ACE100B DC Millivolt Input Amplifier Technical

MAKING MODERN LIVING POSSIBLE
Technical Information
Sensors
ACE100B DC Millivolt Input
Amplifier
powersolutions.danfoss.com
Technical Information
ACE100B DC Millivolt Input Amplifier
Revision history
Table of revisions
2
Date
Changed
Rev
November 2015
Converted to Danfoss layout
0003
August 2010
Typos
AC
July 2010
Typos
AB
July 2010
Initial release (was BLN-95-9050)
AA
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
Contents
Overview
Technical data
Installation
Description..........................................................................................................................................................................................4
Features................................................................................................................................................................................................4
Theory of operation.........................................................................................................................................................................5
Input stage.....................................................................................................................................................................................5
Controller stage........................................................................................................................................................................... 5
Power drive stage........................................................................................................................................................................5
Block diagram...............................................................................................................................................................................5
Ordering information......................................................................................................................................................................6
Electrical...............................................................................................................................................................................................7
Control..................................................................................................................................................................................................7
Environmental................................................................................................................................................................................... 7
Weight.................................................................................................................................................................................................. 8
Dimensions......................................................................................................................................................................................... 9
Mounting ............................................................................................................................................................................................9
Wiring....................................................................................................................................................................................................9
Slope control connection............................................................................................................................................................10
Grade control connection...........................................................................................................................................................11
Steering control connection...................................................................................................................................................... 11
Startup procedure ........................................................................................................................................................................ 12
Troubleshooting.............................................................................................................................................................................13
Check valve................................................................................................................................................................................. 13
Check amplifier..........................................................................................................................................................................13
L1011817 • Rev 0003 • November 2015
3
Technical Information
ACE100B DC Millivolt Input Amplifier
Overview
Description
The ACE100B Panel Mount Amplifier is designed for use in grade, steering and slope control applications.
A grade position sensor such as the MCX103A can be connected to ACE100B, providing a proportional
millivolt dc input signal to the amplifier. In slope control applications, the MCX104A Level Sensor is used.
In mobile use, the sensor detects the position of the machine with respect to a reference such as gravity
or stringline. The amplifier converts the deviation information into a proportional output to power a twowire servovalve such as the KVF. The servovalve repositions a final drive element in the proper direction
to eliminate the error signal. In steering control applications, a feedback unit such as the ACX104C may
also be needed to protect against over-correction.
The ACE100B has fully adjustable gain, MANUAL/AUTO switching, JOG switch and a continuous display
deviation meter to aid the machine operator.
Features
•
•
•
•
•
•
•
•
4
Deviation meter—zero center meter shows direction and amount of servovalve drive
Resists vibration
Reverse polarity protection
Short circuit protection
EMI/RFI protection
Manual override—a JOG switch provides manual commands to the servovalve
RUN/STANDBY switch
Moisture protection—Circuit board components are coated to guard against corrosion
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
Overview
Theory of operation
The ACE100B amplifier, shown in the Block diagram on page 5, is powered by a 12 Volt system. The
internal circuitry of the ACE100B consists of three basic stages:
Input stage
The input stage accepts a millivolt signal from the external sensor. The sensor voltage is compared to a
reference voltage, and the difference is amplified.
Controller stage
The dc error signal is summed with a variable amplitude 400 Hz signal, creating a dynamic balance
between the two halves of the time-proportional output to the valve. An increased gain setting reduces
the amount of error signal required to supply full drive (maximum voltage) to the valve.
Power drive stage
The amplifier output goes to the power drive stage, creating a pulse width output. The output signal
provides both dither and power to the load at a rate of 440 Hz. With zero error signal, the drive in each
direction will be equal, resulting in no net power delivered to the valve. With the introduction of an error
signal, the drive in one direction will be longer than the other, resulting in net power delivered to the
valve.
Block diagram
ACE100B block diagram
ACE100B
1
2
5
3
6
7
KVF
4
kwa1392495699153
1
Rotary position, level or steering sensor
5
Power drive
2
Input
6
Run/standby and jog switches
3
Controller
7
Flow control servovalve
4
Gain
L1011817 • Rev 0003 • November 2015
5
Technical Information
ACE100B DC Millivolt Input Amplifier
Overview
Ordering information
Specifications
Model number
ACE100B1002
Sensor(s)
ACX104C, MCX103A or MCX104A
Valve(s)
KVF
Slope set unit
MCQ101
Cables and connectors
Components location
7
2
1
6
3
4
kwa1392495705350
Components
6
Callout
Part number
Description
1
110160114
Deviation meter (includes face plate, gasket, screws, washer and
nuts)
2
K02632
Front plate
3
K15530
Case
4
K04387
JOG switch
5
K04382
Cover (not shown)
5A
——
Cover retaining screws (not shown) (4 required, #6-32, 1/4 inch long)
6
K04201
RUN/STANDBY switch
7
K32689
Gain potentiometer (P2, 10K)
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
Technical data
Electrical
Supply voltage
1 to 15 Vdc
Power consumption
0.5 ampere maximum
Voltage output
0 to 5.8 ± 0.4 Vdc with 12 Vdc supply voltage
Frequency of pulse width modulation is 440 ± 40 Hz
Control
Run/standby switch
In the RUN position, the output is proportional to the sensor error signal. In the STANDBY position, the
output of the ACE100B is switched off.
Jog switch
Spring return to open center position. The JOG switch overrides the sensor signal and provides manual
valve control regardless of the RUN/STANDBY switch position.
Sensor supply voltage
The amplifier provides +6 Vdc to the sensors. Inputs to the amplifier run at a common mode of +3 Vdc. If
the sensors are at center with 6 Volts applied, the resultant 3 Volt input will balance the controller.
Meter
Displays output of the amplifier. The output may or may not be connected to the load, depending upon
the RUN/ STANDBY switch position. With the switch in the STANDBY position, the meter will continue to
indicate errors generated by the sensor. Zero drive is at mid scale. Needle in the red indicates output
greater than 3 Vdc.
Gain adjustment
A ±35 millivolt dc error signal will result in full output to the servovalve when the gain potentiometer is
turned fully clockwise (maximum gain). With the gain potentiometer turned fully counterclockwise
(minimum gain), a ±1.0 Vdc error signal will result in full output to the servovalve. Shaft rotation of the
gain adjustment is 270°.
C
Caution
Potentiometer will break. To prevent the potentiometer from breaking, do not force the gain adjustment
potentiometer beyond the travel stops.
Environmental
Vibration
Withstands a vibration test designed for mobile equipment devices that includes two parts:
1. Cycling from 5 to 2000 Hz over a range of ±1.0 g’s to ±3.0 g’s for a period of one hour (if there are four
resonant points), for two hours (if there are two or three resonant points) and for three hours (if there
is one or no resonant point). The cycling test is performed on each of the three major axes.
2. Resonance dwell for one million cycles over a range of ±1.0 g’s to ±3.0 g’s for each of the four most
severe resonant points on each of the three major axes.
L1011817 • Rev 0003 • November 2015
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Technical Information
ACE100B DC Millivolt Input Amplifier
Technical data
Shock
Withstands a shock test designed for mobile equipment devices that consists of three shocks of 50 g and
11 ms duration in both directions of the three major axes for a total of 18 shocks.
Temperature
Operating temperature
-18° to +66° C (0° to +150° F)
Storage temperature
-40° to +77° C (-40° to +170° F)
EMI/RFI
EMI/RFI
10 VM from 10 to 350 MHz
Electrical transients
•
Operate device at maximum rated temperature, maximum rated voltage supply at:
‒ Maximum load 168 hours ometer sensor
•
Jump start:
‒ Apply ± 26.5 Vdc to device for 5 minutes with device in operation
•
Inductive load switching
•
Alternative field decay:
‒ -90 Vdc, 0.038 sec time constant
Weight
Weight
8
L1011817 • Rev 0003 • November 2015
0.97 kilograms (2 pounds, 2 ounces)
Technical Information
ACE100B DC Millivolt Input Amplifier
Installation
Dimensions
ACE100B mounting and panel cutout dimensions in millimeters [inches]
Mounting holes
5.60
[0.22]
10.40
[0.41]
2PL
147.6
[5.81]
7.10
[0.28]
63.50
[2.50]
33.30
[1.31]
4.80
[0.19]
127.00
[5.00]
128.60
[5.06]
138
[5.44]
4.80
[0.19]
38.10
[1.50]
2PL
76.20
[3.00]
25.40
[1.00]
111.00
[4.37]
67.00
[2.63]
Panel cutout
kwa1392495724161
Mounting
The ACE100B amplifier is designed to be mounted in a panel. Select a mounting location convenient for
the operator. Cut a rectangle hole in the panel as shown in the dimension drawing above. Drill two holes
in the panel in the location shown. If the amplifier is to be secured with sheet metal screws, use #10
screws and drill holes with a #30 drill. If the panel is to be drilled and tapped, use a #21 drill and tap for
10/32 screws. Otherwise drill 7/32 inch clearance holes, and use 10/32 screws and nuts to fasten the
ACE100B.
Wiring
Wiring connections are usually made to 6/32 screws on terminal strips located on the back of the case.
For wiring connections diagrams for systems see Slope control connection on page 10, Grade control
connection on page 11, and Steering control connection on page 11 .
L1011817 • Rev 0003 • November 2015
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Technical Information
ACE100B DC Millivolt Input Amplifier
Installation
Slope control connection
MCQ101
A
B
C
10.2 K ± 1 %
+
ACE100B
G
+12 Vdc
B
K
A
H
Ground
P
100 Ω
3W
A
B
C
+
RUN
R
J
S
STANDBY
JOG
E
F
MCX104A
Slope Sensor
Flow Control
Servovalve
KVF
kwa1392495731812
The 10.2 KW resistor is required for proper scaling, and is to be mounted on a terminal strip.
100 Ω resistor is required for proper sensor supply voltage.
Reverse sensor direction (facing rear) when used with MCQ101.
10
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
Installation
Grade control connection
ACE100B
±30⁰
A
R (+)
B
B
C
A
C
S
Ground
RUN
STANDBY
JOG
E
F
Flow Control
Servovalve
KVF
kwa1392495737213
C
Caution
Reverse power may damage the sensor.
Steering control connection
MCX103A
Hall Sensor
ACE100B
3 V ± 1.5 %
A
R
B
K
C
S
+12 Vdc
B
(+)
±30⁰
Ground
A
RUN
JOG
A
±156⁰
J STANDBY
B
ACX104C
Feedback POT
E
F
Flow Control
Servovalve
C
3 V ± 1.5 %
KVF
kwa1392495743629
C
Caution
Reverse power may damage the sensor.
L1011817 • Rev 0003 • November 2015
11
Technical Information
ACE100B DC Millivolt Input Amplifier
Installation
Startup procedure
Example: Steering system
1. With the amplifier on STANDBY, start the machine.
a) Straighten the steering post using the JOG switch
b) Turn off the machine.
2. Disconnect all remote sensors, unplugging them at the sensor.
a) Set the gain at halfway.
3. Turn on the electric power, but do not start the machine.
The ACE100B should show a centered deviation meter.
4. Re-connect the stringline sensor.
a) Position the stringline so that it centers the deviation meter.
b) Fasten the sensor in this position.
5. Re-connect the steering feedback sensor (if used).
a) Rotate its shaft until the deviation meter nulls.
b) Make a tight engagement between the feedback sensor and the steering post.
6. Disconnect the stringline sensor and start the machine.
a) Intermittently jog the amplifier, until the steering post returns to straight ahead.
If the steering post deviates quickly to one side, reverse the valve connections at E and F and repeat
this step.
7. Re-connect the stringline sensor.
The proportional feedback system should be in working order. If the steering post moves in the
opposite direction from that required, reverse the stringline sensor connections at G and J (or R and
S).
8. Adjust the amplifier gain to operator machine requirements.
If an obvious instability occurs, reduce the gain.
12
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
Installation
Troubleshooting
The ACE100B is designed to give years of trouble-free service. When a system malfunction develops, the
first step must be to isolate the problem in the system. To make the troubleshooting task easier, it is
important to know the following:
• Provided power to the panel mount amplifier is on, the deviation meter will indicate 1. deviations in
grade, slope or steering at all times.
• The JOG switch will function regardless of the setting of the RUN/STANDBY switch.
• In the RUN mode, the amplifier output is connected to the valve. In the STANDBY mode, the amplifier
output is not connected to the valve until the JOG switch is activated.
Preliminary checks should include examination of the cables or screw terminals. Look for damaged or
broken wires. Examine areas where shorting may occur. Check the power supply voltage, making sure it
is greater than 11 Vdc.
Check valve
1. Place RUN/STANDBY switch in STANDBY position.
2. Operate the JOG switch in both directions while noting operation of valve.
If valve operation is satisfactory, proceed with checkout.
Check amplifier
1. Remove the remote setpoint connections and sensor connections at the back of the ACE100B.
2. Turn the gain potentiometer fully clockwise (maximum gain).
3. Touch terminal C to terminal G.
The deviation meter should drive fully clockwise. If not, the amplifier is probably defective.*
In the RUN mode, the amplifier output is connected to the valve. In the STANDBY mode, the amplifier
output is not connected to the valve.
* A faulty meter may be the problem. A faulty meter would not indicate any amplifier output when
there actually may be some. If a faulty amplifier is indicated, change the RUN/STANDBY switch to RUN
and perform the check again while observing the hydraulic valve and system.
L1011817 • Rev 0003 • November 2015
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Technical Information
ACE100B DC Millivolt Input Amplifier
14
L1011817 • Rev 0003 • November 2015
Technical Information
ACE100B DC Millivolt Input Amplifier
L1011817 • Rev 0003 • November 2015
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