W.E.ST. Elektronik GmbH

Transcription

1 Technical Documentation POS-124-A-PDP POS-124-I-PDP Two axes positioning and synchronisation control module with integrated profibus interface and SSI sensor interface

2 CONTENTS 1 General Information Order number Scope of supply Accessories Symbols used Using this documentation Legal notice Safety instructions Characteristics Device description Use and application Installation instructions Typical system structure Method of operation Commissioning Technical description Input and output signals LED definitions Circuit diagram Typical cabling Connection examples Technical data Parameters Parameter overview Parameter description LG (Changing the language for the help texts) PDPADR (Profibus adress) MODE (Switching between parameter groups) SENS (Module monitoring) STROKE1 /STROKE2 (Full stroke) VRAMP1 /VRAMP2 (Ramp time for external speed demand) VMODE1 / VMODE2 (Switching over the control mode) VMA1 / VMA2 (Maximum speed in NC Mode) POL1 / POL2 (Output polarity) EOUT1 / EOUT2 (Output signal in case of error) INP (Sensor type define) SSI:OFFSET (Sensor offset) SSI:POL (Direction of the sensor signal) SSI:RES (Signal resolution) SSI:BITS (Number of bits) SSI:CODE (Signal coding) AIN (Analogue input scaling) A1 / A2 (Acceleration time) D1 / D2 (Deceleration / braking distance) V 01 / V 02 (Loop gain setting) CTRL1 / CTRL2 (Deceleration function characteristic) GL: P (gain of the synchronization in SDD mode) GL: V0 (gain of the synchronization in NC mode) GL:T1 (Time constant of the synchronisation control) GL:E (Window for the synchronization error) Page 2 of 45 POS-124-*-PDP

3 HAND1 / HAND2 (Manual speed) MIN / MIN2 (Overlap compensation) MA1 / MA2 (Limitation) TRIGGER (Response threshold for the MIN parameter) OFFSET1 / OFFSET2 (Zero correction) INPOS:S1 / INPOS:S2 (In position window) INPOS:D1 / INPOS:D2 (following error window) PROCESS DATA (Monitoring) Appendix Failure monitoring Troubleshooting Description of the command structure Profibus DP interface Profibus functions Installation GSD Configuration File Description Profibus DP interface Commands via PROFIBUS Command map Definition of the control bits: DATA send to PROFIBUS Feedback map Definition of the status bits: Notes Page 3 of 45 POS-124-*-PDP

4 1 General Information 1.1 Order number POS-124-A-PDP POS-124-I-PDP-1121 triple stage module with digital SSI-interface with analogue ±10 V differential output, housing width 67,5 mm triple stage module with digital SSI-interface with analogue 4 20 ma output, housing width 67,5 mm Alternative products: POS-124-A-PDP-S POS-124-I-PDP-S double stage module without digital SSI-interface with analogue ±10 V differential output, 45 mm housing width double stage module without digital SSI-interface with analogue 4 20 ma output, 45 mm housing width 1.2 Scope of supply The scope of supply includes the module including the terminal blocks which are a 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 Accessories RS232-SO USB-SO WPC-300 PDP-Plug - Programming cable with RS232 interface - Programming cable with USB interface - Start-Up-Tool (download: - Profibus connector with switchable terminating resistors 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 4 of 45 POS-124-*-PDP

5 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 Niederkrüchten Tel.: +49 (0) Fax.: +49 (0) Homepage: or Date: 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 copyright. Page 5 of 45 POS-124-*-PDP

6 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 45 POS-124-*-PDP

7 2 Characteristics This electronic module has been developed for controlling hydraulic positioning drives. Both axes are controlled complete autonomous via the Profibus. Optionally an interconnection to a two axes synchronised system is intended. The differential outputs are covered for activation of constant valves with integrated or external electronics (differential input). Intended is this module for the connection of analogue way sensors V or mA (scalable) or digital SSI sensor interfaces. The internal control signals operating states and error conditions via Profibus to the higher-level control. The operation is signaled by a switch output. Typical applications: Positioning control or synchronization control with hydraulic axes. Features Two independent positioning axes Can be combined for synchronization controls Command position parameter, actual value response, on loop control byte and status byte via fieldbus Profibus DP Principle of stroke-dependent deceleration for the shortest positioning time or NC profile generator for constant speed Analogue or digital (SSI) actual value registration for both axes Superimposed synchronization controller as PT1 actuator Usable with zero lapped control valves Fault diagnosis and extended function checking Simplified parameterization with WPC-300 software version 3.2 Page 7 of 45 POS-124-*-PDP

8 2.1 Device description 99,0000 mm 67,5000 mm D-outputs Ready 24 V 0 V Enable D-inputs Analogue GND GND Pos. 1 Pos. 2 A Differential B output 121,0000 mm 114,0000 mm Made in Germany Date: Add.: ID: V: W.E.ST. Elektronik D Niederkrüchten Homepage: Typenschild und Anschlussbelegung Type plate and terminal pin assignment W.E.ST. LEDs RS232 Interface Ready Status Online Profibus 9pol SUBD Klemmblöcke (steckbar) Terminals (removable) PROFIBUS Buchse PROFIBUS connector Page 8 of 45 POS-124-*-PDP

9 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 a requirement that no strong electro-magnetic interference sources are installed nearby when using our control and regulation modules. Typical installation location: 24V 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 space close to the PLC (24 V area) is most suitable. All digital and analogue inputs and outputs are fitted with filters and surge protection 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- connected 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 shielded. 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 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. 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 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 IEC , 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 9 of 45 POS-124-*-PDP

10 3.2 Typical system structure This minimal system consists of the following components: (*1) proportional valve (*2) hydraulic cylinder (*3) position sensor (*4) POS-124-PDP control module (*5) interface to PLC with analogue and digital signals 3.3 Method of operation This control module supports simple point-to-point positioning with hydraulic drives. The system works based on the principle of stroke-dependent deceleration, i.e. the control gain (deceleration stroke) is set via parameters D:A and D:B. Alternatively the loop gain will be used in NC mode. The deceleration characteristics can be set linearly (LIN) or approximately quadratically (SQRT1) via the CTRL parameter. For normal proportional valves SQRT1 is the input setting. For control valves with a linear flow curve it depends on the application. If LIN is selected for these valves a significantly shorter deceleration distance can often be set (D:A and D:B). Page 10 of 45 POS-124-*-PDP

11 Positioning sequence: The positioning is controlled via Profibus. After releasing (ENABLE input), the command position is set to the actual position of the sensor and the axis stays in closed loop position control mode. The READY output indicates that the system is generally ready for operation. When setting the START-signal, the preset command value will be taken over. The axis immediately will drive to this new command position and indicates reaching it by setting the InPos output. The InPos output stays active as long as the axis is within the preset InPos window and the START input is active. The driving velocity is forced by preset parameter, too. The axis can be driven in manual mode (START is off) using the control bits HAND+ or HAND-. The velocity is programmable. When the HAND signal is deactivated, the command position is set to the actual position and the system stays in closed loop position control mode. Setting the synchronous bit (GL) will synchronize both axes and the synchronization controller is overriding the position controller of axis 2. Axis 2 is now following axis 1 according to the master-slave-principle. 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 with our modules a resolution of < 0.01% only needs to be considered with long positions. In addition, the linearity of the individual signal points (PLC, sensor and control module) must be considered. The worst-case scenario is that a system-specific absolute fault occurs. The repeat accuracy is, however, not affected by this. V+ A:A volumetric flow P-A and B-T MA:A D:A control direction driving out control direction driving in V+ D:B MA:B A:B Page 11 of 45 POS-124-*-PDP

12 3.4 Commissioning Step Installation Switching on for the first time Setting up communication Pre-parameterisation Control signals Profibus communication Switching on the hydraulics Activating ENABLE Activating START 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 metal protective housing (control cabinet or similar). 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 cabling. Switch the device off immediately and check the cabling. 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. Now set up the following parameters (with reference to the system design and circuit diagrams): The STROKE, POSITION, SENSOR SETTING, POLARITY, ACCELERATION and DECELERATION. Pre-parameterisation is necessary to minimise the risk of uncontrolled movements. Parameterise specific settings for the control element (MIN for following error compensation and MA for maximum velocity). Reduce the speed limitation to a value which is uncritical for the application. Check the control signal with a voltmeter. The control signals (PIN 15 to PIN16 and PIN19 to PIN20) lies in the range of ± 10V. In the current state it should be 0V. Alternatively, if current signals are used, approx. 0 ma should flow. CAUTION! This signal depends on the EOUT setting. Activate the profibus communication and check whether the right values and bits are send to the module. 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 is in the current position (with ENABLE the actual position is accepted as the required position). Should the drive move to an end position the polarity is probably wrong. With the start signal the demand value on 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. Manual (HAND) operation If START is disabled the axis can be moved manually with HAND+ or HAND-. After disabling the HAND signal, the axis stops in a controlled manner at the current position. Optimise controller Now optimise the controller parameters according to your application and your requirements. Page 12 of 45 POS-124-*-PDP

13 4 Technical description 4.1 Input and output signals Connection PIN 3, PIN 31 and PIN 35 PIN 4, PIN 32 and PIN 36 Connection PIN 13 PIN 14 Supply Power supply (see technical data) 0 V (GND) connection. Caution, PIN 4 is connected internally to PIN 11 (and also possibly to PIN 12 depending on the model). These connections serve as a reference potential for the analogue sensor or demand value signals. Analogue signals Analogue position actual value (1), range 0 100% corresponds to 0 10V or 4 20 ma Analogue position actual value (2), range 0 100% corresponds to 0 10V or 4 20 ma PIN 15 / 16 Analogue differential output for activation of the axis 1: % corresponds to V. PIN 19 / 20 Analogue differential output for activation of the axis 2: % corresponds to V. Connection PIN PIN 33, 34 PIN PIN 47, 48 Connection PIN 8 PIN 2 PIN 1 SSI sensors Interface 1 to the SSI sensor. RS422 interface and power supply Interface 2 to the SSI sensor. RS422 interface and power supply Digital inputs and outputs Enable input: This digital input signal initializes the application. The signal will be approved in connection with the software enable the corresponding axis. Synchronous error output (only active in synchronous mode): ON: Slave axis within the error window (GL:E) OFF: Slave axis outside the error window (GL:E) 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. Page 13 of 45 POS-124-*-PDP

14 4.2 LED definitions LEDs GREEN YELLOW GREEN (right side) Description of the LED function Identical to the READY output. OFF: ON: Flashing: no power supply or ENABLE is not activated System is ready for operation Only active in synchronous mode: OFF: ON: Profibus connection. OFF: ON: Error discovered (valve solenoid or 4 20 ma). The error of one axis results to a flashing LED. Slave axis outside the error window Slave axis within the error window No Profibus communication Profibus communication in prozess Page 14 of 45 POS-124-*-PDP

15 4.3 Circuit diagram Profibus DP 9 Profibus SUBD 9polig POS-124-A/I-PDP Speed via Feldbus Position via Feldbus ws1 v1 Speed Profil Generator Commands: - STROKE VMODE = NC w1 - xd1 Control Function Commands: - A:A and A:B - D:A and D:B Output limitation Output Adaptation Internal Power 24 V 3 VMODE = SDD Commands: - MIN: A and B - MA: A and B - TRIGGER - OFFSET - POL u1 DC DC Output: A Output: B 0 V V PELV 0 V Differentialinput ANA Feedback Position 1 0 V 0..10V 4..20mA 0 V Input Scaling Commands: AIN:W INP = ANA VMODE = SDD x1 AIS 1 I-Version: ma PIN 15 = +, PIN 12 = GND SSI Feedback Position V 0 V CLK+ CLK- SSI Sensor Commands: SSI:RES SSI:BITS SSI:CODE SSI:POL1 SSI:OFFSET1 x1 Synchronous Controller DATA+ DATA- INP = SSI x2 Commands: - GL:P - GL:T1 - GL:E Enable Sync. via Feldbus ANA Feedback Position 2 0 V SSI Feedback Position V 4..20mA 0 V V 0 V CLK+ CLK- Input Scaling Commands: AIN:W SSI Sensor Commands: SSI:RES SSI:BITS SSI:CODE SSI:POL2 SSI:OFFSET2 x2 INP = ANA x2 AIS 2 u2 Output: A Output: B Differentialinput I Version: ma PIN 19 = +, PIN 18 = GND DATA+ DATA- INP = SSI Enable 8 24 V input Commands: - TS (sample time) - MODE (Expert or Standard) - EOUT (Error Mode) - INPOS (InPos output) Control program RS232 C 9600 Baud 1 Stopbit no parity 24 V output 24 V output PE via DIN-RAIL 1 2 Ready Synchron Error 3,5 mm JISC-6560 Buchse Page 15 of 45 POS-124-*-PDP

16 4.4 Typical cabling 24V power 0V supply +/- 10 V (4...20mA) to control valve V DC GND ENABLE SSI 1 sensor interface CLK+ CLK- DATA+ DATA PE Profibus 9pol Buchse PE Klemme DATA- DATA+ CLK- CLK+ SSI 2 sensor interface 0..10V, 4..20mA sensor position 13 = 1, 14 = 2 GND +24 V DC +/- 10 V (4...20mA) to control valve 1 GND +24 V DC power supply communication modul 4.5 Connection examples SPS / PLC V speed input signal +In PIN 10 -In PIN 9 GND PIN 11 z. B. 24 V PLC or sensor with ma (two wire connection) +In PIN 13 or 14 AIN:W C ( für %) PIN 12 (GND) SPS / PLC V command and feedback signal +In PIN 13 or PIN 14 In PIN 12 (GND) z. B. 24 V PLC or sensor with ma (three wire connection) +In PIN 13 or 14 AIN:W C ( für %) 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 - Page 16 of 45 POS-124-*-PDP

17 4.6 Technical data Supply voltage Current requirement External protection Digital inputs Input resistance Digital outputs Analogue inputs (sensor and demand value signal) Signal resolution [VDC] [ma] [A] [V] [V] [kohm] [V] [V] [V] [ma] [%] 24 (±10 %) medium time lag logic 0: < 2 V logic 1: > 10 V,current consumption < 0,1 ma 25 logic 0: < 2 V logic 1: > 12 V; max. 10 ma kohm Ohm 0.01(internally ) inc. oversampling Analogue outputs Voltage Signal resolution Current Signal resolution [V] [ma] [%] [ma] [%] 2 x 0 10; Differential output 5 (max. load) ; 390 Ohm maximum load SSI interface - RS-422 Spezifikation, 150 kbaud Controller sample time [ms] 1 Serial interface Profibus DP Baud rate ID Number RS 232C, Baud, 1 stop bit, no parity, Echo Mode 9.6,19,2,93.75,187.5,500,1500, , kbits/s 1810h Housing Snap-on module to EN PA 6.6 polyamide Flammability class V0 (UL94) Protection class Temperature range Storage Temperature Humidity Connections [ C] [ C] [%] IP <95 (non-condensing) RS232: 3,5mm JISC x 4-pole terminal blocks Profibus DP, D-Sub 9 pol. PE: via the DIN mounting rail EMC EN : 8/2002 Weight [kg] 0,375 EN : 6/2005 Page 17 of 45 POS-124-*-PDP

18 5 Parameters 5.1 Parameter overview Command Default Unit Description LG GB - Changing language help texts. PDPADR Address of the unit at the Profibus. MODE STD - Mode parameter. SENS ON - Activation and disabling of internal failure monitoring functions. INP SSI - Switching between SSI and analog sensors. STROKE1 STROKE2 = mm Working stroke of the sensor. VRAMP1 VRAMP2 100 ms Ramp function for external speed input. VMODE1 VMODE2 SDD - Control structure for positioning process. VMA1 VMA2 POL1 POL2 EOUT1 EOUT2 SSI:OFFSET1 SSI:OFFSET2 SSI:POL1 SSI:POL2 50 mm/s Maximum speed in NC mode. + - Reversal of output polarity. 0 0,01% Error output signal nm Position offset + - Sensor polarity SSI:RES nm Resolution of the sensors (the same for both) SSI:BITS 24 - Number of transmitted bits (the same for both) SSI:CODE GRAY - transfer Encoding (the same for both) AIN:I A B C V - - 0,01 % - Analogue input scaling for 1 and 2. A1:I A2:I :A 100 :B 100 ms Acceleration times. D1:I D2:I :A 25 :B 25 :S 10 mm mm mm Deceleration distance Deceleration distance Emergency deceleration distance V01:I V02:I :A 10 :B 10 1/s 1/s Loop gain setting. CTRL 1 CTRL 2 sqrt1 - Specification of control characteristics. GL:P GL:T1 GL:E ,01 ms µm Definition of the synchronization actuator. GL:P adjusted the gain, GL:T1 effects a decelerated action of the actuator (revised stability) and.gl:e for error-window in synchronous run (out of window GL-Error-Bit is set on the Profibus) HAND1:I HAND2:I :A 3330 :B ,01% Output signal in manual mode. Page 18 of 45 POS-124-*-PDP

19 MIN1:I MIN2:I 0 0 0,01 % 0,01 % Zero point setting /following error compensation. MA1:I MA2:I ,01 % 0,01 %% Maximum output signal limitation. TRIGGER1 TRIGGER ,01 % 0,01 %% Trigger threshold for activating the following error compensation (MIN). OFFSET1 OFFSET ,01 % 0,01 %% Offset value (added to the output signal).axis 1 and axis 2 separate definable. INPOS1:I INPOS2:I µm µm Range for InPos signal. Page 19 of 45 POS-124-*-PDP

20 5.2 Parameter description LG (Changing the language for the help texts) LG x x= DE GB - 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) PDPADR (Profibus adress) PDPADR x= STD Slave address in the Profibus network MODE (Switching between parameter groups) MODE x x= STD EP - STD This command changes the operating mode. Various commands (defined via STD/EP) are blanked out in Standard Mode. The commands in Expert Mode have a more significant influence on system behaviour and should accordingly be changed with care. Page 20 of 45 POS-124-*-PDP

21 5.2.4 SENS (Module monitoring) SENS x x= ON OFF - STD This command is used to activate and disable monitoring functions (4 20 ma sensors and internal module monitoring). ON: OFF: Monitor function is activ. Failures are ignored. Normally, monitoring is always active as otherwise no errors are signalled via the PIN 1 (READY) output. It can, however, be disabled for fault finding STROKE1 /STROKE2 (Full stroke) STROKE1 STROKE2 x= mm 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 VRAMP1 /VRAMP2 (Ramp time for external speed demand) VRAMP1 VRAMP2 x= ms STD 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 (VS = ET) has been parametrised. Page 21 of 45 POS-124-*-PDP

22 5.2.7 VMODE1 / VMODE2 (Switching over the control mode) VMODE1 VMODE2 x= SDD NC EP 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 set deceleration point the drive then switches to 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 set control gain. The advantage is that the speed is constant (regardless of external influences 2 ) 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. 80% of the maximum speed is typical although especially the system behaviour and the load pressure should be taken into account when specifying the speed VMA1 / VMA2 (Maximum speed in NC Mode) VMA1 VMA2 x= mm/s 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) 3. The maximum 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 parametrised to NC. 2 There are deviations due to external influences which are then compensated for. The time response is defined by the system dynamics. 3 If the retraction speed and the outward speed are different, the smaller one has to be used Page 22 of 45 POS-124-*-PDP

23 5.2.9 POL1 / POL2 (Output polarity) POL1 POL2 x= STD This command enables the output signal polarity to be reversed EOUT1 / EOUT2 (Output signal in case of error) EOUT1 EOUT2 x= ,01% EP Error output value. A value (degree of valve opening) for use in the event of a sensor error 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 behaviour. CAUTION! If the output signal is 4 20 ma, the output is switched off if EOUT = 0. If a null value = 12 ma is to be output in the event of an error, EOUT must be set to 1 4. CAUTION! The output value defined here is stored permanently (independently of the parameter set). The effects should be analysed by the user for each application from the point of view of safety CAUTION! If EOUT is activated, the HAND mode should not be used. After deactivating the HAND mode the output will be set to the programmed EOUT value.. 4 This is necessary if using valves without error detection for signals lower than 4 ma Page 23 of 45 POS-124-*-PDP

24 INP (Sensor type define) INP x= SSI ANA STD With this parameter the appropriate sensor type can be activated. SSI: The SSI sensor interfaces are active. The SSI sensors have to be adjusted via the SSI commands to the sensors. The relevant sensor data must be available. ANA: The analog sensor interfaces ( V or ma) are active. The sensors are scaled with the commands AIN: The SSI interface is suitable for digital position sensor. The internally processed accuracy is 1 micron. CAUTION: It can only be used SSI sensors of the same type, ie the resolution of the sensor, the number of bits transmitted and the transmission coding must be the same! SSI:OFFSET (Sensor offset) SSI:OFFSET1 SSI:OFFSET2 x= µm INP = SSI This command is a sensor offset (zero point of the sensor) SSI:POL (Direction of the sensor signal) SSI:POL1 SSI:POL2 x= INP = SSI To reverse the working direction of the sensor, with this command, the polarity can be changed. Example: Sensor Length = 200 mm, reverse the direction of work is required. Set SSI: POL to "-" (internally, the sensor position is subtracted from the stroke ). Page 24 of 45 POS-124-*-PDP

25 SSI:RES (Signal resolution) SSI:RES x= ,01 µm INP = SSI This command defines the signal resolution of the sensor. Data entry has a resolution of 10 nm (nanometers or 0.01 micron). If the sensor has one micron resolution, the value must be set to 100. This makes it possible to scale rotational sensors. Take the data from the sensor data sheet. Caution: The signal resolution for both SSI sensors must be equal SSI:BITS (Number of bits) SSI:BITS x= 8 31 bits INP = SSI With this command the number of data bits can be set. Take the data from the sensor data sheet. Caution: The number of bits for both SSI sensors must be equal SSI:CODE (Signal coding) SSI:CODE x= GRAY BIN - INP = SSI With this command the signal coding can be set. Take the data from the sensor data sheet. Caution: The signal coding for both SSI sensors must be equal. Page 25 of 45 POS-124-*-PDP

26 AIN (Analogue input scaling) AIN:I A B C i= 1 2 a= b= c= x= V C % - STD This command can be used to scale the individual inputs. The following linear equation is used for scaling. = The c value is the offset (e.g. to compensate the 4 ma in the case of a 4 20 ma input). The variables a and b define the gain factor. e.g.: correspond to: a = 2345, b =1000 The internal measuring resistor for measuring the current (4 20 ma) is activated via the x value and the evaluation switched over accordingly. Typical settings: Command Input Description AIN: V 0 10V Range: 0 100% AIN: V OR AIN: V AIN: V OR AIN: V AIN: C OR AIN: C 1 9V Range: 0 100%; 1 V = 1000 used for the offset and gained by 10 / 8 (10V divided by 8 V (9V -1V) 0,5 4,5V Range: 0 100%; 0,5 V = 500 used for the offset and gained by 10 / 4 (10V divided by 4 V (4,5V -0,5V) 4 20mA Range: 0 100% The offset will be compensated on 20% (4 ma) and the signal (16 ma = 20mA 4 ma) will be gained to 100% (20 ma). Page 26 of 45 POS-124-*-PDP

27 A1 / A2 (Acceleration time) A1:I A2:I i= A B x= ms ms STD 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 D1 / D2 (Deceleration / braking distance) D1:I D2:I i= A B S x= mm mm mm VMODE = SDD VMODE = SDD SDD + NC This parameter is specified in mm 5. The deceleration distance 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 loop gain. A longer deceleration distance should be specified in the event of instability. Parameter D:S is used as the emergency 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 demand value. G = Intern STROKE D i Calculation of control gain CAUTION: If the maximum position (POSITION command) is changed, the deceleration distance must also be adjusted. Otherwise this can result in instability and uncontrolled movements. 5 CAUTION! With older modules this parameter was specified in % of the maximum path. Since data specification for this module has now been converted to mm the relationship between the path (PATH command) and these parameters must be taken into account. Page 27 of 45 POS-124-*-PDP

28 V 0 1 / V 0 2 (Loop gain setting) V01:I V02:I i= A B x= s -1 s -1 VMODE = NC This parameter is specified in s -1 (1/s). In NC Mode the loop gain is normally specified rather than the deceleration distance 6. The internal gain is calculated from this gain value together with the VMA and POSITION parameters. G v Di = V Intern max 0 STROKE = 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 distance with stroke-dependent deceleration. The conversion and therefore also the correct data demands related to the control system are relatively simple if the relationship described here is taken into account. 6 The loop gain is alternatively defined as a KV factor with the unit (m/min)/mm or as Vo in 1/s. The conversion is KV = Vo/ Page 28 of 45 POS-124-*-PDP

29 CTRL1 / CTRL2 (Deceleration function characteristic) CTRL1 CTRL2 x= lin sqrt1 sqrt2 - STD The deceleration characteristic is set with this parameter. In the case of positively overlapped proportional valves the SQRT function should be used. The non-linear flow function of these valves is linearised by the SQRT 7 function. In the 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: SQRT2: Root function for braking curve calculation. The gain is increased by a factor of 3 (in the target position). This is the default setting. 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 Velocity Velocity CTRL = SQRT CTRL = SQRT CTRL = LIN CTRL = LIN Stroke Time 1 Braking function with respect to stroke and time 7 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 29 of 45 POS-124-*-PDP

30 GL: P (gain of the synchronization in SDD mode) GL: V0 (gain of the synchronization in NC mode) GL:T1 (Time constant of the synchronisation control) GL:E (Window for the synchronization error) GL:P GL:V0 GL:T1 GL:E = = = = mm s -1 ms µm VMODE = SDD VMODE = NC STD STD These parameters are used to optimize the synchronization controller The SYNC-controller works as a PT1 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 GLP, 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 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. The GL:E command defines a monitoring window in which the GL-Error message is displayed. The monitoring window is placed centrally on the required position value. The actual position value within this window is signalled by the GL-Error message at the status output (see signal description PROFIBUS). The positioning process is not influenced by this message. The control remains active. Master/Slave Profibus w Rampfunction w xw A:A, A:B D:A, D:B u2 x2 x2 - - xk2 GL:P, GL:V0 GL:T1 x1 x1 Page 30 of 45 POS-124-*-PDP

31 HAND1 / HAND2 (Manual speed) HAND1:I HAND2:I i= A B x= ,01% 0,01% STD The manual speeds are set with these parameters. Entering the speed and direction at will enables any switch input to be assigned. The drive moves in a controlled manner in the defined direction when the manual signal is active. After the manual signal has been disabled, the drive remains under closed loop control in the current position. In the event of a fault (position sensor fault) the drive can still be moved with the manual function. The output is zero after the manual signals have been disabled. The manual speed is limited by the speed demand (MIN evaluation) via the Profibus. Page 31 of 45 POS-124-*-PDP

32 MIN / MIN2 (Overlap compensation) MA1 / MA2 (Limitation) TRIGGER (Response threshold for the MIN parameter) MIN1:I i= A B x= ,01% STD MA1:I x= ,01% TRIGGER1 x= ,01% MIN2:I x= ,01% MA2:I x= ,01% TRIGGER2 x= ,01% 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 behaviour. At the same time, non linear volume flow characteristics can also be adjusted with this compensation 8. CAUTION: If there should also be adjustment options for dead zone 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. MA:A Output flow linearization standard deadband compensation MIN:A Input MIN:B TRIGGER value MA:B 8 Various manufacturers have valves with a defined linear 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 behaviour. To compensate for 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 a higher overall gain can often be set. Page 32 of 45 POS-124-*-PDP

33 OFFSET1 / OFFSET2 (Zero correction) OFFSET1 OFFSET2 x= ,01% STD This parameter is entered in 0.01% units. The offset value is added to the control element signal at the output. Control element (valve) zero offsets can be compensated with this parameter INPOS:S1 / INPOS:S2 (In position window) INPOS:S1 INPOS:S2 x= µm STD This parameter is entered in µm. The INPOS:S command defines a monitoring window in which the INPOS:S message is displayed. The monitoring window is placed centrally on the required position value. The actual position value within this window is signalled by the INPOS:S message at the status output (see signal description PROFIBUS). The positioning process is not influenced by this message. The control remains active INPOS:D1 / INPOS:D2 (following error window) INPOS:D1 INPOS:D2 x= µm STD This parameter is entered in µm. The INPOS:D command defines a monitoring window in which the INPOS:D message is displayed. The monitoring window is placed centrally on the required position value. The actual position value within this window is signalled by the INPOS message at the status output (see signal description PROFIBUS). The positioning process is not influenced by this message. The control remains active. In NC Mode this message is used to monitor the following error (depending on the parameterisation). Page 33 of 45 POS-124-*-PDP

34 PROCESS DATA (Monitoring) Command Parameters Unit WA1/WA2 W1/W2 1/2 D1/D2 K2 V1/V2 U1/U2 Actual command position axis 1 / 2 External command position axis 1 / 2 Feedback positon axis 1 / 2 Control error axis 1 / 2 Synchronisation error at axis 2 Speed set point 1 / 2 Control signal axis 1 / 2 0,01 mm 0,01 mm 0,01 mm 0,01 mm 0,01 mm 0,01 % 0,01 % The process data are the variables which can be continuously observed on the monitor or on the oscilloscope. Page 34 of 45 POS-124-*-PDP

35 6 Appendix 6.1 Failure monitoring Following possible error sources are monitored continuously: Source Fault Characteristic Command signal PIN ma Feedback signal PIN ma SSI-VERSION Sensor value EEPROM (at switching on) Out of range or broken wire. Out of range or broken wire. Out of range or broken wire. Data error The output will be switched off. The output will be switched off. The output will be switched off. The output is deactivated. The module can be activated by saving new parameters (pressing of the SAVE Button). CAUTION: Take care of the EOUT command. Changes will influense the behaviour. 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 parametrisation has been set with the assistance of the valve data sheets. The RC in monitor mode can be used to analyse 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 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) or ENABLE signal via Profibus 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- signals (measuring the output signal to the valve helps). Page 35 of 45 POS-124-*-PDP

36 ENABLE is active, the READY LED is flashing. 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 flashing, 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 spot. Speed too low Speed too high The flashing READY LED signals that a fault is been detected by the module. The fault could be: A broken cable or no signal at the input (PIN 10/9 or PIN 14/13), if 4 20 ma signals are parametrised. 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 localised 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 or PIN 19 and PIN 20. Serious positioning errors can result from incorrect parametrisation or incorrect system design. Is the cylinder position specified correctly? Are the deceleration distances correct (to start the system the deceleration distances should be set to approx % of the cylinder position 9 )? 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 parametrisation 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 parametrisation 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% (± 10V), 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? The drive should move to position. The drive moves in and out too fast leading to uncontrolled behaviour. Reducing the speed (MA or VELO parameter) has very little or no effect. The hydraulic system is over-sized. The entire parametrisation of the movement cycle cannot be reproduced (overlap and deceleration distance settings) 9 The stability criterion of the hydraulic axes must be taken into account. Page 36 of 45 POS-124-*-PDP