W.E.St. PAM-140-P -A-10101, -I-1010, PAM-190-P, PAM-193-P, PAM-199-P Universal Mobile Power Amplifier Technical Documentation
Below you will find brief information for PAM-140-P PAM-140-P-A-10101, PAM-140-P PAM-140-P-I-1010, PAM-190-P PAM-190-P. This power amplifier is used to control proportional valves with one solenoid. The compact solution is implemented in an inexpensive IP-65 housing. A typical input signal of 0… 10 V (optional 4... 20 mA) can be used. The output current is closed loop controlled and therefore independent from the supply voltage and a varying solenoid resistance.
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Technical Documentation
PAM-140-P
Universal mobile power amplifier
CONTENTS
Page 2 of 25 PAM-190-P-*-1010
1 General Information
1.1 Order number
PAM-140-P-A-1010
1
- Power amplifier for proportional valves with 0…10 V input in IP65-version
PAM-140-P-I-1010 - Power amplifier for proportional valves with 4...20 mA input in IP65-version
Alternative and extended products
PAM-190-P
PAM-193-P
PAM-199-P
- Power amplifier (plug) for proportional valves with M12 connection
- Amplifier with potentiometers and DIL switches for top hat rail mounting
- Universal digital amplifier with USB interface for top hat rail mounting
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
ULA-310
AKL-311
- Start-Up-Tool (downloadable from our homepage
– products/software)
- Programming device with USB interface
- Cable adapter to ULA-310
1
The number of the version consists of the hardware-version (first two digits) and the software-version (second two digits).
Because of the development of the products these numbers can vary. They are not strictly necessary for the order. We will always deliver the newest version.
Page 3 of 25 PAM-190-P-*-1010
1.4 Symbols used
General information
Safety-related information
1.5 Legal notice
W.E.St.
Elektronik GmbH
Gewerbering 31
D-41372 Niederkrüchten
Tel.: +49 (0)2163 577355-0
Fax.: +49 (0)2163 577355-11
Home page: www.w-e-st.de
or www.west-electronics.com
EMAIL: [email protected]
Date: 18.08.2015
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 4 of 25 PAM-190-P-*-1010
1.6 Safety instructions
Please read this document and the safety instructions carefully. This document will help to define the product area of application and to put it into operation. Additional documents (WPC-300 for the start-up software) and knowledge of the application should be taken into account or be available.
General regulations and laws (depending on the country: e. g. accident prevention and environmental 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 5 of 25 PAM-190-P-*-1010
2 Characteristics
This power amplifier is used to control proportional valves with one solenoid. The compact solution is implemented in an inexpensive IP-65 housing.
A typical input signal of 0… 10 V (optional 4... 20 mA) can be used. The output current is closed loop controlled and therefore independent from the supply voltage and a varying solenoid resistance.
The parameterization can be done via the PC interface and the ULA-310 adapter or internally via the UP and
DOWN buttons.
By the free parameterization of the power amplifier all typical proportional valves of the different manufactures can be optimal adapted.
Typical applications: Controlling of the solenoid of proportional throttle or pressure valves.
Features
Power amplifier for proportional valves
Electronic board in a housing IP-65
Digital reproducible adjustments
Free scaling of the input signal
Reference output to supply potentiometers
Free parameterization of ramps, MIN and MAX, DITHER (frequency, amplitude) and
PWM frequency
Current range: 1 A, and 2,5 A
Simple and application orientated parameter settings
Failure monitoring and extended function check
Adjustments via LIN/USB interface, simplified parameterizing with WPC-300 software
Parameter settings via integrated buttons and a selector switch (reduced functionally against the
USB / LIN-bus)
Adaptable to all standard proportional valves
Page 6 of 25 PAM-190-P-*-1010
2.1 Device description
4,5 mm
PG 11
46 mm
58 mm
Selection
Switch/
Drehschalter
Button Down/
Taste Ab
Button Up/
Taste Auf
Operation LED/
Funktions LED
8
9 0
6
1
2
45
Parameter LED/
Parameter LED
Page 7 of 25 PAM-190-P-*-1010
25 mm
34 mm
3 Use and application
3.1 Installation instructions
All cables which lead outside must be screened; complete screening is required. It is also a requirement that no strong electro-magnetic interference sources are installed nearby when using our control and regulation modules.
The equipment should be installed and wired in accordance with the documentation bearing in mind
EMC principles. If other consumers are operated with the same power supply, a star- connected ground wiring scheme is recommended. The following points must be observed when wiring:
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 > 3m. Inexpensive SMD ferrites can be used with high-frequency radiation.
The screening should be connected to PE (PE terminal) as close to the equipment as possible. The local requirements for screening must be taken into account in all cases. The screening should be connected to at both ends. Equipotential bonding must be provided where there are differences between the connected electrical components.
With longer lengths of cable (>10 m) the diameters and screening measures should be checked by specialists (e.g. for possible interference, noise sources and voltage drop).
Particular care is required with cables of over 40 m in length
– the manufacturer should be consulted if necessary.
A low-resistance connection between PE and the mounting rail should be provided. Transient interference is transmitted from the equipment directly to the mounting rail and from there to the local earth.
Power should be supplied by a regulated power supply unit (typically a PELV system complying with
IEC364-4-4, secure low voltage). The low internal resistance of regulated power supplies gives better interference voltage dissipation, which improves the signal quality of high-resolution sensors in particular. Switched inductances (relays and valve coils connected to the same power supply) must always be provided with appropriate overvoltage protection directly at the coil.
Page 8 of 25 PAM-190-P-*-1010
3.2 Commissioning
Step Task
Installation
Install the device in accordance with the circuit diagram. Ensure it is wired correctly and that the signals are well shielded.
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
Pre-parameterization
Control signal
Once the power input is correct the PC (notebook) should be connected via the
USB interface and the programming device ULA-310. Please see the WPC-
300 program documentation for how to set up communication.
Caution:
The communication works in a HALF DUPLEX process.
Further commissioning and diagnosis are supported by the operating software.
Alternatively, the set-up can be done by the internal parameter selector and the
UP and DOWN buttons.
Parameterize now (with the help of the system redundancy and the connection diagram) the following parameters:
The ANALOGUE INPUT, the output CURRENT and the typical valve parameter DITHER and MIN/MAX.
Pre-parameterization is necessary to minimize the risk of an unintentional movement / pressure.
Check the control signal (output signal). The control signal (solenoid current) lies in the range of 0... 2.5 A. In the current state it should show around 0 A.
The valve current can also be monitored in the WPC program.
Switching on the hydraulics The hydraulics can now be switched on. The module is not yet generating a signal. Drives should be at a standstill or drift slightly (leave its position at a slow speed).
Activating command signal
Controller optimization
CAUTION! The power stage is always active when power supply exists. The output current to the valve will follow the input signal proportionally.
Settings like ramp time or dead band compensation can now be done.
Page 9 of 25 PAM-190-P-*-1010
3.3 Manual parameterization
3.3.1
Parameter overview
The manual adjustment is comparable with the adjustment via potentiometer. Not all parameter of the power plug are available in this mode
2
.
Switch position
Parameter Setting range Remark
0
1
2
3
7
8
9
4
5
6
-
-
-
DEFAULT
CURRENT
MIN
MAX
R:UP
-
0 | 1
Released only by pressing the button "Up" and "DOWN" simultaneously. Response: a short and fast flashing of the LED.
0 = low current range; press button
“DOWN“
1 = high current range; press button
“UP“
0…60%
Deadband compensation in relation to the current range
30…100%
Reduction in the maximum current in relation to the current range
50ms…5sec
Ramp time up
R:DOWN
50ms…5sec
Ramp time down
PWM
60…1500 Hz
PWM output frequency
No function
No function
No function
3.3.2
Procedural method
1. Press a button or turn the selector switch which activates the manual adjustment mode. The parameter-LED flashes.
2.
Select the desired parameter (1… 6) by the selector switch.
3. The parameter LED indicates - by flashing - the parameter mode. a. At the lower boundary the LED lights only briefly b. At the upper boundary the LED lights almost continuously
4. Press the UP or DOWN button. a. A short activation of one of the buttons will change the parameter by a value of app. 1%. b. A continual activation of one of the buttons will change the parameter continually (up to the point where the upper or lower boundary is reached).
5. The parameters are stored automatically (app. 1 second after the last parameter adjustment). The manual adjustment will be finished after 60 seconds.
2
The full functionality of the power plug is available via the PC interface only.
Page 10 of 25 PAM-190-P-*-1010
4 Technical description
4.1 Input and output signals
Terminal
K3 PIN 2
K3 PIN 3
Terminal
K3 PIN 5
K1 PIN 3
K3 PIN 4
Terminal
K2 PIN 2 / PIN 3
K2 PIN 1
Terminal
K1 PIN 2
K3 PIN 1
K1 PIN 1
Analogue inputs and outputs
External command value, range of
0… 10 V or 4… 20 mA, scalable
Reference voltage 8V / 10 mA.
Power supply
Power supply (see technical data)
0V (GND)
Solenoid
PWM output for solenoid control.
PE
Communication interface
LIN-bus connection (to ULA-310)
GND
4.2 LED definitions
LEDs
FUNCTION LED
(yellow THD)
PARAMETER LED
(yellow SMD)
Description of the LED function
OFF:
ON:
Flashing: no power supply
System is ready for operation
Error detected:
Active in manual mode only.
Page 11 of 25 PAM-190-P-*-1010
4.3 Circuit diagram
Page 12 of 25 PAM-190-P-*-1010
4.4 Typical wiring
Terminal Pin Function
K3 1
2
3
LIN
AIN +
REF
K2
K1
2
3
3
1
1
2
4
5
GND
UB
PE
Solenoid
Solenoid
GND
LIN
UB
4.5 Connection examples
PLC 0... 10 V
+In PIN 2
-In PIN 4
GND PIN 3
4... 20 mA input
+In PIN 2
-In PIN 4
GND
AIN:W 2000 1600 2000 C (for 0... 100%)
Potentiometer
8V
+In
-In
AIN:W 1000 800 0 V (for 0... 100%)
GND
Page 13 of 25 PAM-190-P-*-1010
4.6 Technical data
Supply voltage
Current requirement
External protection
Analogue command input
Reference voltage
PWM output
PWM frequency
Sample time (pressure control)
Sample time (solenoid current control)
Serial interface
Baudrate
Housing
Dimensions
Weight
Protection class
Temperature range
Storage temperature
Connections
Cable-cross section
EMC
[VDC]
12… 30 (incl. ripple)
[mA]
[A]
< 50 + solenoid current
3 medium time lag
[V]
[mA]
[%]
0… 10; 90 kOhm
4...20; 240 Ohm
< 0,1 (intern 0,02) incl. oversampling
[V] 8 (max. 10 mA)
[A]
[Hz]
Max. 1 or 2.5 (selectable)
60
… 2650 adjustable stepwise
[ms]
[ms]
1
0,167
[kB]
LIN-bus
19,2
[mm]
PA 6-GB 30, Seal: CR
98 x 64 x 34
[kg] 0,110
[°C]
[°C]
IP 65/DIN EN 60529
-
20… 60
> 95 (not condensing)
[mm²]
Push-in CAGE CLAMP
0.
2… 1.5 / 24… 16 AWG
EN 61000-6-2: 8/2002
EN 61000-6-3: 6/2005
Page 14 of 25 PAM-190-P-*-1010
5 Parameters
5.1 Parameter overview
Group Command Default
Basic parameters
LG
MODE
Input signal adaptation
Signal scaling
EN -
STD -
Unit
A: 1000
B: 1000
C: 0
X: V
-
-
0,01 %
-
Range monitoring
Ramp function
R:UP
R:DOWN
Output signal adaptation
MIN
TRIGGER
Powerstage parameters
CURRENT
DFREQ
DAMPL
PWM
PPWM
IPWM
0 0,01 %
100
100 ms ms
0 0,01 %
10000 0,01 %
200 0,01 %
+ -
0 -
120 Hz
0 0,01 %
488 Hz
1
40
-
-
Description
Changing language help texts
Parameter view
Free scaling of the analogue input.
Signal monitoring function (e.g. joystick error)
Command signal ramp times
Deadband compensation
Output scaling
Deadband compensation trigger point
Output polarity
Current output range
Dither frequency
Dither amplitude
PWM frequency
Gain of the current loop
Page 15 of 25 PAM-190-P-*-1010
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 parameter list has to be updated by pressing the identification button “ID”.
5.2.2
MODE (Parameter view)
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.
Page 16 of 25 PAM-190-P-*-1010
5.3 Input signal adaptation
5.3.1 AIN (Analogue input scaling)
Command
AIN:W
A
B
C
X
Parameters
a= -10000… 10000 b= -10000… 10000 c= -10000… 10000 x= V|C
Unit
-
-
0,01 %
-
Group
STD
This command offers an individual scalable input. The following linear equation is used for the scaling.
Output
a b
(
Input
c
)
The
“C” value
is the offset (e.g. to compensate the 4 mA in case of a 4… 20 mA input signal).
The variables
A
and
B
are defining the gain factor 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
X
value.
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 (20-
4). 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 (see below)
Typical settings:
Command
AIN:X 1000 1000 0 V
AIN:X 10 8 1000 V OR
AIN:X 1250 1000 1000 V
AIN:X 10 4 500 V OR
AIN:X 2500 1000 500 V OR
AIN:X 20 16 2000 C OR
AIN:X 2000 1600 2000 C OR
AIN:X 1250 1000 2000 C
Input
0… 10 V
1… 9 V
0,5… 4,5 V
4… 20mA
Description
Range: 0… 100 %
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))
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))
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 %.
Page 17 of 25 PAM-190-P-*-1010
5.3.2
LIM (Signal monitoring)
Command
LIM X
Parameters
x= 0… 2000
Unit
0,01 %
Group
EXP
This command defines the pressure, which corresponds to 100 % of the input signal. If the demand is set incorrectly, this leads to incorrect system settings, and the dependent parameters cannot be calculated correctly.
Example: LIM 500 (5% lower/upper limitation)
If the input signal gets higher than 95 % or lower than 5%, it leaves the permitted range and the output will switch off.
100% error range for unipolar signals working range
0%
5.3.3
R (Command signal ramp time)
Command
R:I X
Parameter
i= UP|DOWN x= 50… 10000
Unit
ms
Two quadrant ramp function.
The ramp time is separately set for UP and DOWN ramps.
Group
STD
Page 18 of 25
A:UP
PAM-190-P-*-1010
A:DOWN t
5.4 Output signal adaptation
5.4.1
MIN (Deadband compensation)
5.4.2
MAX (Output scaling)
5.4.3
TRIGGER (Response threshold for the MIN parameter)
Command
MIN
MAX
X
X
TRIGGER X
Parameters
x= 0… 6000 x= 2000… 10000 x= 0… 3000
Unit
0,01 %
0,01 %
0,01 %
Group
STD
With this command, the output signal is adjusted to the valve characteristics. With the MAX value the output signal (the maximum valve current) will be defined. With the MIN value the overlap (dead band of the valve) will be compensated. Via the TRIGGER the activation point of the MIN function is set and so a non-sensitive range around the zero-point
3
can be specified.
CAUTION: If the MIN value is set too high, it influences the minimal pressure, which cannot be adjusted any longer. In extreme case this causes to an oscillating at small input values.
10V
MAX
TRIGGER
Eingang / Input
100%
MIN
3
This dead band is necessary, in order to avoid unrequested activations caused by small variations of the input signal. If this module is used in a position controls, the TRIGGER value should be reduced (typical
: 1…10).
Page 19 of 25 PAM-190-P-*-1010
5.4.4 POL (Output polarity)
Command Parameter Unit Group
POL X x= + | - -
EXP
This command allows a switch over of the output signal direction (after the MIN-MAX function).
Example: POL:A
POL:A
+
-
Input signal 0… 100 %, nominal output current 0… 100 %.
Input signal 0… 100 % nominal output current 100… 0 %.
5.5 Output signal adaptation
5.5.1
CURRENT (Rated current range)
Command
CURRENT X
Parameters
x= 0|1
Unit
-
Group
STD
The nominal current range is set with this parameter. Dither and also MIN/MAX always refer to the selected current range.
0 = 1.0 A range
1 = 2.5 A range
5.5.2
DFREQ (Dither frequency)
5.5.3
DAMPL (Dither amplitude)
Command
DFREQ
DAMPL
X
X
Parameters
x= 60… 400 x= 0… 3000
Unit
Hz
0,01 %
Group
EXP
The dither
4
can be defined freely with this command. Different amplitudes or frequencies may be required depending on the respective valve. The dither amplitude is defined in % of the nominal current (see: CURRENT command).
CAUTION: The PPWM and IPWM parameters influence the effect of the dither setting. These parameters should not be changed again after the dither has been optimized.
CAUTION: If the PWM frequency is less than 500 Hz, the dither amplitude should be set to zero.
4
The DITHER is a superimposed signal to reduce the hysteresis. This function is defined by the amplitude and frequency.
The DITHER frequency should not be confused with the PWM frequency. In some proportional valve documentations a mistake is done by the definition of the DITHER / PWM frequency. It is recognizable by missing information about the
DITHER amplitude.
Page 20 of 25 PAM-190-P-*-1010
5.5.4 PWM (PWM Frequency)
Command
PWM X
Parameter
x= 60… 2650
Unit
Hz
Group
STD
This parameter is entered in Hz. The optimum frequency depends on the valve.
CAUTION: when using low PWM frequencies the PPWM and PPWM parameters should be adjusted
5
.
The PWM frequency can only be set in defined steps. This means that there are deviations between the specified and the actual frequency. The next highest frequency step is always used.
5.5.5 PPWM (P gain of the current loop)
5.5.6 IPWM (I gain of the current loop)
Command
PPWM
IPWM
X
X
Parameters
x= 0… 30 x= 1… 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.
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.
5
Due to the longer dead times at low PWM frequencies the stability of the control circuit is reduced. Typical values are then: PPWM = 1… 3 and IPWM = 40… 70.
Page 21 of 25 PAM-190-P-*-1010
5.6 PROCESS DATA (Monitoring)
Description Command
W
C
U
IA
Command value after input scaling
Comman value after ramp function
Control signal
Solenoid current
6
Unit
%
%
% mA
The process data are the variables which can be observed continuously on the monitor or on the oscilloscope.
6
The display of the solenoid current (in WPC-300 program) is damped in order to be able to bring out a stable signal.
Page 22 of 25 PAM-190-P-*-1010
6 Appendix
6.1 Failure monitoring
Following possible error sources are monitored continuously:
Fault
Out of range
Source
Command signal LIM command
K3 PIN 2 / 4
Command signal
4… 20 mA
K3 PIN 2 / 4
Solenoids output
K2 PIN 2 / 3
EEPROM
(when switching on)
Data error
Characteristic
The output will be switched off and the READY LED flashes.
Out of range or broken wire The output will be switched off and the READY LED flashes.
Wrong cabling, broken wire The output will be switched off and the READY LED flashes.
The output will be switched off and the READY LED flashes.The module can only be activated by saving the parameters again!
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.
FAULT
READY LED is off.
CAUSE / SOLUTION
Presumably no power supply is 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.
READY LED is flashing. The flashing READY LED signals that a fault is detected by the equipment. The fault could be:
Solenoid error or no signal at the input, if 4… 20 mA signals
LIM monitored input signals are parameterized.
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 and ULA-310 the fault can be localized directly via the monitor.
Page 23 of 25 PAM-190-P-*-1010
7 Notes
Page 24 of 25 PAM-190-P-*-1010

Public link updated
The public link to your chat has been updated.
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Key features
- Power amplifier for proportional valves
- Electronic board in a housing IP-65
- Free scaling of the input signal
- Reference output to supply potentiometers
- Free parameterization of ramps, MIN and MAX, DITHER (frequency, amplitude) and PWM frequency
- Simple and application orientated parameter settings
- Failure monitoring and extended function check
- Adjustments via LIN/USB interface, simplified parameterizing with WPC-300 software
- Adaptable to all standard proportional valves