Bucher Hydraulics EVS-AI1-2500 Series Operating
Bucher Hydraulics EVS-AI1-2500 Series is a universal power amplifier designed for controlling proportional valves with a 4...20mA input signal. This compact device is designed for direct mounting on the solenoid and features closed-loop current control for output current independence from supply voltage and solenoid resistance variations. The EVS-AI1-2500 Series offers programmable parameters via a PC interface and the EKL-USB-LIN-1-30D-A1 programming adapter, allowing for customization of ramp times, minimum and maximum current, dither (frequency, amplitude), and PWM frequency. This amplifier is ideal for applications requiring precise control of proportional valves, particularly in hydraulic systems.
Advertisement
Advertisement
Operating Instruction Universal power amplifier for proportional valves Series EVS-AU1-2500… & EVS-AI1-2500… Reference: 400-B-900009-EN-00 Issue: 10.2021 1/24 Published by Bucher Hydraulics AG Frutigen Schwandistrasse 25 CH-3714 Frutigen Phone +41 33 672 61 11 Email [email protected] Internet www.bucherhydraulics.com © 2021 by Bucher Hydraulics AG Frutigen, CH-3714 Frutigen All rights reserved. This documentation, in whole and/or in part, is protected by copyright. It may not be reproduced, nor may it be stored, processed, replicated or distributed by electronic means, without written permission from Bucher Hydraulics. Data is provided for the purpose of product description only, and must not be construed as warranted characteristics in the legal sense. No assertion regarding either a particular property or the fitness for a particular intended purpose can be derived or deduced from this information. The information does not relieve users from the duty of conducting their own evaluations and tests. Because the products are subject to continual improvement, we reserve the right to amend the product specifications contained in this catalogue. The original language and legal terminology of all Bucher Hydraulics documentation is exclusively German. Bucher Hydraulics cannot be held liable for any possible errors in translation. Reference: 400-B-900009-EN-00 Issue: 10.2021 2/24 CONTENTS 1 2 3 4 5 6 General Information ............................................................................................................ 5 1.1 Order number ..................................................................................................................5 1.2 Alternative products .........................................................................................................5 1.3 Scope of supply ...............................................................................................................5 1.4 Accessories .....................................................................................................................5 1.5 Safety instructions ...........................................................................................................6 Characteristics .................................................................................................................... 7 2.1 Features ..........................................................................................................................7 2.2 Device description ...........................................................................................................8 Use and application ............................................................................................................ 9 3.1 Installation instructions ....................................................................................................9 3.2 Commissioning ..............................................................................................................10 Technical description ....................................................................................................... 11 4.1 Input and output signals ................................................................................................11 4.2 LED definitions ..............................................................................................................11 4.3 Block diagram ................................................................................................................12 4.4 Typical wiring .................................................................................................................12 4.5 Technical data ...............................................................................................................13 Manual parametrization .................................................................................................... 14 5.1 Parameter overview.......................................................................................................14 5.2 Procedural method ........................................................................................................15 Parameters......................................................................................................................... 15 6.1 7 Parameter list ................................................................................................................15 Parameter description ...................................................................................................... 16 7.1 LG (Changing language) ...............................................................................................16 7.2 MODE (Switching between parameter groups) .............................................................16 7.3 AIN ((Analogue input scaling) ........................................................................................16 7.4 LIM (Signal monitoring) .................................................................................................18 7.5 R (Command signal ramp time).....................................................................................18 7.6 MIN (Overlap compensation) / MAX (output scaling) / TRIGGER (Threshold value of MIN) ...............................................................................................................................19 7.7 POL (Output polarity).....................................................................................................19 7.8 CURRENT (Rated current range)..................................................................................20 7.9 DAMPL / DFREQ (Ditheramplitude and Dither frequency)............................................20 7.10 PWM (PWM Frequenz) .................................................................................................20 7.11 PPWM / IPWM (Solenoid current controller P gain and I-gain) .....................................21 7.12 PROCESS DATA (Monitoring) ......................................................................................21 Reference: 400-B-900009-EN-00 Issue: 10.2021 3/24 8 9 Appendix ............................................................................................................................ 22 8.1 Failure monitoring ..........................................................................................................22 8.2 Troubleshooting .............................................................................................................22 History ................................................................................................................................ 24 Reference: 400-B-900009-EN-00 Issue: 10.2021 4/24 1 1.1 General Information Order number EVS-AU1-2500-1-30D-A1 1.2 Universal power amplifier with 0... 10V input for proportional valves Alternative products EVS-AI1-2500-1-30D-A1 1.3 - - Universal power amplifier with 4...20mA input for proportional valves Scope of supply The scope of supply includes the module. Cables, adapters and further parts which may be required should be ordered separately. This documentation can be downloaded as a PDF file from www.bucherhydraulics.com. 1.4 Accessories PS1 - GUI for parametrization and monitoring of the power amplifier (free download from www.bucherhydraulics.com) EKL-USB-LIN-1-30D-A1 - Programming adapter with USB interface Reference: 400-B-900009-EN-00 Issue: 10.2021 5/24 1.5 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 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. 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. • The module may not be used in an explosive environment. • The device must be disposed of in accordance with national statutory provisions. Reference: 400-B-900009-EN-00 Issue: 10.2021 6/24 2 Characteristics This amplifier plug is used to control proportional valves with one solenoid. The compact solution will be mounted directly on the solenoid. A typical input signal of 0…10 V (optional 4…20mA) can be used. The output current is closed loop controlled and therefore independent from the supply voltage and a varying solenoid resistance. The parametrization can be done via the PC interface and the EKL-USB-LIN-1-30D-A1 programming adapter or internally via the UP and DOWN buttons. 2.1 Features • Power amplifier for proportional valves located in a DIN EN 175 301-803-A plug housing • Digitally reproducible adjustments • Free scaling of the input signal • Also usable as Soft-Switch-amplifier (soft switch-on and switch-off) • M12 connector • Programmable via USB/LIN bus • Free parameterization of Ramps, Minimum- and Maximum current, Dither (frequency, amplitude) and PWM frequency • Parameter settings via integrated buttons and a selector switch (reduced functionally against the USB / LINbus) • Nominal output current range: 0.5… 2.5 A Reference: 400-B-900009-EN-00 Issue: 10.2021 7/24 2.2 Device description Reference: 400-B-900009-EN-00 Issue: 10.2021 8/24 3 3.1 Use and application Installation instructions • All cables which lead outside must be shielded; a complete shielding 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 • A low-impedance connection between PE and valve must be provided. Transient interference voltages are conducted from the device directly to the valve and thus to local grounding. • Power should be supplied by a regulated power supply unit (typically a PELV system complying with IEC364-4-4, secure low voltage) or by a battery. 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. Reference: 400-B-900009-EN-00 Issue: 10.2021 9/24 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 amperemeter 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 via the USB interface and the programming adapter EKL-USB-LIN-1-30D-A1. Please see PS1 software documentation for how to set up communication. 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: Pre-parameterization The “analog 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. Control signal 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 PS1 software. 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 The output current to the valve will follow the input signal proportionally. The power stage is always active when power supply exists. Drives can now leave their position and move to an end position at full speed. Take safety measures to prevent personal injury and damage. Optimize settings Now optimize the remaining parameters according to your application and your requirements. Reference: 400-B-900009-EN-00 Issue: 10.2021 10/24 4 Technical description 4.1 Input and output signals Connection Supply PIN 1 Power supply (see technical data) PIN 3 0 V (GND) Power supply (ground). Connection Analogue signals PIN 2 Command signal input +, signal range 0… 10 V, scalable PIN 4 Command signal input -, signal range 0… 10 V, scalable Connection Communication LIN-bus communication port PIN 5 4.2 Via EKL-USB-LIN-1-30D-A1 programming adapter the plug can be read out and parameterized. LED definitions LEDs Description of the LED function READY display YELLOW OFF: No power supply (THT) ON: System is ready for operation Flashing: Error discovered Operational mode Off: YELLOW (SMD) Normal operation Flashing sequences at rotary switch position 0...6: Manual parameter setting mode is active At rotary switch position 8: from indication "Off" via increasing flashing duration to continuous light, the "output current" is displayed. At rotary switch position 9: from indication "Off" via increasing flashing duration to continuous light, the "setpoint" is displayed Reference: 400-B-900009-EN-00 Issue: 10.2021 11/24 4.3 Block diagram 4.4 Typical wiring Reference: 400-B-900009-EN-00 Issue: 10.2021 12/24 4.5 Technical data Supply voltage (Ub) Current consumption (w/o solenoid) External fuse [VDC] [mA] [A] Analog inputs: Voltage 12… 30 (incl. ripple) < 50 3 medium time lag Unipolar / differential [V] 0…10 Input resistance [kOhm] > 90 Signal resolution [%] 0.026 Current [mA] 4…20 Burden [Ohm] Signal resolution [%] PWM output 240 0.055 Wire break and short circuit monitored Max. output current [A] 2.5 Frequency [Hz] 61...2604 selectable in defined steps Solenoid current control [µs] 167 Signal processing [ms] 1 Sample times Serial Interface Transmission rate Housing acc. DIN EN 175301-803-A - LIN-Bus [kBaud] 19.2 - 3-pole 2 P+E Material - PA 6.6 polyamide Color - black Flammability class - V0 (UL94) Weight Protection class [g] - 80 IP65 with gasket (with appropriate mating connector and proper fitting and sealing) Temperature range [°C] -20… +65 Storage temperature [°C] -20 …+70 Humidity [%] <95 (not condensing) Connections EMC M12, 5pole (DESINA standard) EN 61000-6-2: 8/2005 EN 61000-6-4: 6/2007 + A1:2011 Reference: 400-B-900009-EN-00 Issue: 10.2021 13/24 5 5.1 Manual parametrization Parameter overview The manual adjustment is comparable with the adjustment via potentiometer. Not all parameters of the power plug are available in this mode. For full functionality, the use of the PC interface is necessary. Switchposition Parameter Range Remarks Released only by pressing the button "up" and "down" simultaneously. Response: A short and fast flashing of the LED. 0 = low current range; press „down“ 1 = high current range; press „up“ Deadband compensation in relation to the current range Reduction in the maximum current in relation to the current range 0 DEFAULT - 1 CURRENT 0|1 2 MIN 0…60% 3 MAX 30…100% 4 R:UP 50ms…5sec Ramp time up 5 R:DOWN 50ms…5sec Ramp time down 6 PWM 61…2604 Hz PWM output frequency 7 - 8 - 9 - No function Current monitoring, no parameter input, see LED definitions. Setpoint monitoring, no parameter input, see LED definitions. Reference: 400-B-900009-EN-00 Issue: 10.2021 14/24 5.2 Procedural method Task Parameter 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. The parameter LED indicates - by flashing - the parameter mode. 3 a. At the lower boundary the LED lights only briefly b. At the upper boundary the LED lights almost continuously Press the UP or DOWN button. 4 6.1 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). The parameters are stored automatically (app. 1 second after the last parameter adjustment). The manual adjustment will be finished after 60 seconds. 5 6 a. Parameters Parameter list Command LG MODE Unit EN - Changing language help texts STD - Parameter mode (standard or expert) Free scaling of the analogue input signal 0 0.01% Signal monitoring function (e.g. joystick error) 100 100 ms ms MIN 0 0.01 % Compensation of the dead band MAX 10000 0.01 % Scaling of the max. output signal 200 0.01 % Trigger point for activating the MIN value. POL + - Output polarity CURRENT 0 - Current output range DAMPL 0 0.01 % LIM R:UP R:DOWN TRIGGER 1000 1000 0 V Description 0.01 % - AIN:W a: b: c: X: Default Command signal ramp times Dither amplitudes. Related to the nominal output Reference: 400-B-900009-EN-00 Issue: 10.2021 15/24 Command Default Unit DFREQ 120 Hz Dither frequency PWM 488 Hz PWM frequency PPWM IPWM 1 40 - 7 7.1 Description current. Parameters for the closed loop current controllers Parameter description LG (Changing language) Command LG Parameter x Unit Group x= DE | EN - STD Either German or English can be selected for the help texts in the PS1 software. After changing the language settings, the parameter list has to be updated by pressing the speed button “ID” in the PS1. 7.2 MODE (Switching between parameter groups) Command MODE Parameter x Unit x= STD | EXP Group - STD This command changes the parameter mode. Various commands (defined via STD/EXP) are blanked out in standard mode. The several commands in expert mode have more significant influence on the system performance. Therefore they should be changed with care. 7.3 AIN ((Analogue input scaling) Command Parameter AIN:W a b c x a= -10000… 10000 b= -10000… 10000 c= -10000… 10000 x= V | C Unit Group 0.01 % - STD Reference: 400-B-900009-EN-00 Issue: 10.2021 16/24 This command offers an individual scalable input. The following linear equation is used for the scaling. ππππππππππππ = π΄π΄ ∗ (πΌπΌπΌπΌπΌπΌπΌπΌπΌπΌ − πΆπΆ) π΅π΅ 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). Finally (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. FUNCTION = 195 Input signal AIN:X 1000 1000 0V AIN:X 10 8 1000 V OR 1250 1000 1000 V AIN:X 10 4 500 V OR 2500 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... 4.5 V 1000 Range 0...100% Range: 0… 100 % 1… 9 V AIN:X AIN:X 0… 10 V Description 500 V 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 % AIN:X 20 16 2000 C OR AIN:X 2000 1600 2000 C OR AIN:X 1250 1000 2000 C 4… 20 mA 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 %. Reference: 400-B-900009-EN-00 Issue: 10.2021 17/24 7.4 LIM (Signal monitoring) Command LIM Parameter x x= 0… 2000 Unit 0.01 % Group EXP The signal monitoring deactivates the output current if the input signal leaves the permitted range after scaling. This function makes it possible to detect a short circuit or cable break of a joystick or potentiometer. Example: LIM 500 (5% lower/upper limitation) If the input signal gets higher than 95 % or lower than 5%, it leaves the permitted range and the outputs will switch off. 7.5 R (Command signal ramp time) Command R:I Parameter x i= UP | DOWN x= 50… 10000 Unit ms Group STD The ramp time is set separately for the rising (UP) and falling ramp (DOWN). The ramp time is related to 100 % signal step. Reference: 400-B-900009-EN-00 Issue: 10.2021 18/24 7.6 MIN (Overlap compensation) / MAX (output scaling) / TRIGGER (Threshold value of MIN) Command Parameter Unit MIN x x= 0… 6000 0.01 % MAX x x= 2000… 10000 0.01 % x= 0… 3000 0.01 % TRIGGER x Group STD The output signal is adapted to the valve by these commands. With the MAX value the output signal (the maximum valve current) will be defined. With the MIN value the overlap (dead band of the valve) will be compensated. Via the TRIGGER command the activation point of the MIN function is set and so a nonsensitive range around the zero-point can be specified. This threshold is necessary, in order to avoid unrequested activations caused by small variations of the input signal. If the MIN value is set too high, it influences the minimal velocity, which cannot be adjusted any longer. 7.7 POL (Output polarity) Command POL Parameter x x= + | - Unit Group - EXP This command allows a switch over of the output signal direction (after the MIN-MAX function). Example: POL:A + Input signal 0… 100 %, nominal output current 0… 100 %. POL:A - Input signal 0… 100 % nominal output current 100… 0 %. Reference: 400-B-900009-EN-00 Issue: 10.2021 19/24 7.8 CURRENT (Rated current range) Command Parameter Unit Group CURRENT x i= 0 | 1 - 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 7.9 DAMPL / DFREQ (Ditheramplitude and Dither frequency) Command Parameter Unit DAMPL x x= 0… 3000 0.01 % DFREQ x x= 60… 400 Hz Group EXP The dither can be defined freely with this command. 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. Different amplitudes or frequencies may be required depending on the respective valve. The dither amplitude is defined in % of the nominal current. 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. If the PWM frequency is less than 500 Hz, the dither amplitude should be set to zero. 7.10 PWM (PWM Frequenz) Command PWM x Parameter Unit Group x= 61… 2604 Hz EXP This parameter is entered in Hz. The optimum frequency depends on the valve. Due to the longer dead times at low PWM frequencies the stability of the control circuit is reduced. When using low PWM frequencies the PPWM and Reference: 400-B-900009-EN-00 Issue: 10.2021 20/24 IPWM parameters should be adjusted. 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. 7.11 PPWM / IPWM (Solenoid current controller P gain and I-gain) Command Parameter Unit PPWM x x= 0… 30 - IPWM x x= 1… 100 - Group EXP The PI current controller for the solenoid is parameterized with these commands. These parameters should not be changed without adequate measurement facilities and experiences. If the PWM frequency is < 250 Hz, the dynamic of the current controller has to be decreased. Typical values are: PPWM = 1… 3 IPWM = 40… 80. If the PWM frequency is > 1000 Hz, the default values of PPWM = 7 IPWM = 40 should be chosen. 7.12 PROCESS DATA (Monitoring) Command Description Unit W Command value after input scaling % C Command value after linearization % U Command value to current controller % IA Output current of solenoid mA The process data are the variable values which can be continuously observed on the monitor or on the oscilloscope of the PS1 software Reference: 400-B-900009-EN-00 Issue: 10.2021 21/24 8 8.1 Appendix Failure monitoring Following possible error sources are monitored continuously: Source Command signal PIN 2 / 4 LIM command Command signal PIN 2 / 4 4… 20 mA Solenoids output EEPROM (when switching on) 8.2 Fault Characteristic Out of range The output will be switched off and the FUNKTION LED flashes. Out of range or broken wire The output will be switched off and the FUNKTION LED flashes. Wrong cabling, broken wire The output will be switched off and the FUNKTION LED flashes. Data error The output will be switched off and the FUNKTION LED flashes.The module can only be activated by saving the parameters again. Troubleshooting Initial situation is an operable status of the device and existing communication between the module and the PS1 software. Furthermore, the parameterization of the valve control has to be done with the assistance of the valve data sheets. The RC mode in monitor can be used to analyze faults. If using the RC (Remote Control) mode, all safety aspects have to be checked solidly. In this mode the module is actuated directly and the machine control has no influence on the module. FAULT FUNKTION 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 PS1 software, then a power supply is also available. Reference: 400-B-900009-EN-00 Issue: 10.2021 22/24 FAULT CAUSE / SOLUTION The flashing READY LED signals that a fault is detected by the equipment. The fault could be: FUNKTION LED is flashing. • 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 PS1 software and EKL-USB-LIN-1-30D-A1 programming adapter the fault can be localized directly via the monitor. Reference: 400-B-900009-EN-00 Issue: 10.2021 23/24 9 History Revision Date Short mark Comment 00 01.12.2021 FT / MAK Initial version Reference: 400-B-900009-EN-00 Issue: 10.2021 24/24 ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- 4...20mA input
- Closed-loop current control
- Compact DIN EN 175 301-803-A plug housing
- Programmable via PC interface
- Adjustable ramp times, current limits, dither, PWM frequency
- M12 connector
- IP65 protection class
- Temperature range: -20β¦ +65Β°C