Ultimate Actuator Drivebox 30A Quick start guide

2016 Ultimate Actuator Drivebox 30A Quick start guide info@e-tronix.cz e-tronix s.r.o. 1.1.2016

OBSAH Identification... 3 Serial Number... 3 Manufacturer and reseller contact... 4 Before Start... 4 UAD30A model specifics... 4 What do you have to know about the actuator for appropriate UAD configuration?... 4 is it a Simple actuator?... 4 What type of position sensor is used in the actuator?... 5 What is the configuration (calibration) of position sensor with respect to the dc motor rotation?... 5 Connecting power supply... 5 UAD panels Description... 7 Connecting actuator... 8 Before the next step, please make sure UAD is properly set up, see UAD30A model specifics... 8 Connecting external devices... 9 Connecting to computer... 9 BLuetooth connection and password... 9 Power-ON... 10 What do you want to do with the actuator?... 10 I want to turn actuator to specific position (e.g. for callibraiton purposes) or i want to check if the actuator is working properly... 10 I want to check the hard stops position (Internal or on application)... 10 I want to turn actuator with broken position sensor... 10 I want to change actuator position cyclically for longer period of time (testing)... 10 I want to set my own UAD configuration... 10 I want to apply certain amount of force or momentum onto hard stop (Usually specified by application)... 11 Technical information if using UAD with voltage or pwm actuators... 12 direction switch setup... 12 feedback switch setup... 12 1

MODE switch setup... 12 External demand input... 13 sensor and dc motor interface... 14 DC Motor current sensor output... 14 INFOrmation showed on display... 15 Stat. and mode indicators function... 16 Error states (debugging)... 16 Communicate with us!... 17 2

ULTIMATE ACTUATOR DRIVEBOX - Quick start guide - Guide version: M007-1/2016, released in January 2016 - Publisher of this guide is e-tronix s.r.o. IDENTIFICATION Name: Ultimate Actuator Drivebox 30A Abbreviation: UAD30A 1 Identification label on UAD: Picture 1- Identification label HW: type of UAD / version of hardware SN: serial number HTT: Honeywell number without Bluetooth module inside with Bluetooth module inside Picture 1- Identification label SERIAL NUMBER The product is labeled with serial number SN (see picture Picture 1- Identification label) Where 107 is type designation and dash shows unit serial number. Please provide this number if communicating with manufacturer or service/calibration center: SN:107-001 1 Terms device and product are also used in this guide. 3

MANUFACTURER AND RESELLER CONTACT e-tronix s.r.o. Prostřední 250 66446 Radostice Czech Republic Email: info@e-tronix.cz IČ: 24759422 DIČ: CZ24759422 BEFORE START Usage is followed up with conditions defined in Honeywell ES-002-083. For safety instructions please read operating manual. This guide is only a brief overview on how to use the UAD. Before use, correct configuration has to be set up for selected actuator, power cord and actuator cable have to be connected. UAD30A MODEL SPECIFICS UAD 30A is modified model that is to be used for larger actuators and/or larger loads. Compared with original UAD48W unit described in ES-002-083, the main differences are: 1) Best in class modern automotive H-Bridge ST VNH5019A is used: - 18mOhn RDS(on) - 12A continuous (30A short time max) current - Integrated precise current sensor proportional to DC motor current see chapter DC MOTOR CURRENT SENSOR OUTPUT 2) DC Motor current sensor output available (0-5V) 3) UAD30A has no main switch WHAT DO YOU HAVE TO KNOW ABOUT THE ACTUATOR FOR APPROPRIATE UAD CONFIGURATION? IS IT A SIMPLE ACTUATOR? YES UAD may be used NO UAD may not be used 4

WHAT TYPE OF POSITION SENSOR IS USED IN THE ACTUATOR? VOLTAGE = FEEDBACK switch into VOLTAGE position PWM = FEEDBACK switch into PWM position SENT = external SENT>VOLTAGE converter has to be used with UAD. e-tronix provides SENT II convertor as accesories. WHAT IS THE CONFIGURATION (CALIBRATION) OF POSITION SENSOR WITH RESPECT TO THE DC MOTOR ROTATION? CLOCKWISE = DIRECTION switch into CW position COUNTERCLOCKWISE = DIRECTION switch into CCW position For CW/CCW definition see chapter > DIRECTION SWITCH SETUP CONNECTING POWER SUPPLY Powering UAD with power supply. Using an improper power supply may cause functional glitches. UAD30A does not have any power on switch. The unit will start operation immediately after power supply is connected. UAD30A can be ordered with validated 12V power supply. If the unit is ordered without power supply, it will come with one spare Weipu SP1310/S2 connector so customers can make custom power supply connection according to their needs. Attention shall be paid to the technical requirements on power supply and cabling: Power supply connector (WEIPU SP 1310/S2) into power input socket located on the bottom side of UAD. 5

For UAD30A it is important to used high current capacity power supply. If variable power supply is needed, a high quality laboratory power supply rated for 12A and above may be used. It is recommended to use linear mode power supply with power output 200W or more. Switching mode power supply is not recommended for potential stability issues. In any case, connecting cable between power supply and UAD30A shall meet following requirements: - max 1m cable length - min 0.75mm 2 wire cross section - Original WEIPU SP1310/S2 connector is used In case when only 12V constant power supply voltage is needed, then e-tronix offers as accessory AC/DC power supply. It provides continuous current over 12 A and peak current up to 30A. This power supply option has been validated with UAD30A hence is recommended to use. Picture 2 Power supply connection 6

UAD PANELS DESCRIPTION 1) Display 2) Position demand 3) Mode switch 4) Feedback switch 5) Direction switch 6) Battery status 7) Mode indicator 8) Status indicator Picture 3 - Front panel of UAD Picture 4 - Top panel of UAD 7 UAD Top panel description: 1) Ground 2) Actuator position feedback input 3) Sensor power output 4) USB cable socket 5) Motor NEGATIVE terminal 6) Motor POSITIVE terminal 7) External input BNC socket 8) External input/potentiometer position demand switch 7

Picture 5 Bottom panel of UAD 8 UAD Bottom panel description 1) DC Motor current sensor output 2) Reset button (Used only for firmware re-flashing) 3) Power input (power supply, connector WEIPU SP1310/S2) Polarity: PIN 1 negative, PIN 2 positive. Voltage range unchanged 10.8V 16V 4) Identification label > version of hardware, serial number and HTT number. Warranty label damaged and/or unrecognizable label(s) causes loss of customer's warranty. Manufacturer can t be neither liable for damages caused by using of such UAD unit. CONNECTING ACTUATOR To connect actuator, special cable, depending on type of actuator, has to be used. Actuator is to be connected on top panel of UAD, see Picture 4 - Top panel of UAD BEFORE THE NEXT STEP, PLEASE MAKE SURE UAD IS PROPERLY SET UP, SEE UAD30A MODEL SPECIFICS UAD 30A is modified model that is to be used for larger actuators and/or larger loads. Compared with original UAD48W unit described in ES-002-083, the main differences are: 1) Best in class modern automotive H-Bridge ST VNH5019A is used: - 18mOhn RDS(on) - 12A continuous (30A short time max) current - Integrated precise current sensor proportional to DC motor current see chapter DC MOTOR CURRENT SENSOR OUTPUT 2) DC Motor current sensor output available (0-5V) 3) UAD30A has no main switch What do you have to know about the actuator for appropriate UAD configuration? After actuator is connected, it can work in standalone mode, see Honeywell specification ES- 002-083 section 4.2 standalone functions and 4.3. computer driven functions 8

CONNECTING EXTERNAL DEVICES To connect computer or other communication device (android), USB or Bluetooth (optional) can be used. CONNECTING TO COMPUTER USB standard mini USB connector. Use either standard USB cable, or water-proof USB cable, provided as an optional hardware with UAD. After connecting to PC, UAD is recognized as new hardware and operating system (Windows) then installs device drivers. How do I get the drivers? Drivers usually get installed automatically (WinXP and newer). If for some reason drivers need to be installed manually, then, depending on type of used HW-USB converter (see Chyba! Nenalezen zdroj odkazů. version), please go to www.ftdichip.com/ftdrivers.htm (for FTDI version) or http://www.silabs.com/support/pages/documentlibrary.aspx (for CP210x version) and download the latest VCP driver for the particular interface. Drivers can also be found at : http://www.e-tronix.cz/manual Once the drivers ale installed, operating system assigns UAD number to the COM PORT. This is so called VCP (Virtual Com Port), using this port, it is possible to communicate with UAD using communication protocol see Honeywell ES 002-083 chapter 4.4. BLUETOOTH CONNECTION AND PASSWORD Bluetooth module is optional internal accessories. If the UAD is equipped with Bluetooth (see Picture 6 Bluetooth), UAD may be found as a Bluetooth device named UAD_BTxxx, where xxx are the last three numbers of Serial Number (SN) of UAD (Dash). To pair the device with other BT apparatus, a PIN code needs to be entered. The PIN code for UAD is: 1234 and it never changes. After successful BT connection, operating system assigns VCP (virtual com port) to UAD as with the USB connection. Usage is exactly the same as when using the USB connection. Picture 6 Bluetooth included label 9

POWER-ON UAD30A does not have any power on switch. The unit will start operation immediately after power supply is connected. WHAT DO YOU WANT TO DO WITH THE ACTUATOR? I WANT TO TURN ACTUATOR TO SPECIFIC POSITION (E.G. FOR CALLIBRAITON PURPOSES) OR I WANT TO CHECK IF THE ACTUATOR IS WORKING PROPERLY 1) MODE into CLOSEDLOOP position 2) Use potentiometer to set or change position (DEMAND SELECT is switched into KNOB) 3) Also UAD PC Utility may be used (in this case change DEMAND SELECT to EXT.IN) I WANT TO CHECK THE HARD STOPS POSITION (INTERNAL OR ON APPLICATION) 1) MODE switch into OPEN LOOP position, DEMAND SELECT switch into KNOB position, potentiometer set to middle position (value 5). 2) Turn potentiometer one direction (e.g. value 4) = actuator moves to hard stop in that direction, write down the feedback value displayed. 3) Turn potentiometer other direction (e.g. value 6) = actuator moves to hard stop in the other direction, again write down the feedback value displayed. 4) Also UAD PC Utility SW, which includes automatic HS test, may be used. It shows hard stop positions and also helps to discover possible fold back of position sensor. I WANT TO TURN ACTUATOR WITH BROKEN POSITION SENSOR 1) MODE switch into OPEN LOOP position, DEMAND SELECT into KNOB position, potentiometer set to middle position (value 5). 2) After connecting the actuator use potentiometer to turn actuator into demanded position. If the position sensor is not working correctly, feedback showed on display may not correspond with its actual position. I WANT TO CHANGE ACTUATOR POSITION CYCLICALLY FOR LONGER PERIOD OF TIME (TESTING) 1) MODE switch into CLOSEDLOOP position. 2) Use UAD PC Utility. I WANT TO SET MY OWN UAD CONFIGURATION 1) MODE switch into CLOSEDLOOP position. 2) Use UAD PC Utility. 10

I WANT TO APPLY CERTAIN AMOUNT OF FORCE OR MOMENTUM ONTO HARD STOP (USUALLY SPECIFIED BY APPLICATION) 1) MODE switch into CLOSEDLOOP position. 2) Use UAD PC Utility to set low limit and high limit in Volts and PWM limit in %. Other option MODE switch to OPEN LOOP + UAD PC UTILITY used to set PWM limit for HS test in %. 11

TECHNICAL INFORMATION IF USING UAD WITH VOLTAGE OR PWM ACTUATORS Detailed information found in Honeywell ES-002-083. Actuators with voltage feedback are mainly mentioned in the text. If actuators with PWM are used, analogy for feedback is: 0V~0% /5V~100%. This conversion is valid for both Demand and Feedback. Presumption for voltage feedback is that analog output of the actuator s position sensor is proportional towards VCC (ratio metric sensor used). This means that voltage position feedback is always normalized considering the actual value of VCC. Displayed value doesn t need to be converted with respect of the actual value of VCC. DIRECTION SWITCH SETUP DC motor terminals polarity FEEDBACK SWITCH SETUP Feedback switch has to be set up depending on the type of actuator (PWM or Voltage feedback). PWM signal is supposed to be 0 100% with amplitude 5V (VCC) or Voltage analog output between 0 5V (VCC) MODE SWITCH SETUP MODE button is switching between two main operating modes: CLOSED LOOP: actuator position may me controlled by potentiometer, with voltage input through EXTERNAL INPUT or using USB. In closed loop mode, UAD checks position sensor output and sets the demanded position with PID regulator. OPEN LOOP: potentiometer or voltage through EXTERNAL INPUT sets actuator s position directly, not considering the position sensor output. Moving potentiometer out of middle position (or setting Ext.In. voltage different than 2.5V) will cause actuator movement: 12

Picture 7 - OPEN LOOP check using Ext. input and potentiometer DC Motor current sensor output 0 5V Picture 8 - High level block diagram of UAD interactions EXTERNAL DEMAND INPUT BNC connector (Picture 4 - Top panel of UAD) marked as Ext.In. is an input for applying outer voltage 0...5 VDC. It is used to drive the actuator by another device using voltage amplitude. In closed loop mode, input voltage directly represents actuator position demand. I.e. 4V on BNC connector demands actuator to move to position according do 4V sensor output position. For open loop mode je see Picture 7 - OPEN LOOP check using Ext. input and potentiometer Ext. In. is activated only if the Demand switch is in Ext. In. mode. (Picture 4 - Top panel of UAD). In this case, BNC connector input is responsible for all functions of potentiometer both in closed loop and open loop. 13

On the other hand, if the Demand switch (Picture 4 - Top panel of UAD) is in Knob mode, Ext.In. is inactive and potentiometer keeps its functions. Rem.: Ext.In. is protected against over voltage higher than +16V and against under voltage lower than -16V. SENSOR AND DC MOTOR INTERFACE Actuator is to be connected using five banana plugs. Red, white and black are VCC, Vout and GND. In case of PWM feedback, position signal is also connected to Vout socket. VCC UAD Output: UAD supplies voltage of 5V +- 0,2V for actuator s position sensor. Maximal current is 30 ma. Vout UAD input: on this connector UAD senses actuator s current position, using actuator s feedback sensor. For analog output: 0 5V (VCC), for PWM signal 0 100%, with amplitude of 5V (VCC). DC Motor interface Two banana plugs are used: green = DC+, blue = DC for proper connection see chapter DIRECTION SWITCH SETUP DC MOTOR CURRENT SENSOR OUTPUT This is additional feature compared to original UAD48W. UAD30A provides feedback signal of DC Motor current draw by the BNC connector on bottom panel. Provided voltage range is 0-5V. Protections: Output is protected against short circuit, overvoltage (+16V), reverse voltage (-16V) and ESD 1kV. The same levels as other existing UAD interfaces. Approximate sensor feedback definition is 0.34V / Amp. Each UAD30A comes with calibration sheet showing exact definition (current vs. feedback voltage) for particular unit. See: picture 9 Current sensor calibration sheet example 14

9 Current sensor calibration sheet example INFORMATION SHOWED ON DISPLAY After powering on UAD, value 60 will be displayed for about two seconds, then UAD goes to normal mode (voltage output will be displayed). If no actuator is connected, 0V will be displayed. Value showed on display represents actuator s voltage feedback (normalized to VCC). In case of PWM feedback, voltage is also displayed (not duty cycle of PWM), conversion is: 0V=0%, 5V=100% 15

STAT. AND MODE INDICATORS FUNCTION UAD incorporates STAT. a MODE indicators STAT - blinking = UAD status is ok, not blinking = error status Mode - blinking = open loop mode is active, is lit = closed loop mode For indicators placement see Picture 3 - Front panel of UAD ERROR STATES (DEBUGGING) Status indicator not blinking 1) If PC is used, stop the communication (unplug USB cable) 2) Restart UAD After UAD restart, 60 stays on display 1) USB cable probably remained connected during restart. 2) Unplug USB cable and restart UAD. 3) If 60 remains after correct restart, please contact service point. Value of 0V is projected on display 1) Actuator s position sensor is probably not connected or is faulty. 2) Inspect actuator s position sensor connection. During rapid actuator positional changes the unit restarts, interrupts or freezes. 1) Problem is caused by momentary supply voltage drop which may be spotted on front panel battery indicator. This happens when PID controller is aggressively setup (with high PWM dc limits set) and inadequate power supply is used at the same time. 2) Use adequate power supply see chapter CONNECTING POWER SUPPLY 3) Check power supply cable which shall be: - max 1m length - min 0.75mm2 wire cross section - original WEIPU connector 4) Degrease PID controller constants and/or reduce the PWM dc limits in order to make controller less aggressive as last resort. 16

In closed loop mode, actuator moves to hard stop by itself where it stops. Actuator doesn t respond to position demand. Feedback displayed doesn t correspond with actuator s real position. 1) Position sensor is connected incorrectly to UAD = check the connection. 2) Position sensor is broken down. 3) Actuator with voltage feedback is connected with PWM mode switched on = change feedback switch into proper mode. In closed loop mode, actuator moves to hard stop by itself where it stops. Actuator doesn t respond to position demand. Feedback displayed approximately corresponds with actuator s real position. 1) Direction switch is in wrong mode = switch it into other position. In closed loop mode, actuator position oscillates and feedback displayed approximately corresponds with actuator s real position. 1) Voltage feedback mode is probably chosen with PWM feedback position actuator = change feedback switch to PWM position. In open loop mode, feedback displayed is OV, in some cases actuator randomly changes its position. 1) Actuator s position sensor is faulty. 2) Incorrectly connected actuator. 3) Voltage feedback actuator connected, with PWM feedback mode on. In closed loop or open loop actuator doesn t respond to position demand, feedback displayed approximately corresponds with actuator s real position. 1) Incorrectly selected demand mode: controlling actuator with potentiometer with selected Ext. In. and vice versa COMMUNICATE WITH US! Please communicate with us, send us any suggestions, how we can make UAD better or extend its functions. Also share with us any of UAD s error states that you came across with (suitably with video or photo of this difficulty). Our e-mail address is: info@e-tronix.cz 17