W.E.ST. CSC-152 U, P positioning and synchronization module, POS-124 PDP, CSC-156 SSI positioning module Technical Documentation
Below you will find brief information for positioning and synchronization module CSC-152 U, positioning and synchronization module CSC-152 P, positioning module POS-124 PDP. These modules are designed for hydraulic applications in open or closed-loop control circuits. The CSC-152 U and P models feature programmable outputs and can be used with proportional valves with integrated or external electronics. The POS-124 PDP is a two-axis positioning module with SSI or analogue sensor interface, ProfibusDP interface and synchronous control. All models offer internal profile generation and high resolution analogue signals, ensuring good positioning behavior.
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Technical Documentation
CSC-152-U
CSC-152-P
Universal positioning and synchronization module, alternatively with power output stage
CONTENTS
Page 2 of 48 CSC-152-*-2030
Page 3 of 48 CSC-152-*-2030
1 General Information
1.1 Order number
CSC-152-U 1 -2030
CSC-156-SSI
2 - with programmable output (±10 V differential output or 4… 20 mA) and analogue
sensor interface
- with integrated power output stage up to 2,6 A (see additional information) CSC-152-P-2030
Extended, alternative versions
POS-124-PDP - two axes positioning module with SSI or analogue sensor interface, ProfibusDP interface and synchronious control
- up to four axes with extended position and pressure control, SSI or analogue sensor interface and ProfibusDP communication (coupler needed).
1.2 Scope of supply
The scope of supply includes the module plus the terminal blocks which are 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
WPC-300 - Start-Up-Tool (downloadable from our homepage – products/software)
1 Compared with older versions (ordering code A for voltages output and I for current output) the code U (universal) is used for programmable outputs.
2 The number of the version consists of the hardware version (first two digits) and the software version (last 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.
Page 4 of 48 CSC-152-*-2030
1.4 Symbols used
General information
Safety-related information
1.5 Using this documentation
Structure of the documentation:
The standard product is descibed up to chapter 6. The extensions like POWER STAGE or SSI-INTERFACE are described in the chapters ADDITIONAL INFORMATION.
1.6 Legal notice
W.E.St.
Elektronik GmbH
Gewerbering 31
D-41372 Niederkrüchten
Tel.: +49 (0)2163 577355-0
Fax.: +49 (0)2163 577355-11
Home page: www.w-e-st.de
or www.west-electronics.com
EMAIL: [email protected]
Date: 30.12.2015
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 protected by copyright.
Page 5 of 48 CSC-152-*-2030
1.7 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 protection) must be complied with.
These modules are designed for hydraulic applications in open or closed-loop control circuits.
Uncontrolled movements can be caused by device defects (in the hydraulic module or the components), application errors and electrical faults. Work on the drive or the electronics must only be carried out whilst the equipment is switched off and not under pressure.
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 commissioning instructions must be followed. Guarantee and liability claims are invalid if the instructions 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, contamination 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.
Page 6 of 48 CSC-152-*-2030
2 Characteristics
This electronic module has been developed for controlling hydraulic positioning / synchronization drives. Proportional valves with integrated or external electronics can be controlled with the differential output.
The internal profile generation is optimized for stroke-dependent deceleration or NC control. The controller and the controller setting are adapted to the typical requirements and thus permit rapid and uncritical optimization of the control behavior. The time-optimized control function offers a high degree of precision together with high stability for hydraulic drives. The movement cycle is controlled via the external position and speed inputs.
The high resolution of the analogue signals ensures good positioning behavior.
The synchronization control works as a second overriding velocity / position controller. Failure between the axes will be compensated by adjusting the speed of the slave axis. The speed can be limited with the external analogue speed input.
Alternatively, a P version is available with an integrated power output stage (see additional information:
POWER OUTPUT STAGE). The advantage of the integrated power output stage lies in the integrated control behavior without additional dead times. This allows higher dynamics and higher stability for proportional valves.
Setting up this module is simple and easy to handle with our WPC-300 start-up software.
Typical applications: Synchronization and positioning of two axes (up to 4 axes in master slave mode).
Features
Analogue position and speed inputs
Analogue feedback sensors
Simple and intuitive scaling of the sensor
Motion command values in mm resp. mm/s
Internal profile definition by acceleration, velocity and deceleration
Principle of stroke-dependent deceleration for fast and robust positioning
NC profile generator for constant speed
Superimposed synchronization controller
Usable with overlapped proportional valves and with zero lapped control valves
Fault diagnosis and extended function checking
Simplified parameterization with WPC-300 software
Optionally: o Integrated power output stage (P version)
Page 7 of 48 CSC-152-*-2030
2.1 Compatibility
As a result of further developments some smaller changes have to be taken in consideration.
Functionality:
1. Downward compatible to the older modules.
2. 100 % wiring compatible.
3. Baud rate: The default baud rate has changed from 9600 baud to 57600 baud. This is adaptable in
WPC-300: OPTIONS/SETTINGS/INTERFACE.
FIXBAUDRATE = 57600 and/or AUTO BAUDRATE DETECTION = 57600
4. Technical enhancements: a. Programmable analogue output: only one version (U instead A and I) is necessary b. Improved profile generator c. Independent adjustment between SDD and NC mode
Parameterization:
1. Standardizing of parameter names
2. Simplified and intuitive parameterization of the analogue inputs and sensors
3. Compatibility mode of the input scaling (AINMODE), if necessary
4. Adaptation of the output signal (current or voltages) and the polarity with the command SIGNAL:U
(the POL commando is removed)
Page 8 of 48 CSC-152-*-2030
2.2 Device description
Standard module
– for the P-Version look at point 7.2
99,0000 mm 23,0000 mm
9 10 11 12
13 14 15 16
114,0000 mm
Made in Germany
Date:
ID:
V:
Add.:
W .
E .
ST .
Elektronik
D-41372 Niederkrüchten
Homepage: http://www.w-e-st.de
Typenschild und Anschlussbelegung
Type plate and terminal pin assignment
LEDs
1 2 3 4
5 6 7 8
W.E.ST.
Ready A B
USB-Interface
9 10 11 12
13 14 15 16
Klemmblöcke (steckbar)
Terminals (removable)
Page 9 of 48 CSC-152-*-2030
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 necessary to avoid strong electro-magnetic interference sources being installed nearby when using our open and closed loop control modules.
Typical installation location: 24 V control signal area (close to PLC)
The devices must be arranged in the control cabinet so that the power section and the signal section are separate from each other.
Experience shows that the installation place close to the PLC (24 V area) is most suitable. All digital and analogue inputs and outputs are fitted with filters and surge absorbers 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-shaped 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 (frequency converters, power contactors) and cable lengths > 3 m. 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.
If having 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).
Special care is required if using cables of over 40 m in length, and if necessary the manufacturer should be consulted if necessary.
A low-resistance connection between PE and the mounting rail should be provided. Transient interference 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) which are connected to the same power supply must always be provided with appropriate overvoltage protection directly at the coil.
Page 10 of 48 CSC-152-*-2030
3.2 Typical system structure
This minimal system consists of the following components:
(*1) Proportional valves with or without integrated electronic
(*2) Cylinder drive
(*3) CSC-152 -P control modules
(*4) Interface to PLC with analogue and digital signals
(*5) Position sensors
3.3 Method of operation
The structure of the synchronization controller is derived from our positioning controllers. The inputs 13 (input position of the axis) and 14 (feedback position of the axis) is used to control the movement. The input 6 (feedback position of another axis (usually the master axis)) in addition to feedback position PIN 14 is used to supply the slave axis with the position of the master axis and improves the synchronization accuracy.
Through the activation of the GL-active input the synchronization controller is activated. If there are two axes in synchronism, the actual position of the other axis can be linked crosswise. In this case a master / master synchronization control (averages control) is possible. Both inputs GL-active (master and slave) have to be activated.
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The function of the status output is switched automatically. If the input GL-active is deactivated the status signal is generated by the InPos messages (error between the input position (13) and feedback position (14)). If the input GL-active is activated, the synchronization error (feedback position (14) and master's feedback position (6)) is monitored.
The synchronization works reliable if the master axis or the speed is limited at 70….80% of the maximum speed. To be able to compare faults the slave axes must be able to drive faster than the master axis.
For a stable behavior of the synchronous controller the maximum speed should be reduced to approximately
70… 80% of the possible drive speed. For compensating errors the slave axes have to be able to drive faster than the master axis. This reserve is necessary and should be considered when planning the system.
If using 4… 20mA sensors the input 6 of the slave will also be connected parallel to input 14 of the master.
Both inputs are measuring via the same resistor what increases the accuracy.
The input 6 has to be parameterized standard for using 4 to 20 mA.
V+
volumetric flow P-A and B-T
MAX:A
A:A D:A control direction driving out control direction driving in
D:B
A:B
MAX:B
V+
Influences on positioning accuracy:
The positioning accuracy is determined by the hydraulic and mechanical conditions. The right choice of valve is therefore a decisive factor. In addition, two mutually contradictory requirements (short position time and high accuracy) must be taken into account when designing the system.
The electronic limitations lie mainly in the resolution of the analogue signals, although a resolution of
< 0,01 % only needs to be considered for our modules with long strokes. In addition, the linearity of the individual signal points (PLC, sensor and control module) must be taken into account too.
It is generally recomended to calculate the static and dynamic behavior of the hydraulic axis. For supporting this, following technical basic data are required:
- minimum natural frequency of the cylinder,
- maximum theoretical speed for extending and retracting,
- valve characteristics (natural frequency, overlapped or zero lapped, hysteresis and the flow gain (flow and pressure drop),
- system pressure, maximum pump flow,
- and a description of the general system requirements.
Page 12 of 48 CSC-152-*-2030
3.4 Commissioning
Step
Installation
Task
Install the device in accordance with the circuit diagram. Ensure it is wired correctly and that the signals are well shielded. The device must be installed in a protective 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 serial 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
Control signal
Switching on the hydraulics
Activating ENABLE
Speed demand
Activating START
GL-ACTIVE
Optimize controller
Now set up the following parameters (with reference to the system design and circuit diagrams):
The SYS_RANGE, SENSOR SETTING, OUTPUT SIGNAL, ACCELERATION and DECELERATION.
Pre-parameterization is necessary to minimize the risk of uncontrolled movements.
Parameterize specific settings for the control element (MIN for deadzone compensation and MAX for maximum velocity).
Reduce the speed limitation (VELO command) to a value which is uncritical for the application.
Check the control signal with a voltmeter. The control signal (PIN 15 to PIN16) lies in the range of ± 10 V. In the current state it should be 0 V. Alternatively, if current signals are used, approx. 0 mA should flow.
The hydraulics can now be switched on. Since the module is not yet generating a signal, the drive should be at a standstill or drift slightly (leave its position at a slow speed).
CAUTION! The drive can now leave its position and move to an end position at full speed. Take safety measures to prevent personal injury and damage.
The drive stays in the current position (with ENABLE the actual position is accepted as the required position). If the drive moves to an end position, the polarity is probably wrong.
The speed can be limited by means of the VELO parameter or the external speed demand (SIGNAL:V).
With the start signal the demand value of the analogue demand value input is accepted and the axis moves to the predefined target position.
If START is disabled, the axis stops in the preset deceleration distance D:S.
This input hase to be activated depending on the start-up procedure. If each axis can be started-up indiviually this input has to be activated after the optimisation of the axes. Now the system can be driven in synchronous control.
Now optimize the control parameters according to your application and your requirements.
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4 Technical description
4.1 Input and output signals
Connection Supply
PIN 3
PIN 4
Connection
PIN 9 / 10
PIN 6
PIN 13
PIN 14
PIN 11 / PIN 12
PIN 15 / 16
Connection
PIN 8
PIN 7
PIN 5
PIN 1
PIN 2
Power supply (see technical data)
0 V (GND) connection.
Analogue signals
External speed demand (V), range
0… 10 V or 4… 20 mA (scalable)
Feedback value of the master axes (k), range 0… 10 V or 4… 20 mA (scalable)
Position demand value (W), range 0… 10 V or 4… 20 mA (scalable)
Analogue position actual value (X), range 0… 10 V or 4… 20 mA (scalable)
0 V (GND) connection for analogue signals
Valve control signal.
Type of signal and polarity can be selected by the parameter SIGNAL:U.
Digital inputs and outputs
Enable input:
This digital input signal initializes the application and error messages are deleted. The controller and the READY signal are activated. The output signal to the control element is enabled.
The actual position is accepted as the command position and the drive remains stationary under control at this position.
If the input is disabled, the output (control signal) is switched off(disabled). Take care of the
EOUT-command!
START (RUN) input:
The position controller is active and the external analogue demand position is accepted as the demand value. If the input is disabled during the movement, the system is stopped within the set emergency stopping distance (D:S).
GL-ACTIVE input:
ON: The synchronization controller is active.
OFF: The synchronization controller is inactive.
READY output:
ON: The module is enabled; there are no discernable errors.
OFF: Enable (PIN 8) is disabled or an error (sensor or internal error) has been detected.
STATUS output:
INPOS message: Depending on PIN 5 for postion (OFF) or synchronous (ON) error
ON: INPOS message. The axis is within the INPOS window.
OFF: INPOS message. The axis is outside the INPOS window.
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4.2 LED definitions
LEDs
GREEN
Description of the LED function
Identical to the READY output.
OFF:
ON:
No power supply or ENABLE is not activated
System is ready for peration
Flashing: Error discovered
Only active when SENS = ON
YELLOW A
GREEN +
YELLOW A+B
YELLOW A +
YELLOW B
Identical to the STATUS output.
OFF: The axis is outside the INPOS window.
ON: The axis is within the INPOS window.
1. Chasing light (over all LEDs): The bootloader is active. No normal functions are possible.
2. All LEDs flash shortly every 6 s: An internal data error was detected and corrected automatically! The module still works regularly. To acknowledge the error the module has to be cycle powered.
Both yellow LEDs flash oppositely every 1 s: The nonvolatile stored parameters are inconsistent! To acknowledge the error, the data have to be saved with the SAVE command or the corresponding button in the WPC. If the function of the module has changed via the
FUNCTION parameter, all parameters are deleted purposely and set to default values. In this case the LEDs indicate no error, but a desired state. To acknowledge please save.
Page 15 of 48 CSC-152-*-2030
4.3 Circuit diagram
n tio ut ita tp lim
Ou d ee Sp
Page 16 of 48 CSC-152-*-2030
4.4 Typical wiring
24V digital outputs to PLC
InPos
Ready
24V digital inputs from PLC
Enable
Run
GL-Aktiv
1 2 3 4
5 6 7 8
24V power supply
0V
Analogue actual master position (0..10 V, 4..20 mA)
Analogue command speed
(0... 10 V, 4... 20 mA)
9 10 11 12
0V 0V
13 14 15 16
Analogue command position
(0..10 V, 4..20 mA)
Analogue actual position
(0..10 V, 4..20 mA)
4.5 Connection examples
PLC 0... 10 V speed input signal
+In PIN 10
-In PIN 9
GND PIN 11 e.g. 24 V shield to power amplifier / proportional valve.
use differential input.
PLC or sensor with 4... 20 mA (two wire connection)
+In PIN 13 or 14
PIN 12 (GND)
PLC 0... 10 V command and feedback signal
+In PIN 13 or PIN 14
In PIN 12 (GND)
Valve (6 + PE plug) with OBE electronics
Module
PIN 12
PIN 15
PIN 16
A : 24 V supply
B : 0 V supply
C : GND or enable
D : + differential input
E : - differential input
F : diagnostics
PE -
PLC or sensor with 4... 20 mA (three wire connection)
+In PIN 13 or 14
PIN 12 (GND)
Page 17 of 48 CSC-152-*-2030
4.6 Technical data
Supply voltage (U b
)
Current requirement
External protection
Digital inputs
Input resistance
Digital outputs
Maximum output current
Analogue inputs
Signal resolution
Analogue outputs
Voltage
Signal resolution
Current
Signal resolution
Controller sample time
Serial interface
Housing
Weight
Protection class
Temperature range
Storage temperature
Humidity
Connections
EMC
[VDC] 12… 30 (incl. ripple)
[mA] <100
[A] 1 medium time lag
[V]
[V]
[kOhm]
OFF : < 2
ON : > 10
25
[V]
[V]
[mA]
[V]
[mA]
[%]
OFF: < 2
ON: max. U b
50
0… 10; min. 25 kOhm
4… 20; 240 Ohm
0,003 incl. Oversampling
[V]
[mA]
[%]
[mA]
[%]
2 x 0… 10; differential output
10 (max. load)
0,006
4… 20; 390 Ohm maximum load
0,006
[ms] 1
USB in RS 232C Emulation
(9600… 57600 Baud, 1 stop bit, no parity, echo mode)
Snap-on module to EN 50022
PA 6.6 polyamide
Flammability class V0 (UL94)
[kg] 0,170
[°C]
[°C]
[%]
IP20
20… 60
20… 70
< 95 (non-condensing)
USB-B
4 x 4-pole terminal blocks
PE: via the DIN mounting rail
EN 61000-6-2: 8/2005
EN 61000-6-4: 6/2007 ; A1:2011
Page 18 of 48 CSC-152-*-2030
5 Parameters
5.1 Parameter overview
Group Command Default
Basic parameters
AXES
Input signal adaptation
Sensor scaling
Command signal
Master position
Speed input
Profile generator
Closed loop control parameters
PT1
EN -
STD -
2 -
ON -
0 0,01 %
200 µm
100 mm
U0-10
100 mm
0 µm
U0-10 -
U0-10 -
0 µm
Unit
OFF -
10000 0,01 %
200 ms
SDD -
250 mm/s²
50 mm/s
100
100 ms ms
25
25
10 mm mm mm
10
10
1
1/s
1/s
-
1 ms
SQRT1 -
Description
Changing language help texts
Parameter view
Number of axes
Malfunction monitor
Output signal if no ready
Range of the in position monitoring
Active working stroke
Type of input
Nominal range
Sensor offset
Type of input
Type of input
Sensor offset master axis
Type of input
Internal speed value (SIGNAL:V = OFF)
External speed ramp time
Method of positioning
Acceleration in NC mode
Maximum speed in NC mode
Acceleration (ramp times) in SDD mode
Deceleration stroke in SDD mode
Closed loop gain in NC mode
PT1 time constant (damping)
Control characteristics
Page 19 of 48 CSC-152-*-2030
Group Command Default Unit
Synchronisation loop control parameters
25 mm
GL:V0
GL:T1
Output signal adaptation
Special commands
AINMODE
10 1/s
30 ms
0
0
0,01 %
0,01 %
10000
10000
0,01 %
0,01 %
200 0,01 %
0 0,01 %
U+-10 -
EASY -
I= W|X|V|K
A: 1000
B: 1000
C: 0
X: V
-
-
0,01 %
-
Description
Deceleration stroke in SDD mode
Closed loop gain in NC mode
Time constant
Deadband compensation or flow characteristic linearization
Output scaling
Deadband compensation trigger point
Output offset value
Type of output signal and polarity
Input scaling mode
Free scaling of the analogue inputs
(AINMODE = MATH).
Page 20 of 48 CSC-152-*-2030
5.2 Basic parameters
5.2.1
LG (Changing the language)
Command
LG x
Parameters x= DE|EN
Unit
-
Group
STD
Either German or English can be selected for the help texts.
CAUTION: After changing the language settings, the ID button (SPEED BUTTON) in the menu bar
(WPC-300) must be pressed (module identification).
5.2.2
MODE (STD or EXP parameters)
Command
MODE x
Parameters x= STD|EXP
Unit
-
Group
STD
This command changes the operating mode. Various commands (defined via STD/EXP) are blanked out in
Standard Mode. The commands in Expert Mode have a more significant influence on system behavior and should accordingly be changed with care.
5.2.3 AXES (Number of axes)
Command
AXES x
Parameters x= 1… 6
Unit
-
Group
STD
The number of axes is used to calculate the correct feedback value of the master axis (K) if current signals are used. Chosing “1” means no corrective calculation like in former versions of the controller.
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5.2.4 SENS (monitoring of the modul functions)
Command
SENS x
Parameters Unit x= ON|OFF|AUTO -
Group
STD
This command is used to activate/deactivate the monitoring functions (4… 20 mA sensors, output current, signal range and internal failures) 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 monitor ing 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 mainly for troubleshooting.
5.2.5 EOUT (Output signal: READY = OFF)
Command
EOUT x
Parameters Unit x= -10000… 10000 0,01 %
Group
EXP
Output value in case of a detected error or a deactive ENABLE input. A value (degree of valve opening) for use in the event of a sensor error (or the module is disabled) can be defined here. This function can be used if, for example, the drive is to move to one of the two end positions (at the specified speed) in case of a sensor error.
|EOUT| = 0 The output is switched off in the event of an error. This is normal behavior.
CAUTION! If the output signal is 4… 20 mA, the output is switched off when |EOUT| = 0. If a null value = 12 mA is to be output in the event of an error, EOUT must be set to 1 3 .
The output value defined here is stored permanently (independently of the parameter set). The effects should be analyzed by the user for each application from the point of view of safety.
Do not use the manual mode in conjunction with the EOUT command. After the deactivation of the HAND input the output is set to the EOUT value.
3 This is necessary if using valves without error detection for signals lower than 4 mA. If the valve has an error detection, it moves into a defined position after switching off the output.
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5.2.6 INPOS (In position range)
Command
INPOS x
Parameters x= 2… 200000
Unit
µm
Group
STD
This parameter is entered in µm.
The INPOS command defines a range for which the INPOS message is generated. This function monitors the failure between the command and actual position. If the failure is less than the programmed value a INPOS message is displayed at the status output and the STATUS LED. The positioning process is not influenced by this message.
When the synchronous controller is active, this window is used for displaying the synchronous error.
PIN 7 (START) muss be acivated to generate the INPOS messages.
Page 23 of 48 CSC-152-*-2030
5.3 Input signal adaptation
5.3.1
SYS_RANGE (Active working stroke)
Command Parameters
SYS_RANGE x x= 10… 10000
Unit mm
Group
STD
This command defines the full stroke, which corresponds to 100 % of the input signal. If the demand is set incorrectly, this leads to incorrect system settings, and the dependent parameters such as speed and gain cannot be calculated correctly.
5.3.2 SIGNAL (Type of input)
Command Parameter Unit Group
SIGNAL:i x i= W|X|V|K x= OFF
U0-10
U10-0
I4-20
I20-4
-
EASY
This command can be used to change the type of input signal (voltages or current) and to define the direction of the signal. This command is available for all analogue inputs (W, X, and V).
OFF= Deactivation of the input 4 .
5.3.3 N_RANGE:X (Nominal range of the sensor)
Command Parameter Unit Group
N_RANGE:X x x= 10… 10000 mm
EASY
N_RANGE (nominal range or nominal stroke) is used to define the length of the sensor. This value should be always higher than SYS_RANGE. The addicted control parameters like speed and gain cannot be calculated correctly in case of wrong values.
4 The deactivation can be used to deactivate the velocity (speed) input PIN_9/10 (the VELO value is active).
Page 24 of 48 CSC-152-*-2030
5.3.4 OFFSET:X (Sensor offset)
5.3.5 OFFSET:K (Sensor offset master axis input)
Command Parameter Unit Group
OFFSET:X x x= -100000… 100000 µm
OFFSET:K x x= -100000… 100000 µm
EASY
EASY
Adjustment of the zero point of the sensor.
OFFSET:X is limited to SYS_RANGE internally.
The value for the OFFSET:K normally can be taken from the OFFSET:X of the master axis.
5.3.6 Using of the commands SYS_RANGE, N_RANGE:X and OFFSET:X
The application scaling will be done by these three commands. In this example the system is defined by a length of 120 mm of the sensor, a working stroke of 100 mm of the cylinder and an offset of 5 mm. These parameters have to be typed in and the axis is driving between 5 mm and 105 mm of the sensor stroke and between 0 mm and 100 mm of the cylinder stroke.
Correct scaling:
SYS_RANGE = 100 (mm)
N_RANGE:X = 120 (mm)
OFFSET:X = -5000 (µm)
100,00 mm
120,00 mm
5,00 mm
Figure 1 (Input scaling of the sensor)
Page 25 of 48 CSC-152-*-2030
5.3.7
Speed demand
The SIGNAL:V command is used to switch over between external or internal speed limitation.
SIGNAL:V = OFF Internal speed limitation is active (VELO command)
Otherwise SIGNAL:V defines the type of external signal for what VRAMP provides a ramp generator function 5 .
5.3.8
VELO (Internal speed demand value)
Command
VELO x
Parameters x= 1… 10000
Unit
0,01 %
Specification of the internal speed limitation.
Group
SIGNAL:V = OFF
5.3.9
VRAMP (Ramp time for external speed demand)
Command
VRAMP x
Parameters x= 10… 5000
Unit ms
Group
SIGNAL:V
The rate of change of the external speed demand can be limited by this ramp time. The command is only active if external speed demand (SIGNAL:V <> OFF) has been parameterized.
5 The output signal is directly limited in SDD mode (default mode). In NC mode the speed profile of the generator is limited.
The lowest adjustable speed is 0,01 mm/s (VMAX = 1 mm/s and VELO = 1 %).
Page 26 of 48 CSC-152-*-2030
5.4 Profile generator
5.4.1
VMODE (Methode of positioning)
Command
VMODE x
Parameters x= SDD|NC
Unit
-
Group
EXP
The fundamental control structure can be changed with this parameter.
SDD:
NC:
Stroke-Dependent Deceleration. In this mode, stroke-dependent deceleration is activated. This mode is the default mode and is suitable for most applications. With stroke-dependent deceleration the drive comes to a controlled stop at the target position. From the deceleration setpoint the drive then switches to closed loop control mode and moves accurately to the desired position. This control structure is very robust and reacts insensitively to external influences such as fluctuating pressures. One disadvantage is that the speed varies with the fluctuating pressure as the system runs under open-loop control.
Numerically Controlled. In this mode a position profile is generated internally. The system always works under control and uses the following error to follow the position profile. The magnitude of the following error is determined by the dynamics and the closed loop gain. The advantage is that the speed is constant (regardless of external influences) due to the profile demand. Because of continuous control, it is necessary not to run at 100 % speed, as otherwise the errors cannot be corrected. 70… 80 % of the maximum speed is typical although especially the system behavior and the load pressure should be taken into account when specifying the speed.
5.4.1 ACCEL (Acceleration in NC mode)
Command Parameters Unit Group
ACCEL x x= 1… 20000 mm/s² VMODE=NC
This command is used to define the acceleration in NC mode. The command is only active if the VMODE has been parameterized to NC.
5.4.2
VMAX (Maximum speed in NC mode)
Command
VMAX x
Parameters x= 1… 2000
Unit mm/s
Group
VMODE=NC
Specification of the maximum speed in NC mode. This value is defined by the drive system and should be specified as precisely as possible (not too high under any circumstances). The speed is scaled by means of the VELO value or via the external speed demand. The command is only active if the VMODE has been parameterized to NC.
Page 27 of 48 CSC-152-*-2030
5.5 Positioning controller
5.5.1
A (Acceleration (ramp) time)
Command
A:i x
Parameters i= A|B x= 1… 5000
Unit ms
Group
VMODE=SDD
Ramp function for the 1 st and 3 rd quadrants.
The acceleration time for positioning is dependent on the direction. “A” corresponds to connection 15 and “B” corresponds to connection 16 (if POL = +).
Normally A = flow P-A, B-T and B = flow P-B, A-T.
For quadrants 2 and 4, parameters D:A and D:B are used as the deceleration distance demand.
5.5.2
D (Deceleration stroke / braking distance)
Command
D:i x
Parameters i= A|B|S x= 1… 10000
Unit mm
Group
VMODE = SDD
This parameter is specified in mm 6 .
The deceleration stroke is set for each direction of movement (A or B). The control gain is calculated internally depending on the deceleration distance. The shorter the deceleration distance, the higher the gain. A longer deceleration distance should be specified in the event of instability.
Parameter D:S is used as the stopping ramp when disabling the START signal. After disabling, a new target position (current position plus D:S) is calculated in relation to the speed and is specified as a command value.
G
Intern
N _ RANGE : X
Calculation of control gain
D i
CAUTION: If the maximum stroke (SYS_RANGE command) is changed, the deceleration distance must also be adjusted. Otherwise this can result in instability and uncontrolled movements.
6 CAUTION! In older modules this parameter was specified in % of the maximum stroke. Since data specification for this module has now been converted to mm, the relationship between the stroke (SYS_RANGE command) and these parameters must be taken into account.
Page 28 of 48 CSC-152-*-2030
5.5.3
V
0
(Loop gain setting)
Command
V0:i x
Parameters i= A|B x= 1… 400
Unit s -1
Group
VMODE = NC
This parameter is specified in s -1 (1/s).
In NC Mode normally the loop gain is specified rather than the deceleration stroke 7 .
The internal gain is calculated from this gain value together with the parameters VMAX and SYS_RANGE.
D i
v max
V
0
G
Intern
N
_
RANGE
:
X
D i
Calculation of the internal control gain
In NC Mode the following error at maximum speed is calculated by means of the loop gain. This following error corresponds to the deceleration stroke with stroke-dependent deceleration. The conversion and therefore also the correct data demands related to the closed loop control system are relatively simple if the relationship described here is taken into account.
5.5.4 V0:RES (Scaling of the loop gain)
Command Parameters Unit
V0:RES x x= 1|100 -
V0:RES = 1 loop gain in s -1 (1/s) units.
V0:RES = 100 loop gain in 0,01 s -1 units 8 .
The increased resolution should be used in case of V
0
< 4.
Group
VMODE = NC
7 The loop gain is alternatively defined as a KV factor with the unit (m/min)/mm or as V
0
in 1/s. The conversion is
KV = V
0
/16,67.
8 In case of very low loop gains (1 s -1 to 3 s -1 ) the better resolution of the adjustment should be selected.
Page 29 of 48 CSC-152-*-2030
5.5.5 PT1 (Timing of the controller)
Command Parameter Unit Group
PT1 x x= 0… 300 ms EXP
This parameter can be used to change the internal timing of the control function.
Hydraulic drives are often critically to control especially in case of high speeds and very fast valves. The PT1 filter can be used to improve the damping rate and allows therefore higher loop gains.
Requirements for the use are: The natural frequency of the valve should be equal or higher than the natural frequency of the drive.
5.5.6
CTRL (Deceleration characteristics)
Command
CTRL x
Parameters Unit x= LIN|SQRT1|SQRT2 -
Group
STD
The deceleration characteristic is set with this parameter. In case of positively overlapped proportional valves the SQRT function should be used. The non-linear flow function of these valves is linearized by the SQRT 9 function.
In case of zero lapped valves (control valves and servo valves) the LIN or SQRT1 function should be used regardless of the application. The progressive characteristic of the SQRT1 function has better positioning accuracy but can also lead to longer positioning times in individual cases.
LIN: Linear deceleration characteristic (gain is increased by a factor of 1).
SQRT1: Root function for braking curve calculation. The gain is increased by a factor of 3 (in the target position). This is the default setting.
SQRT2: Root function for braking curve calculation. The gain is increased by a factor of 5 (in the target position). This setting should only be used with a significantly progressive flow through the valve.
Braking stroke
D:A or D:B
Deceleration time
D:A or D:B
CTRL = SQRT
CTRL = SQRT
CTRL = LIN
CTRL = LIN
Stroke Time
Figure 2 (Braking function with respect to stroke and time)
9 The SQRT function generates constant deceleration and thus reaches the target position faster. This is achieved by increasing the gain during the deceleration process.
Page 30 of 48 CSC-152-*-2030
5.6 Synchronization controller
5.6.1 GL:P (Proportional control gain)
5.6.2 GL:V0 (Proportional control gain in NC mode)
5.6.3 GL:T1 (damping of the synchronization control function)
Commands
GL:P
GL:V0
GL:T1 x x x
Parameter x= 1… 10000 x= 1… 400 x= 1… 300
Units mm s -1 ms
Group
VMODE = SDD
VMODE = NC
STD
These parameters are used to optimize the synchronization controller The SYNC-controller works as a PT1 or
PI compensator for optimized controlling of hydraulic drives. The parameter T1 effects a delayed action of the
SYNC Controller. The stability of the compensator could be increased in critical cases with the up streamed T1
Filter.
In SDD-mode is specified with GL:P, the braking distance in mm. The gain will depend on the stopping distance is calculated internally. In short braking distance, the high gain is calculated.
In the case of instability should be given a longer stopping distance.
In the NC-mode parameters of the GL: V0 is in s-1 (1 / s) specified.
In this mode, the loop gain is entered.
The parameter GL: T1 causes a delayed action of the synchronized controller. The stability of the controller can be increased by the upstream T1-filter in critical cases.
w, control value rampfunction w e A:A, A:B
D:A, D:B c u
x x feedback
e_s GL:P
GL:T1 c_s k k feedback
Page 31 of 48 CSC-152-*-2030
5.7 Output signal adaptation
5.7.1
MIN (Deadband compensation)
5.7.2
MAX (Output scaling)
5.7.3
TRIGGER (Response threshold for the MIN parameter)
Command
MIN:i x
MAX:i x
TRIGGER x
Parameters i= A|B x= 0… 6000 x= 3000… 10000 x= 0… 4000
Unit
-
0,01 %
0,01 %
0,01 %
Group
STD
The output signal to the valve is adjusted by means of these commands. A kinked volume flow characteristic is used instead of the typical overlap step for the position controls. The advantage is better and more stable positioning behavior. At the same time, kinked volume flow characteristics can also be adjusted with this compensation 10 .
CAUTION: If there should also be adjustment options for deadband compensation on the valve or valve amplifier, it must be ensured that the adjustment is performed either at the power amplifier or in the module.
If the MIN value is set too high, this has an effect on the minimum speed, which can then no longer be adjusted. In extreme cases this leads to oscillation around the controlled position.
MAX:A non lineare Flow compensation
Standard deadband compensation
MIN:A
Input
MIN:B TRIGGER
MAX:B
10 Various manufacturers have valves with a defined nonlinear curve: e.g. a kink at 40 or 60 % (corresponding to 10 % input signal) of the nominal volume flow. In this case the TRIGGER value should be set to 1000 and the MIN value to 4000
(6000).
If zero lapped or slightly underlapped valves are used, the volume flow gain in the zero range (within the underlap) is twice as high as in the normal working range. This can lead to vibrations and jittery behavior. To compensate this, the TRIGGER value should be set to approximately 200 and the MIN value to 100. The gain in the zero point is thus halved and an overall higher gain can often be set.
Page 32 of 48 CSC-152-*-2030
5.7.4
OFFSET (Zero correction)
Command
OFFSET x
Parameters Unit x= -4000… 4000 0,01 %
Group
STD
This parameter is entered in 0,0 1% units.
The offset value is added to the output value. Valve zero offsets can be compensated with this parameter.
5.7.5 SIGNAL:U (Type and polarity of the output signal)
Command Parameter Unit Group
SIGNAL:U x x= U+-10
I4-12-20
U-+10
I20-12-4
-
EXP
This command is used to define the output signal (voltage or current) and to change the polarity 11 .
Differential output ± 100 % corresponds with ± 10 V (0… 10 V at PIN 15 and PIN 16).
Current output ± 100 % corresponds with 4… 20 mA (PIN 15 to PIN 12). 12 mA (0 %) = center point of the valve.
An output current of << 4 mA indicates an error and the module is disabled. The current input of the proportional valves should be monitored by the valve. The valve have to be deactivated in case of < 4 mA input signal. Otherwise the EOUT command can be used to get a defined output signal.
11 The older POL command is removed.
Page 33 of 48 CSC-152-*-2030
5.8 Special commands
5.8.1 AINMODE (Input scaling mode)
Command
AINMODE x
Parameter x= EASY|MATH
Unit
-
Group
STD
The AINMODE is used to define the kind of parameterizing of the analogue inputs. The EASY mode
(DEFAULT) supports a simple and application oriented input scaling.
The MATH mode supports the free input scaling by a linear equation. This mode is compatible to our older modules.
Attention: This command can be executed in the terminal window only. In case of switching back,
DEFAULT data should be reloaded.
5.8.2 AIN (Free analogue input scaling)
Command
AIN:i
A
B
C
X
Parameters i= W|X|V|K a= -10000… 10000 b= -10000… 10000 c= -10000… 10000 x= V|C
Unit
-
-
0,01 %
-
Group
MATH
This command offers an individual scalable input. It is available for the inputs W (command signal), X (feedback signal), K (Master position) and V (Speed limit). The following linear equation is used for the scaling.
Output
a
( Input b
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 with which the signal range is scaled up to 100 % (e.g. 1.25 if using 4… 20mA input signal, defined in default current settings by A = 1250 and B = 1000). The internal shunt for the current measuring is activated with switching the it is connected parallel to master’s feedback).
X value (not at master position input K because
The gain factor is calculated by setting the usable range ( A ) in relation to the real used range ( B ) of the input signal. Usable are 0… 20mA, means ( A ) has the value 20 . Really used are 4… 20mA, means ( B ) has a value of 16 (204). Not used are 0… 4mA. In a range of 20mA this is an offset of 20%, means a value of 2000 for
( C ). Last but not least ( X ) has to be set to C choosing current signal.
In this case AIN command would look like this:
AIN:I 20 16 2000 C or AIN:I 1250 1000 2000 C
Page 34 of 48 CSC-152-*-2030
Typical settings:
Command
AIN:X 1000 1000 0 V
AIN:X 10 8 1000 V OR
AIN:X 1000 800 1000 V
AIN:X 10 4 500 V OR
AIN:X 1000 400 500 V
AIN:X 20 16 2000 C OR
AIN:X 2000 1600 2000 C OR
AIN:X 1250 1000 2000 C
Input Description
0… 10 V Range: 0… 100 %
1… 9 V Range: 0… 100 %; 1 V = 1000 used for the offset and gained by 10 / 8 (10 V divided by 8 V (9 V -1 V))
0,5… 4,5
V
Range: 0… 100 %; 0,5 V = 500 used for the offset and gained by 10 / 4 (10 V divided by 4 V (4,5 V -0,5 V))
4… 20mA Range: 0… 100 %
The offset will be compensated on 20 % (4 mA) and the signal (16 mA = 20 mA
– 4 mA) will be gained to 100 %
(20 mA).
Each of this parameterization for 4… 20 mA is setting the range to 0… 100 %.
5.9 PROCESS DATA (Monitoring)
Command
WA
W
V
X
E
C
K
E_S
C_S
U
IA
IB
Description
Demand value (input signal)
Demand value (according to the profile generator)
Speed input
Actual value
Position error
Output of the positioning controller
Master position
Synchronisation error
Output of the synchronous controller
Output signal of the module
Solenoid current A
Solenoid current B
Unit mm mm
% mm mm
% mm mm
%
% mA (P Version only) mA (P Version only)
The process data are the variables which can be observed continuously on the monitor or on the oscilloscope.
Page 35 of 48 CSC-152-*-2030
6 Appendix
6.1 Failure monitoring
Following possible error sources are monitored continuously when SENS = ON/AUTO:
Source
Command speed PIN 10
4... 20 mA
Command signal PIN 13
4... 20 mA
Feedback signal PIN 14
4… 20 mA
P-VERSION
Solenoids on PIN 17-20
EEPROM
(when switching on)
Fault Characteristic
Out of range or broken wire The output will be switched off.
Out of range or broken wire The output will be switched off.
Out of range or broken wire The output will be switched off.
Wrong cabling, broken wire The power stage will be deactivated.
Data error The output is deactivated.
The module can only be activated by saving the parameters again!
CAUTION: Take care of the EOUT command. Changes will influence the behavior.
6.2 Troubleshooting
It is assumed that the device is in an operable state and there is communication between the module and the
WPC-300. Furthermore, the valve control parameterization has been set with the assistance of the valve data sheets.
The RC in monitor mode can be used to analyze faults.
CAUTION: All safety aspects must be thoroughly checked when working with the RC (Remote
Control) mode. In this mode the module is controlled directly and the machine control cannot influence the module.
Page 36 of 48 CSC-152-*-2030
FAULT
ENABLE is active, the module does not respond and the
READY LED is off.
CAUSE / SOLUTION
There is presumably no power supply or the ENABLE signal (PIN 8) is not present.
If there is no power supply, there is also no communication via our operating program. If a connection has been made to the WPC-300, then a power supply is also available.
If the power supply exists, an attempt should be made to see whether the system can be moved by means of the HAND+ and HAND- inputs (measuring the output signal to the valve helps).
ENABLE is active, the
READY LED is flashing.
The flashing READY LED signals that a fault has been detected by the module. The fault could be:
A broken cable or no signal at one of the inputs if 4… 20 mA signals are parameterized.
A broken cable or incorrect cabling to the solenoids (in the P version only).
Internal data error: press the command/SAVE button to delete the data error. The system reloads the DEFAULT data.
With the WPC-300 operating program the fault can be localized directly via the monitor.
The control circuit polarity is incorrect. The polarity can be changed with the POL command or by reversing the connections to PIN 15 and PIN 16.
ENABLE is active; the
READY LED is on, the system moves to an end position.
ENABLE is active, the
READY LED is on, the
STATUS LED is not on, the system moves to the target position but doesn’t reach it
(positioning error).
ENABLE is active, the
READY LED is on, and the system oscillates on the target.
Speed too low
Serious positioning errors can result from incorrect parameterization or incorrect system design.
Is the cylinder position specified correctly?
Are the deceleration strokes correct (to start the system the deceleration distances should be set to approx.
20… 25 % of the cylinder position 12 )?
Is the valve a zero lapped control valve or a standard proportional valve?
In the case of a proportional valve, the valve overlap which may be present should be compensated for with the MIN parameters. Typical values are to be found in the valve data sheet.
The system is working and also actuating the valve.
Various potential problems could be:
The parameterization is not yet adjusted to the system (gain too high).
There is severe interference on the power supply.
Very long sensor cables (> 40 m) and sensor signal interference.
The MIN setting to compensate the valve overlap is too high.
As a basic principle, the parameterization of the sensor data and the controller settings must be carried out first (before switching on). An incorrect demand is equivalent to incorrect system design which then leads to incorrect operation. If the system oscillates, the gain should first be reduced (longer deceleration distances for
D:A and D:B) and in the case of overlapped valves the MIN parameter should also be reduced.
The drive may be able to move to position but the speed is too low.
Check the control signal to the valve.
Via the integrated oscilloscope (U variable).
Measure the signal to the valve with an external oscilloscope / voltmeter.
If the control is within the range of ± 100 % (± 10 V), the fault must be sought in the hydraulics.
If the control signal is relatively low, the following points should be checked:
Is the internal/external speed signal limiting the speed?
Which setting has been specified for the deceleration distance in relation to the POSITION?
12 The stability criterion of the hydraulic axes must be taken into account.
Page 37 of 48 CSC-152-*-2030
FAULT
Speed too high
Positioning is OK, the synchronization error is too high.
CAUSE / SOLUTION
The drive should move to position. The drive moves in and out too fast leading to uncontrolled behavior. Reducing the speed (MAX or VELO parameter) has very little or no effect.
The hydraulic system is over-sized. The entire parameterization of the movement cycle cannot be reproduced (overlap and deceleration distance settings)
There may be several reasons. The synchronization accuracy is determined by the parameter GL:P. The higher the value, the smaller the synchronization error (within physical limits).
Reasons:
1. The parameter setting is different between the two axes.
2. The hydraulic system pressure is not sufficient. The supply pressure is not constant.
13
3. The slave axis can’t follow the master axis at high speeds. This means that the natural velocity of the master axis is higher than that of the slave axis 14 . In this case, the maximum speed of the master axis should be limited (MAX parameter).
4. The sensor scaling or the position of sensor includes an offset error. This error is typically constant. Solution: Move the sensor mechanically or compensate for the fault over the AIN command.
13 High demands to the synchronization have to be regarded with high demands to the pressure supply. Pressure errors lead always to synchronization faults, which the control has to compensate for.
14 In principle, the master axis should be limited in the master/slave configuration in the speed.
The slave axis must have the possibility of driving faster than the master axis. Otherwise control errors cannot be compensated for.
Page 38 of 48 CSC-152-*-2030
7 ADDITIONAL INFORMATION: Power output stage
7.1 General function
The power output stages have been developed for controlling proportional valves without spool position feedback. The output stage is controlled by the microcontroller on the basic module by means of pulse width modulated signals, and the current is continuously controlled. The cycle time for the controller is 0,125 ms.
The output stage can be ideally adjusted to dynamic requirements via internal parameters.
Valve technology: Proportional valves manufactured by REXROTH, BOSCH, DENISON, EATON, PARKER,
FLUID TEAM, ATOS and others.
Features
Two power output stages with maximum output range of 0.5 A to 2,6 A
Hardware short-circuit protection with 3 µs response time
Adjustable PWM frequency, dither frequency and dither amplitude
High current signal resolution
No additional delay times between the control function and the power stage
Separate power supply for safety-relevant applications
Integrated into the standard controller, no additional wiring necessary
Optimum price/performance ratio
Page 39 of 48 CSC-152-*-2030
7.2 Device description
99,0000 mm 45,0000 mm
13 14 15 16 25 26 27 28
13 14 15 16 29 30 31 32
114,0000 mm
Made in Germany
Date: Add.:
ID:
V:
W .
E .
ST .
Elektronik
D-41372 Niederkrüchten
Homepage: http://www.w-e-st.de
Typenschild und Anschlussbelegung
Type plate and terminal pin assignment
LEDs
USB
Interface
1 2 3 4 17 18 19 20
5 6 7 8 21 22 23 24
W.E.ST.
Ready A B
9 10 11 12 25 26 27 28
13 14 15 16 29 30 31 32
Klemmblöcke (steckbar)
Terminals (removable)
Page 40 of 48 CSC-152-*-2030
7.3 Inputs and outputs
Connection Signal description
PIN 22 +
PIN 24 -
Power supply : 10… 30 VDC: For safety-related applications, the output stage can be deactivated thanks to the separate power supply inputs.
PIN 17 + 19
PIN 18 + 20
Solenoid current output A
Solenoid current output B
Connection Signals modified from the standard (A and I version)
PIN 15
PIN 16
0… 10 V / 4… 20 mA output with the scaled position demand value
0 … 10 V / 4… 20 mA output with the scaled feedback position value
7.4 Circuit diagram
***-***P
10..30V
0V
Power supply
24 V
0 V
22
24
Internal MCU interface
Power output stage ia 17
19 ib 18
20
Solenoid A
Solenoid B
17
19
20
18
ATTENTION, SENS = AUTO is not recommended is case of correct failure monitoring 15 .
15 In case of deactivated solenoid (solenoid B is active and solenoid A is not active) a failure a solenoid A cannot be recognized always.
Page 41 of 48 CSC-152-*-2030
7.5 Typical wiring
1 2 3 4
17 18 19 20
24V
0V
Power supply
Solenoid A
Solenoid B
5 6 7 8 21 22 23 24
9 10 11 12 25 26 27 28
13 14 15 16
29 30 31 32
CAUTION: The solenoid cables should be screened due to electro-magnetic emissions.
CAUTION: plugs with free-wheeling diodes and LED indicators cannot be used with currentcontrolled power outputs. They interfere with the current control and can destroy the output stage.
7.6 Technical data
Supply voltage
Power consumption max.
Fuse protection
PWM output
PWM frequency
Sample time solenoid current control
Temperature range
Housing
Weight
Connections
[VDC] 10... 30
[W]
[A]
60 (depending on the solenoid)
3 (medium time lag)
[A]
[Hz]
0,5, to 2,6 (step less selectable); broken wire and short circuit monitored
61 … 2604
[ms] 0,125
[°C] 20… 60
Snap-on module EN 50022
Polyamide PA 6.6
Flammability class V0 (UL94)
[kg] 0,250 (incl. standard module)
3 x 4-pole terminal blocks
Page 42 of 48 CSC-152-*-2030
7.7 Parameter overview
Command
Default
V -
Unit Description
ON -
Type of the monitor output signal
1000 mA
2604 Hz
Output current range
121 Hz
Dither frequency
500 0,01 % Dither amplitude
PWM frequency
Automatical calculation of the PPWM and IPWM parameter
7
40
-
-
Current control loop PI control dynamics
+ - Output polarity
The standard parameterization has been used with a large number of proportional vales from various manufacturers. This parameterization has proved to be good as long as no special demands concerning the application have to be fulfilled.
7.8 Parameter description of the power stage
7.8.1 SIGNAL:M (Type of the monitor output signal)
Command Parameter Unit
SIGNAL:M x x= U0-10|I4-20
This command is used to define the output signal.
U0-10 - Voltage signal 0… 10V for 0… 100%.
I4-20 - Current signal 4… 20mA for 0… 100%.
-
Group
EXP
7.8.2
CURRENT (Rated output current)
Command
CURRENT x
Parameters x= 500… 2600
Unit mA
Group
STD
The nominal output current is set. Dither and also MIN/MAX always refer to this current range.
Page 43 of 48 CSC-152-*-2030
7.8.3
DFREQ (Dither frequency)
7.8.4
DAMPL (Dither amplitude)
Command
DFREQ x
DAMPL x
Parameters x= 60… 400 x= 0… 3000
Unit
Hz
0,01 %
Group
STD
STD
The dither 16 can be defined with this commands. Different amplitudes or frequencies may be required depending on the valve.
The dither amplitude is defined in % (peak to peak value) of the nominal output current 17 (see: CURRENT command).
The dither frequency is defined in Hz. Depending on the internal calculations, the frequency is adjustable in steps only 18 .
CAUTION: The PPWM and IPWM parameters influence the effect of the dither setting. These parameters should not be altered again after the dither has been optimized.
CAUTION: If the PWM frequency is less than 500 Hz, the dither amplitude DAMPL should be set to zero.
7.8.5 PWM (PWM Frequenz)
Command
PWM x
Parameter x= 61… 2604
Unit
Hz
Group
EXP
The frequency can be changed in defined steps (61 Hz, 72 Hz, 85 Hz, 100 Hz, 120 Hz, 150 Hz, 200 Hz, 269
Hz, 372 Hz, 488 Hz, 624 Hz, 781 Hz, 976 Hz, 1201 Hz, 1420 Hz, 1562 Hz, 1736 Hz, 1953 Hz, 2232 Hz and
2604 Hz). The optimum frequency depends on the valve.
Attention: The PPWM and IPWM parameters should be adapted when using low PWM frequencies
because of the longer dead times which forces a reduced stability of the closed loop control.
16 The dither is a ripple signal which is superimposed on the current set point and is defined by the amplitude and frequency: the dither frequency and the PWM frequency.
The dither frequency should not be confused with the PWM frequency . In some documentations the PWM frequency is described as a dither. This can be recognized by the lack of the dither amplitude.
17 The dither amplitude is a command signal. Derivations between the commanded amplitude and the real amplitude are possible, depending on the dynamic of the solenoid.
18 The lower the dither frequency, the smaller the steps. Therefore no practical problems are expected.
Page 44 of 48 CSC-152-*-2030
7.8.6
ACC (Current loop ato adjustment )
Command
ACC x
Parameter x= ON|OFF
Unit
-
Group
EXP
Operation mode of the closed loop current control.
ON: In automatic mode PPWM and IPWM are calculated depending on the preset PWM-frequency.
OFF: Manual adjustment.
7.8.7
PPWM (Solenoid current controller P element)
7.8.8
IPWM (Solenoid current controller I element)
Command
PPWM
IPWM x x
Parameters x= 0… 30 x= 4… 100
Unit
-
-
Group
EXP
The PI current controller for the solenoids is parameterized with these commands.
CAUTION: These parameters should not be changed without adequate measurement facilities and experience.
Attention, if the parameter ACC is set to ON, these adjustments are done automatically.
If the PWM frequency is < 250 Hz, the dynamic of the current controller has to be decreased.
Typical values are: PPWM = 1 … 3 and IPWM = 40… 80.
If the PWM frequency is > 1000 Hz, the default values of PPWM = 7 and IPWM = 40 should be chosen.
7.9 Changed parameter from U-version
7.9.1
SIGNAL:U (Polarity of the output signal)
Command
SIGNAL:U x
Parameters x= +|-
Unit
-
Group
STD
In P-version this command provides defined switching the polarity of the output signal.
Page 45 of 48 CSC-152-*-2030
8 HELPING INFORMATION: Schematic diagrams
8.1 2 axes system
The slave can be defined with the digital input PIN 5 (GL-active) if only two axes are synchronized. Activating the synchronous controller in both axes results in a master/master system with average value controlling.
Enable / Start /GL
Enable / Start / GL
Command position (0... 10V)
8 / 7 /5
13
6
CSC-152
Addr= 1 (...)
14
Output
Position sensor
8 / 7 / 5
CSC-152
Addr= 2 (...)
13
6
14
Output
Position sensor
Page 46 of 48 CSC-152-*-2030
8.2 4 axes system
In four axes, the master-/ slave-structure is predetermined. Other control structures are only possible in
CSC-156-SSIC with CAN bus networking.
Enable / Start
Enable / Start / GL
Enable / Start / GL
Enable / Start / GL
Command position (0... 10V)
8 / 7
13
6
CSC-152
Addr= 1 (Master)
14
Output
Position sensor
8 / 7 / 5
CSC-152
Addr= 2 (Slave)
13
6
14
Output
Position sensor
8 / 7 / 5
CSC-152
Addr= 3 (Slave)
13
6
14
Output
Position sensor
13
6
8 / 7 / 5
CSC-152
Addr= 4 (Slave)
14
Output
Position sensor
Page 47 of 48 CSC-152-*-2030
9 Notes
Page 48 of 48 CSC-152-*-2030
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Key features
- Analogue position and speed inputs
- Analogue feedback sensors
- Internal profile definition
- Superimposed synchronization controller
- Simplified parameterization
- Programmable analogue output
- Integrated power output stage (P version)
- ProfibusDP communication (coupler needed)
