short-circuit proof "10V z12 Enable amplifier (on pin z24) >500 ms after switching power on. HIGH when alarm is activated. Output = Supply volts minus 2 volts. I = 50 mA max. LOW when solenoid overload has occurred. (Maintained until reset). Output = 0 to +/-2 volts. Output resistance = 50 ohms. Disable and re-enable on pin z24. Signal Reset after failure Ramp active indicator: Drive ramping up Drive ramping down Drive not ramping Output resistance b12 Drive signal zero indicator: Drive signal at null (within deadband limits) Drive active Output resistance b20 Output >10V Output <-10V Output 0"10V 10 k Output = Supply minus 1,5V; I = 50 mA max. Output = 0"2V 50 Continued on next page 3 Potentiometers: Feed-forward P-gain (depends on DIL switch D2): I-gain range D-gain range Sensor signal gain range Sensor signal offset range Monitor points: Conditioned command signal LVDT (spool) position Command signal Feedback signal PID-controller output Integrator output (100%, independent of D3, D4, D5) Voltage range Monitor point impedance V = 20% to 100% P = 0,1 to 50V/V Ki = 0,5 to 100 V/s/V Kd = 0 to 0,05 V/V/s 90% to 120% "10% MP1 MP2 MP3 MP4 MP5 MP6 "10V 10 k Ambient conditions: Storage temperature range Operating temperature range -25 to +85C (-13 to +185F) 0 to 50C (32 to 122F) Mass 0,4 kg (0.88 lb) approx. Installation and start-up guidelines (supplied with product) Installation wiring requirements for Vickers electronic products Application notes (available on request) 9161 2468 9056 Supporting products: Power supply unit options Electronic accessories Portable test equipment See catalogs: 2419 2460 2462 and 2315 Located on PID module. All amplifiers except EEA-PAM-523/525 models, in which solenoid current is monitored. Warning: Electromagnetic Compatibility (EMC) It is necessary to ensure that the valve is wired up in accordance with the connection arrangements shown in this leaflet. For effective protection, the user's electrical cabinet, the valve subplate or manifold and the cable screens should be connected to efficient earth (ground) points. The metal 7-pin connector part no. 934939 should be used for the integral amplifier. In all cases, both valve and cable should be kept as far away as possible from any source of electromagnetic radiation such as cables carrying heavy current, relays and certain kinds of portable radio transmitters, etc. Difficult environments could mean that extra screening may be necessary to avoid the interference. 4 Circuit and Connections EEA-PAM-5**-D-32 Read circuit in conjunction with that for relevant base amplifier EEA-PAM-5**-A "15V z2 +10V 5 mA b2 -10V 5 mA z24 +24V Close to enable Current command signal Voltage command signals Control zero Dither +24V + - b28 PWM bz4 Sensor failure Feedback = command signal Solenoid current Ramp +15V b18 Inverter b12 b20 Ramp active b24 Ramp enable LVDT failure Main stage LVDT z22 z16 z14 Pilot stage LVDT MP1 + - +15V z22 b16 b14 z18 MP2 d28 d26 d8 Power amplifier PID control module Feed forward V Test loop Valve. Actual connections see table on next page. D7 Polarity + - d16 Test valve d24 MP3 Gain Offset P d2 + d6 - d18 1-10% error P-gain MP4 d10 PIDcontroller enabled D-gain D D Sensor failure d22 d4 P PID-controller output MP5 D6 I Feedback = command signal Error signal To solenoid b26 d12 U Sensor 0 to 20 mA or sensor 4 to 20 mA To solenoid Power amplifier Close to enable PID- controller Sensor 0 to +10V or sensor "10V Drive output status z28 z26 Gain Close to enable +10V Conditioned feedback signal X Overload Deadband compensation b6 b8 b10 z8 z10 Connect to +10V (z2) for p/Q control with automatic switch-over only Feed forward z12 Enable z6 24V DC Power supply bz30 Power zero +24V Output enable Non-invert D9 +24V bz32 24V Power supply MP6 I-gain I + - +24V d14 Close to enable integrator Integrator enabled D3 D5 6% D4 50% 35% Customer's protective ground connection. 5 Solenoid and LVDT Connections for Proportional Valves Amplifier type EEA-PAM-513-D-32 EEA-PAM-523-D-32 EEA-PAM-525-D-32 EEA-PAM-533-D-32 EEA-PAM-535-D-32 EEA-PAM-541-D-32 EEA-PAM-553-D-32 EEA-PAM-561-D-32 EEA-PAM-568-D-32 EEA-PAM-571-D-32 EEA-PAM-581-D-32 Solenoid with LVDT and/or for flow P to B Solenoid without LVDT, or on pilot valve Pilot-stage LVDT, (black plug): Main-stage LVDT, (gray plug): Pin 1 Pin 2 Pin 3 Pin 4 Pin 1 Pin 2 Pin 3 Pin 4 b26/b28 b26/b28 b26/b28 b26/b28 b26/b28 - - - - - - - z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 z26/z28 - - - - - z14 - - - - z14 - - - b14 b14 b14 b14 b14 b14 b14 b14 - - - - - z22 - - - - z22 - - - - - z16 - - - - z16 Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected - - - z22 z22 z22 z22 z22 z22 z22 z22 Installation Dimensions in mm (inches) - - - b16 b16 b16 b16 b16 b16 b16 b16 Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected Not connected 3rd angle projection Plug-in Unit of 3U height, to IEC 297 DIN 41612 F48 male connector. Mating connector must be an F48 female type. 7,92 (0.31) z - pin row b - pin row d - pin row Components envelope M2,5 x 11 (0.43) long collar screws supplied with panel for fixing 2,5 (0.1) 122.4 (4.82) 128.4 (5.06) 100 (3.94) Model designation 8 (0.31) 3 (0.12) 14,2 (0.56) 3 (0.12) 7,45 (0.29) 50,3 (1.98) 6 7,2 (0.28) 14 (0.55) 175,24 (6.9) Application Notes DIL Switches The controller is configured for the application using DIL switches, located on the board. 1 2 3 4 5 6 7 8 9 10 ON OFF Factory setting Location of User Features on PID Module Offset potentiometer Gain potentiometer (sensor signal) (sensor signal) The DIL switch operates as follows: Switch ON OFF D1: For sensors with 4 to 20 mA output For sensors with "10V or 20 mA outputs D2: P-gain 2 to 50 P-gain 0,1 to 2 D6: One-sided limitation of the integrator output. (Only useful for proportional pressure and proportional throttle valves.) No limitations of integrator output D7: Inverts the controller output signal Non-inverted signal D8: For sensors with 4 to 20 mA output For sensors with "10V or 20 mA outputs D9: Ramp signal not inverted Ramp signal inverted D10: Not used - For p/Q control with automatic switch-over, connect d16 to z2 (+10V). The flow command signal (Q) is applied to the feed-forward input, d8, and the desired pressure setpoint voltage applied to a command signal input (b6/8/10 or z6/8/10). The pressure feedback sensor is connected to the sensor input d2, or d6 as required. Reconfiguration of Controller Parameters Once the controller parameters have been optimized and set, they can be measured by means of an ohmmeter. This allows easy reconfiguration of the controller on different cards for use as spare parts or on standard machine series. The pressure control loop will override the flow command to limit the pressure to the level determined by the pressure setpoint voltage. Adjust P, I and D gains for best performance. Four test points are located on the PID-module for this purpose, see diagram for locations. The resistance between the appropriate test point and ground (at the front panel monitor point) determines the controller parameters: P = P-gain I = I-gain D = D-gain V = Feed-forward gain The switches D3, D4 and D5 belong together. They limit the I output volts between 100% (10V) and 5% (0,5V) as follows: D3 D4 D5 l-limit ON ON ON ON OFF OFF OFF OFF ON ON OFF OFF ON ON OFF OFF ON OFF ON OFF ON OFF ON OFF 100% 50% 35% 25% 5,9% 5,8% 5,3% 5,0% Potentiometer In Position 1%-10% DIL switches Test point "P" P-gain Test point "D" D-gain Test point "I" I-gain Test point "V" Feed-forward gain 7 Operation of the Integrated Test Mode The basic operation of the hydraulic actuator can be tested by using the 3-position mode switch mounted on the front panel. To select different modes the toggle switch must be lifted slightly before turning it to a new position. Caution: Before setting the mode switch to either "Test valve" or "Test loop" make sure the test potentiometer is set to "0". Otherwise sudden movements of the actuator may occur. The mode switch has three positions: AUTO The controller operates in closed-loop mode, using the external command signal. The test potentiometer is disconnected. Test potentiometer on front panel External command signal To power amplifier Controller TEST LOOP AUTO TEST VALVE Mode switch on front panel TEST VALVE An open-loop command signal for the valve comes directly from the potentiometer. The external input signal is disconnected. The hydraulic part of the system may be tested in this configuration. TEST LOOP The closed-loop command signal for the PID-controller comes directly from the potentiometer. The external signal input is disconnected. This configuration allows for verification of the valve polarity and the control parameters. E Eaton Hydraulics, Incorporated, 2000 All Rights Reserved Printed in U.S.A.