pqp-175-p-pdp - w.e.st · pdf file5.2.1 lg (changing the language for the help texts) ... page...

W.E.ST. Elektronik GmbH

Technical Documentation

PQP-175-P-PDP

Pump control module with Profibus-DP interface


of 38 PQP-175-P-PDP 13.12.2013

CONTENTS

1 General Information .............................................................................................................................................. 4

1.1 Order number ............................................................................................................................................... 4

1.2 Scope of supply ............................................................................................................................................ 4

1.3 Accessories .................................................................................................................................................. 4

1.4 Symbols used ............................................................................................................................................... 5

1.5 Legal notice .................................................................................................................................................. 5

1.6 Safety instructions ........................................................................................................................................ 6

2 Characteristics ...................................................................................................................................................... 7

2.1 Device description ........................................................................................................................................ 8

3 Use and application .............................................................................................................................................. 9

3.1 Installation instructions ................................................................................................................................. 9

3.2 Typical system structure ............................................................................................................................. 10

3.3 Method of operation .................................................................................................................................... 11

3.4 Commissioning ........................................................................................................................................... 12

4 Technical description .......................................................................................................................................... 13

4.1 Input and output signals ............................................................................................................................. 13

4.2 LED definitions ........................................................................................................................................... 13

4.3 Circuit diagram ........................................................................................................................................... 14

4.4 Typical cabling ............................................................................................................................................ 15

4.5 Connection examples ................................................................................................................................. 15

4.6 Technical data ............................................................................................................................................ 16

5 Parameters ......................................................................................................................................................... 17

5.1 Parameter overview .................................................................................................................................... 17

5.2 Parameter description ................................................................................................................................ 19

5.2.1 LG (Changing the language for the help texts) .................................................................................. 19

5.2.2 MODE (Switching between parameter groups) .................................................................................. 19

5.2.3 TS (Sample time) ............................................................................................................................... 19

5.2.4 PBADR (Profibus address) ................................................................................................................ 20

5.2.5 TRIGGER (Treshold) ......................................................................................................................... 20

5.2.6 PVSEL (Internal speed demand value) .............................................................................................. 20

5.2.7 TYPE (Control mode)......................................................................................................................... 20

5.2.8 P_SENSOR (Working range pressure sensor) .................................................................................. 21

5.2.9 P_NOMINAL (Nominal system pressure) .......................................................................................... 21

5.2.10 P_CORR (Correction value pressure sensor) .................................................................................... 21

5.2.11 PL (Power limitation) .......................................................................................................................... 21

5.2.12 Q:CORR (Flow rate correction value) ................................................................................................ 22

5.2.13 SENS (Module monitoring) ................................................................................................................ 22

5.2.14 AQ (Ramp function flow rate) ............................................................................................................. 22

5.2.15 AP (Ramp function pressure) ............................................................................................................. 23

5.2.16 MIN:XQ (Input scaling displacement sensor) ..................................................................................... 23

5.2.17 MAX:XQ (Input scaling displacement sensor) .................................................................................... 23

5.2.18 AIN:XP (Switching of the input signal) ............................................................................................... 23

5.2.19 CQ (PID-controller displacement control) .......................................................................................... 24

5.2.20 CP (PID-controller pressure control) .................................................................................................. 25

5.2.21 CP:MINV (Compensation of the deadband) ....................................................................................... 26

5.2.22 CP:MAXV / CQ:MAXV (Maximum output signal) ............................................................................... 26

5.2.23 DFREQ (Dither frequency) ................................................................................................................. 27

5.2.24 DAMPL (Dither amplitude) ................................................................................................................. 27

5.2.25 PWM (PWM frequency) ..................................................................................................................... 27

5.2.26 PPWM (Solenoid current controller P gain) ....................................................................................... 28


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5.2.27 IPWM (Solenoid current controller I gain) .......................................................................................... 28

5.2.28 PROCESS DATA (Monitoring) .......................................................................................................... 28

6 Profibus DP interface ......................................................................................................................................... 29

6.1 Profibus functions....................................................................................................................................... 29

6.2 Installation .................................................................................................................................................. 29

6.3 GSD Configuration File .............................................................................................................................. 29

6.4 Description Profibus DP interface .............................................................................................................. 30

6.5 Commands via PROFIBUS ........................................................................................................................ 31

6.5.1 Command map .................................................................................................................................. 31

6.5.2 Definition of the control bits: .............................................................................................................. 32

6.6 DATA send to PROFIBUS ......................................................................................................................... 33

6.6.1 Feedback map ................................................................................................................................... 33

6.6.2 Definition of the status bits: ............................................................................................................... 34

6.7 ST (Status request) .................................................................................................................................... 35

7 Appendix ............................................................................................................................................................ 35

7.1 Failure monitoring ...................................................................................................................................... 35

7.2 Troubleshooting ......................................................................................................................................... 36

8 Notes.................................................................................................................................................................. 37


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1 General Information

1.1 Order number

PQP-175-P-PDP-12221 - with analogue ±10 V differential output and analogue sensor interface

1.2 Scope of supply

To the scope of supply belongs the module including the terminal blocks which are part of the housing. The Profibus plug, interface cables and further parts which may be required should be ordered separately. This documentation can be downloaded as a PDF file from www.w-e-st.de.

1.3 Accessories

RS232-SO - Programming cable with RS232C interface

USB-SO - Programming cable with USB interface

WPC-300 - Start-Up-Tool (downloadable – products/software)

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.


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1.4 Symbols used

General information

Safety-related information

1.5 Legal notice

W.E.St. Elektronik GmbH

Gewerbering 31

D-41372 Niederkrüchten

Tel.: +49 (0)2163 577355-0

Fax.: +49 (0)2163 577355-11

Home page: www.w-e-st.de or www.west-electronics.com

EMAIL: [email protected]

Date: 13.12.2013

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.


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1.6 Safety instructions

Please read this document and the safety instructions carefully. This document will help to define the product area of application and to put it into operation. Additional documents (WPC-300 for the start-up software) and knowledge of the application should be taken into account or be available. General regulations and laws (depending on the country: e. g. accident prevention and environmental protection) must be complied with.

These modules are designed for hydraulic applications in open or closed-loop control circuits. Uncontrolled movements can be caused by device defects (in the hydraulic module or the components), application errors and electrical faults. Work on the drive or the electronics must only be carried out whilst the equipment is switched off and not under pressure.

This handbook describes the functions and the electrical connections for this electronic assembly. All technical documents which pertain to the system must be complied with when commissioning.

This device may only be connected and put into operation by trained specialist staff. The instruction manual must be read with care. The installation instructions and the commissioning instructions must be followed. Guarantee and liability claims are invalid if the instructions are not complied with and/or in case of incorrect installation or inappropriate use.

CAUTION! All electronic modules are manufactured to a high quality. Malfunctions due to the failure of components cannot, however, be excluded. Despite extensive testing the same also applies for the software. If these devices are deployed in safety-relevant applications, suitable external measures must be taken to guarantee the necessary safety. The same applies for faults which affect safety. No liability can be assumed for possible damage.

Further instructions

• The module may only be operated in compliance with the national EMC regulations. It is the user’s responsibility to adhere to these regulations.

• The device is only intended for use in the commercial sector.

• When not in use the module must be protected from the effects of the weather, contamination and mechanical damage.

• The module may not be used in an explosive environment.

• To ensure adequate cooling the ventilation slots must not be covered.

• The device must be disposed of in accordance with national statutory provisions.


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2 Characteristics

This module is used for the displacement, pressure and power/torque control for servo pumps. The struc-ture of the controller provides a separately controlling of a displacement valve (directional valve with one solenoid) and a pressure valve for pressure limitation. The power stage is integrated. Various adjustable parameters enable an optimized adaptation to the respective pump type and application. The closed loop circuit has a cycle time of 1 ms and the power stage works with a cycle time of 0,167 ms for the current control loop.

The command values are set via Profibus and the feedback values are read in as analogue signals (0... 10V or 4... 20mA). The output current is closed loop controlled and therefore independent from the supply voltage and a varying solenoid resistance. The power stage is monitored for cable break down and short circuit proof. In case of detected errors the power stage is shut down.

Typical applications: Displacement control, pressure control and power limitation with Parker PVplus pumps.

Features

• Displacement-, pressure and power limitation control

• Profibus interface

• Compact housing

• Digital reproduceable settings

• Optimized control function

• Adaption to the Parker PVplus pump

• User orientated parameterization

• Fault diagnosis and extended function checking

• Adjustment via RS232C interface, simplified parameterization with WPC-300 software version 3


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2.1 Device description

Pump control module PQP-175-P-PDP

V:ID:

Add.:Date:

Made in Germany

W.E.ST.

Ready

Status

1 2 3 4

5 6 7 8

9 10 11 12

14 15 1613

D-41372 NiederkrüchtenHomepage: http://www.w-e-st.de

W.E.ST. Elektronik

8

7

6

5

4

3

2

1

16

15

14

13

12

11

10

9

30 31 3229

26 27 2825

18 19 2017

22 23 2421

Pro

fib

us

9po

l SU

BD

Online

Klemmblöcke (steckbar)Terminals (removable)

LEDs

RS232C Interface

Typenschild und AnschlussbelegungType plate and terminal pin assignment

45,0000 mm99,0000 mm

114,0000 mm

PROFIBUS BuchsePROFIBUS connector

121,0000 mm


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3 Use and application

3.1 Installation instructions

• This module is designed for installation in a shielded EMC housing (control cabinet). All cables which lead outside must be screened; complete screening is required. It is also necessary to avoid strong electro-magnetic interference sources being installed nearby when using our open and closed loop control modules.

• Typical installation location: 24 V control signal area (close to PLC) The devices must be arranged in the control cabinet so that the power section and the signal section are separate from each other. Experience shows that the installation place close to the PLC (24 V area) is most suitable. All digital and analogue inputs and outputs are fitted with filters and surge absorbers in the device.

• The module should be installed and wired in accordance with the documentation bearing in mind EMC principles. If other consumers are operated with the same power supply, a star-shaped ground wiring scheme is recommended. The following points must be observed when wiring:

• The signal cables must be laid separately from power cables.

• Analogue signal cables must be screened.

• All other cables must be screened if there are powerful interference sources (frequency converters, power contactors) and cable lengths > 3 m. Inexpensive SMD ferrites can be used with high-frequency radiation.

• The screening should be connected to PE (PE terminal) as close to the module as possible. The local requirements for screening must be taken into account in all cases. The screening should be connected to at both ends. Equipotential bonding must be provided where there are differences between the connected electrical components.

• If having longer lengths of cable (> 10 m) the diameters and screening measures should be checked by specialists (e. g. for possible interference, noise sources and voltage drop). Special care is required if using cables of over 40 m in length, and if necessary the manufacturer should be consulted if necessary.

• A low-resistance connection between PE and the mounting rail should be provided. Transient interference is transmitted from the module directly to the mounting rail and from there to the local earth.

• Power should be supplied by a regulated power supply unit (typically a PELV system complying with IEC364-4-4, secure low voltage). The low internal resistance of regulated power supplies gives better interference voltage dissipation, which improves the signal quality of high-resolution sensors in particular. Switched inductances (relays and valve coils) which are connected to the same power supply must always be provided with appropriate overvoltage protection directly at the coil.


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3.2 Typical system structure

This minimal system consists of the following components:

(*1) Unit for displacement adjustment

(*2) Servo pump (Parker PVplus)

(*3) Sensor for displacement and pressure measuring

(*4) Electronic module PQP-175-P-PDP

(*5) Profibus interface to PLC


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3.3 Method of operation

In principle the control unit of the pump controller is comparable with the control of a cylinder (positioning). The position of the cylinder equates to a defined swivel angle. Via the displacement control valve for the swivel angel adjustment the cylinder can be driven in and out. The hydraulic circuit is equivalent to a differential circuit (regenerative) because the rod side is constant connected with the outlet pressure of the pump.

Due to the relative small mass the eigenfrequency of the cylinder is high and the dynamic behaviour predominantly depends on the displacement/swivel angel valve.

The pressure controlling is realized by the pressure limitation valve. If the system pressure gets higher than the electrical preset pressure the valve opens in direction of connector P0 and the cylinder drives out, the pump swivels back (volumetric flow will be decreased).


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3.4 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. The device must be installed in a metal protective housing (control cabinet or similar).

Switching on for the first time

Ensure that no unwanted movement is possible in the drive (e. g. switch off the hydraulics). Connect an ammeter and check the current consumed by the device. If it is higher than specified there is an error in the cabling. Switch the device off immediately and check the cabling.

Setting up communication Once the power input is correct the PC (notebook) should be connected to the serial interface. Please see the WPC-300 program documentation for how to set up communication.

Further commissioning and diagnosis are supported by the operating software.

Pre-parameterization Preparameterization for a complex application like pump ctrolling is extensive but absolutely necessary. For that talk to the manufacturer or the responcible person for the hydraulics who is introduced in the subject matter.

Control signal Check the control signals to the valves. In the current state it should be 0 mA .

Switching on the hydraulics

The hydraulics can now be switched on. Since the module is not yet generating a signal the drive should not do any unwanted reactions.

Activating ENABLE CAUTION! The pump now works in displacement control. Wrong parameterization can cause uncontrollable behaviour.

Activating P CTRL With the P CTRL bit the pressure controller gets activated. Depending on the configuration it works in open or closed loop control. CAUTION! When the pump is working in pressure control, a wrong parameterization can cause uncontrollable behaviour.

Optimize controller Now optimize the controller parameters according to your application and your requirements.


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4 Technical description

4.1 Input and output signals

4.2 LED definitions

Connection Supply

PIN 3 Power supply (see technical data)

PIN 4 0 V (GND) connection.

PIN 29 +

PIN 30 -

Power supply: 10… 30VDC. These pins are internally connected to PIN 31 and PIN 32. Optional they can be separated for an independent supply of the power stage.

PIN 31+

PIN 32 -

Power supply for the Profibus communication. These pins are internally connected to PIN 29 and PIN 30. Optional they can be separated for an independent supply.

Connection Analogue signals

PIN 11/12 0 V (GND)

PIN 6 Analogue position actual value (XQ), for displacement control.

PIN 14 Analogue position actual value (XP), for pressure control.

PIN 17/19 Current controlled PWM output for pressure valve.

PIN 18/20 Current controlled PWM output for displacement valve.

Connection Digital inputs and outputs

PIN 8 ENABLE input:

This digital input signal combined with the ENABLE bit from the Profibus initializes the application and error messages are deleted. The controller and the READY signal are activated.

PIN 1 READY output:

Gets activated if the module is enabled and there are no discernable errors.

LEDs Description of the LED function

GREEN Identical to the READY output.

OFF: no power supply or ENABLE is not activated

ON: System is ready for operation

Flashing: Error discovered.

Only active when SENS = ON.

YELLOW OFF: System is not in power limitation.

ON: System is in power limitation.

PDP GREEN Online-LED: shows active Profibus communivation.


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4.3 Circuit diagram

PE via DIN-RAIL

18

20

8Enable

3,5 mm Cinch PQP-175-P-PDPRS232 C9600 Baud

SUPPORTsave loadback helppara

DIAGNOSTICSdinwa, wb ua, ub ca, cb ia, ib

CONFIGURATION-

Control program

AQ:i xi = UP|DOWNx = 0..60000

Ramp

pwm 60..2600

ipwm = 1..100ppwm = 0..30

dfreq:i x = A/B x = 60..400dampl:i xi = A/B x = 0..3000

Power Supply

24 V

0V

17

19

3

4

24 V

0 V

DC

DC10 V

5 V

11

PID Control function

11

60... 10 VFeedback Q

Solenoid Qiq

ip

1 Ready

24 V input

WQ

xq

Profibus Communication

up

wq

+-

Solenoid P

31

32

24 V

0 V

AP:i xi = UP|DOWNx = 0..60000

Ramp

11

140... 10 V / 4... 20 mA

Feedback P

AIN:XP

Input scaling

+-

WPPID Control function

MAX:PVx = 5000..10000

MIN:PVx = 0..5000

wp

xp

uq

24 V output

Power Stage

Qmax=Lcom x Lfact

Pactual

MIN

Profibus Communication

Profibus Communication 24 V

0V

optional

29

30

DC

DC

Profibus

MIN:XQMAX:XQ

WL


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4.4 Typical cabling

4.5 Connection examples

+In PIN 13 or 14

PIN 12 (GND)

SPS / PLC 0... 10 V speed input signal

+In PIN 10

-In PIN 9

GND PIN 11

AIN:W 2000 1600 2000 C ( für 0... 100%)

SPS / PLC 0... 10 V command and feedback signal

+In PIN 13 or PIN 14

In PIN 12 (GND)

PLC or sensor with 4... 20 mA (two wire connection)

z. B. 24 V

+In PIN 13 or 14

PIN 12 (GND)

AIN:W 2000 1600 2000 C ( für 0... 100%)

PLC or sensor with 4... 20 mA (three wire connection)

z. B. 24 V

8765

16151413

1211109

ENABLEinput

4321

0V

24V0V

20191817

pressure valve P

displacement valve Q

32313029

Pro

fib

us

9po

l plu

g

PE

clam

p

PE

clam

p

0V24V

powersupply

power supply Profibus

0V24V

power supply power stage (optional)

28272625

READYoutput

feedbackdisplacem.

feedbackpressure


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4.6 Technical data

Supply voltage

Current requirement

External protection

[VDC]

[mA]

[A]

12… 30 (incl. ripple)

<100 + solenoid current

3 medium time lag

Digital inputs

Input resistance

[V]

[V]

[kOhm]

logic 0: <2

logic 1: >10

25

Digital outputs [V]

[V]

logic 0: <2

logic 1: >12 (50 mA)

Analogue inputs (sensor

and demand value signal)

Signal resolution

[V]

[mA]

[%]

0… 10; 25 kOhm

4… 20; 250 Ohm

0,01 (internally 0,0031) incl. oversampling

Analogue outputs

Voltage

Signal resolution

[V]

[mA]

[%]

2 x 0,15… 10;

5 (max. load)

0,024

Profibus DP

Baudrate

ID-Nummer

9.6,19.2, 93.75, 187.5, 500, 1500, 3000, 6000, 12000 kbit/s

1810h

PWM Output current

PWM frequency

[A]

[Hz]

Up to 2,6 (current controlled);

* Both solenoids have to work in the same

current range (up to 1A, up to 1,6A or up to

2,6A)

60...2600

Controller sample time [ms] 1 (variable from 0,5 … 3)

Serial interface -

RS 232C, 9600… 57600 Baud, 1 stop bit, no parity, Echo Mode

Housing - Snap-on module to EN 50022

PA 6.6 polyamide

Flammability class V0 (UL94)

Weight [kg] 0,250

Protection class

Temperature range

Storage temperature

Humidity

[°C]

[°C]

[%]

IP20

-20… 60

-20… 70

< 95 (non-condensing)

Connections - RS232C: 3,5 mm JISC-6560

47x 4-pole terminal blocks

PE: via the DIN mounting rail

EMC

- EN 61000-6-2: 8/2002

EN 61000-6-3: 6/2005


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5 Parameters

5.1 Parameter overview

Command Default Unit Description

LG EN - Changing language help texts.

MODE STD - Mode parameter (standard or expert).

TS 10 0,1 ms Changing the controller sample time.

PBADR 126 - Profibus address

TRIGGER 0 0,01 % Trigger threshold for the analogue inputs.

PVSEL 16 - Selection of the used pump.

TYPE F - Control mode (F, P, Q)

P:SENSOR

P:NOMINAL

P:CORR

600

350

15

bar

bar

bar

Working range pressure sensor

Nominal system pressure

Pressure correction value

PL:RPM

PL:EFF

PL:PL

PL:T1

1500

7850

178

500

1/min

0,01%

0,1 kW

0,1ms

Power limitation function.

Q:CORR 0 0,01% Correction of the flow rate waste depending on the pressure.

SENS AUTO - Activation and deactivation of the monitoring functions.

AQ:UP

AQ:DOWN

50

50

ms

ms

Ramp times WQ.

AP:UP

AP:DOWN

50

50

ms

ms

Ramp times WP.

MIN:XQ

MAX:XQ

7289

6262

mV

mV

Analogue input scaling of displacement feedback XQ.

AIN:XP C - Switching of the analogue input signal for pressure feedback XP.

CQ:FF

CQ:P

CQ:I

CQ:I_LIM

CQ:IC

CQ:D

CQ:T1

CQ:MAXV

6000

80

2000

2500

700

100

10

1300

0,01 %

0,01

0,1 ms

0,01 %

0,01 %

0,1 ms

0,1 ms

mA

PID controller for the displacement control

Offset position of the Q valve

P-Gain (100 corresponds to a gain of 1)

I-Gain

I_LIM

IC

D-Gain

T1 (Filter for D-gain)

Maximum output current to the Q valve.


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Command Default Unit Description

CP:FF

CP:P

CP:I

CP:I_LIM

CP:IC

CP:D

CP:T1

CP:MINV

CP:MAXV

8000

50

600

2500

500

0

10

280

1320

0,01 %

0,01

0,1 ms

0,01 %

0,01 %

0,1 ms

0,1 ms

mA

mA

PID controller for the pressure control

Offset position of the Q valve

P-Gain (100 corresponds to a gain of 1)

I-Gain

I_LIM

IC

D-Gain

T1 (Filter for D-gain)

Minimum output current to the P valve(dead band compensation)

Maximum output current to the P valve

DFREQ:Q

DFREQ:P

120

120

Hz

Hz

Adjustment of the dither frequency.

DAMPL:Q

DAMPL:P

400

200

0,01%

0,01%

Adjustment of the dither amplitude.

PWM:Q

PWM:P

2600

2600

Hz

Hz

Choosing PWM frequency.

PPWM:Q

IPWM:Q

PPWM:P

IPWM:P

7

40

7

40

-

-

-

-

Control parameters for the current control loop.

Attention: Displayed default settings are parameters for PVSEL 16.


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5.2 Parameter description

5.2.1 LG (Changing the language for the help texts)

Command Parameters Unit Group

LG X x= DE|EN - STD

Either German or English can be selected for the help texts.

CAUTION: After changing the language settings the ID button (SPEED BUTTON) in the menu bar (WPC-300) must be pressed (module identification).

5.2.2 MODE (Switching between parameter groups)


MODE X x= STD|EXP - STD

This command changes the operating mode. Various commands (defined via STD/EXP) are blanked out in Standard Mode. The commands in Expert Mode have a more significant influence on system behavior and should accordingly be changed with care.

5.2.3 TS (Sample time)


TS X x= 5… 30 0,1 ms EXP

The control dynamics can be influenced with the sample time. Lower values cause faster controlling. Longer times make the behaviour more stable.Changes should only be made by persons who have sufficient knowledge of the dynamic system behavior.

CAUTION! Changes should only be made by persons who have sufficient knowledge of the dynamic system behavior. After changing this value all time-dependent parameters must be checked and reset if necessary.


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5.2.4 PBADR (Profibus address)


PBADR X x= 1… 126 - STD

This command defines the address of the module on the Profibus. If the address should be changed via Profibus, 126 has to be chosen.

Attention: If the address will be changed via Profibus, there is no change in the parameter list. It is still shown 126 but the address chosen via Profibus is active and the only one can be used.

5.2.5 TRIGGER (Treshold)


TRIGGER X x= 0… 3000 0,01 % EXP

Trigger threshold for the analogue inputs.

5.2.6 PVSEL (Internal speed demand value)


PVSEL X x= 16|20|23|32|

40|46|63|80|92|

140|180|270|360

- STD

Specification of the internal speed limitation.

5.2.7 TYPE (Control mode)


TYPE X x= F|P|Q - STD

This command defines the control structure of the pump.

F: Displacement control

P: Displacement control + open loop pressure control

Q: Displacement control + closed loop pressure control


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5.2.8 P_SENSOR (Working range pressure sensor)

5.2.9 P_NOMINAL (Nominal system pressure)

5.2.10 P_CORR (Correction value pressure sensor)


P_SENSOR X

P_NOMINAL X

P_CORR X

x= 10… 600

x= 10… 600

x= 0… 40

bar

bar

bar

EXP

EXP

EXP

This command is for inputing pressure data of the system.

An automatic scaling of the pressure sensor will be done by this.

Typical vlaues are:

P_SENSOR: 600 bar

P_NOMINAL: 350 bar

P_CORR: 17 bar

P_CORR compensates the difference between the output pressure and the control pressure in the primary stage. Typically the output pressure ist round about 17 bar higher than the pressure in primary stage.

5.2.11 PL (Power limitation)


PL:I X i= RPM|EFF|PL|T1

:RPM x= 1… 3000

:EFF x= 500… 10000

:PL x= 1… 5000

:T1 x= 10… 10000

-

U/min

0,01 %

0,1 kW

0,1 ms

EXP

EXP

STD

EXP

The power limitation is parameterized by this commands.

PL:RPM - motor rotation speed

PL:EFF - efficiency factor

PL:PL - power limit

Calculation:

Depending on the chosen pump the theoretical maximum power is calculated like this:

600

Nominal

⋅

⋅⋅

=

Eff

PRPMntDisplacemePMax

If choosing a new pump, PL:PL will be set to this calculated Maximum. The minimally usable power limit is

nearly 20% of the theoretical Maximum.


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5.2.12 Q:CORR (Flow rate correction value)


Q:CORR X x = 0… 1000 0,01 % EXP

With this command the correction value for the flow rate waste is set. Because of increasing pressure the flow rate gets lower linear with it. This correction value allows compensating it (in the range of the possible flow rate).

In this case it is recommended to activate the ramp in order to avoid unwanted oscillations.

5.2.13 SENS (Module monitoring)


SENS X x = ON|OFF|AUTO - EXP

This command is used to activate/deactivate the monitoring functions (4… 20 mA sensors, output current, signal range and internal failures) of the module.

OFF: No monitoring function is active.

ON: All monitoring functions are active. Detected failures can be reset by deactivating the ENABLE input.

AUTO: Auto reset mode. All monitoring functions are active. If the failure doesn’t exist anymore, the module automatically resumes to work.

Normally the monitoring functions are always active (ON or AUTO mode) because otherwise no errors are detectable via the READY output. Deactivating is possible mainly for troubleshooting.

5.2.14 AQ (Ramp function flow rate)


AQ:I X i= UP|DOWN

x= 1… 600000

ms

EXP

This parameter will be entered in ms.

The ramp time is set separately for increasing (UP) and decreasing (DOWN) signal.


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5.2.15 AP (Ramp function pressure)


AP:I X i= UP|DOWN

x= 1… 600000

ms

EXP

This parameter will be entered in ms.

The ramp time is set separately for increasing (UP) and decreasing (DOWN) signal.

5.2.16 MIN:XQ (Input scaling displacement sensor)

5.2.17 MAX:XQ (Input scaling displacement sensor)


MIN:XQ X

MAX:XQ X

x= 0… 10000

x= 0… 10000

mV

mV

STD

STD

By this command the feedback input for the displacement control can be scaled. Herewith also the special feature of PARKER settings is considered, means the contrary functionality.

For example the settings of the PV023:

MIN:XQ = 7498 (7,498 V or 7498 mV)

MAX:XQ = 5678 (5,678 V or 5678 mV)

5.2.18 AIN:XP (Switching of the input signal)


AIN:XP X x= V|C - EXP

This command allows chosing the input signal for the analogue pressure feedback input. Possible is V for voltage (0… 10 V) and C for current (4… 20 mA). Typical is a current signal.

Further settings relating to the pressure are done by commands P_SENSOR, P_NOMINAL and P_CORR.


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5.2.19 CQ (PID-controller displacement control)


CQ:I X i= FF|P|I|I_LIM|IC

|D|T1|

:FF x= 0… 10000

:P x= 0… 10000

:I x= 0… 30000

:I_LIM x= 0… 10000

:IC x= 0… 1000

:D x= 0… 1200

:T1 x= 10… 1000

0,01 %

0,01

0,1 ms

0,01 %

0,01 %

0,1 ms

0,1 ms

EXP

The Q controller is parameterized by these commands.

Defines:

CQ:FF - Offset value for zero point adjustment of the valve. Typical value is 6000

CQ:P - P gain of the controller

CQ:I - Reset time of the integrator, value “0” deactivates the integrator.

CQ:I_LIM - Limitation of the integrator. This value should be selected as small as possible, because it only has to balance the irregularities.

CQ:IC - Integrator control via the pressure controller. If the actual value gets higher than the command value the integrator of the CQ controller will be freezed. If the actual value falls below this treshold it will be deallocated again. With CQ:IC = 0 this function can be deactivated. In this case the integrator is always enabled.

CP:D - Rate time.

CP:T1 - Damping of the D-Gain,typical vlues are approximately 10% of CQ:D.

Attention: The sample time (TS) should not be changed during optimizing the PID-controller, because all time based settings can be changed.

commandvalue

ramp-function

actual value

-

ReglerCQ:P P-gainCQ:I I-gainCQ:D D-gainCQ:T1 T1 damping for D-gainCQ:FF Offset value

CQ:I_LIM IntegratorlimitationCQ:IC Integratoractivation

CQ:P

CQ:ICQ:I_LIMCQ:IC

w

x

CQ:DCQ:T1

-

CQ:FF


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5.2.20 CP (PID-controller pressure control)


CQ:I X i= FF|P|I|I_LIM|IC

|D|T1|

:FF x= 0… 10000

:P x= 0… 10000

:I x= 0… 30000

:I_LIM x= 0… 10000

:IC x= 0… 1000

:D x= 0… 1200

:T1 x= 0… 1000

0,01 %

0,01

0,1 ms

0,01 %

0,01 %

0,1 ms

0,1 ms

EXP

The P controller is parameterized by these commands.

Defines:

CP:FF - Feed forward (open loop opening). Typical values between 8000 and 9000.

CP:P - P gain of the controller. Because of pressure controlling via a pressure valve the value can be set relative low. Typical values: 50… 200.

CP:I - Reset time of the integrator, value “0” deactivates the integrator.

CP:I_LIM - Limitation of the integrator. This value should be selected as small as possible, because it only has to balance the irregularities. Typical 2500 (25%). Depending on the linearity maybe a higher value is necessary.

CP:IC - Integrator control. Reaching adjustet treshold (in % of command value) activates the integrator. This avoids a to heavy overshooting at the start of the controlling. Typical settings are in the range of 1000… 5000.

CP:D - Rate time.

CP:T1 - Damping of the D-Gain,typical vlues are approximately 10% of CP:D.

Attention: The sample time (TS) should not be changed during optimizing the PID-controller, because all time based settings can be changed.

commandvalue

ramp-function

actual value

-

ReglerCQ:P P-gainCQ:I I-gainCQ:D D-gainCQ:T1 T1 damping for D-gainCQ:FF Feed forward value

CQ:I_LIM IntegratorlimitationCQ:IC Integratoractivation

CP:P

CP:ICP:I_LIMCP:IC

w

x

CP:DCP:T1

-

CP:FF


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5.2.21 CP:MINV (Compensation of the deadband)

5.2.22 CP:MAXV / CQ:MAXV (Maximum output signal)


CQ:MAXV X

CP:MINV X

CP:MAXV X

x= 300… 2600

x= 0… 1000

x= 300… 2600

mA

mA

mA

EXP

The output signal is adapted to the valve by this commands.

If the MIN value is set too high, it influences the minimal velocity, which cannot be adjust-ed any longer. In extreme case this causes to an oscillating around the closed loop con-trolled position.

CAUTION: Internally the current is switch in the ranges of 1A, 1,6A and 2,6A. Because of that it is necessary that both valves are working in the same range. It is not possible to use a pressure valve with 1 A and a displacement valve with 2,6 A at the same time.

Input100%

10V

Outp

ut

MAX

MIN

TRIGGER


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5.2.23 DFREQ (Dither frequency)

5.2.24 DAMPL (Dither amplitude)


DFREQ:I X

DAMPL:I X

I= P|Q

x= 60… 400

I= P|Q

x= 0… 3000

Hz

0,01 %

EXP

The dither can be defined freely with this command. Different amplitudes or frequencies may be required depending on the respective valve.

The dither amplitude is defined in % of the nominal current range.

CAUTION: The PPWM and IPWM parameters influence the effect of the dither setting. These pa-rameters 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.

5.2.25 PWM (PWM frequency)


PWM X x= 60|72|85|100|

120|150|200|270|

370|490|630|780|

980|1200|1420|

1560|1740|1950|

2230|2600

Hz EXP

This parameter is entered in Hz. The optimum frequency depends on the valve.

CAUTION: The PPWM and PPWM parameters should be adapted when using low PWM frequen-cies because of the longer dead times which forces a reduced stability of the closed loop control.


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5.2.26 PPWM (Solenoid current controller P gain)

5.2.27 IPWM (Solenoid current controller I gain)


PPWM X

IPWM X

X = 0… 30

X = 1… 100

-

-

EXP

The PI current controller for the solenoids is parameterized with these commands.

A higher P-gain forces a higher dynamic of the current control loop and also the effect of the dither settings.

The I-gain should only be changed if detailed knowledge about the current control loop is proven.

CAUTION: These settings are depending on the dynamic response of the solenoid (inductive reactance). These parameters should not be changed without adequate measurement facilities and experiences.

If the PWM frequency is > 2500 Hz, the dynamic of the current controller can be increased.

Typical values are: PPWM = 7… 15 and IPWM = 20… 40.

If the PWM frequency is < 250 Hz, the dynamic of the current controller has to be reduced.

Typical values are: PPWM = 1… 3 and IPWM = 40… 80.

5.2.28 PROCESS DATA (Monitoring)

Command Parameters Unit

WQ

XQ

UQ

WP

XP

UP

WL

XL

IQ

IP

Demand value displacement

Feedback value displacement

Control signal Q valve

Demand value pressure

Feedback value pressure

Control signal P valve

External demand value for power limitation

Power limitation output signal

Solenoid current Q

Solenoid current P

%

%

%

bar

bar

%

%

%

mA

mA

The process data are the variables which can be observed continuously on the monitor or on the oscilloscope.


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6 Profibus DP interface

6.1 Profibus functions

The module supports all baud rates from 9,6 kbit/s up to 12000 kbit/s with auto detection of the baud rate. The functionality is defined in IEC 61158. The Profibus address can be programmed by a terminal program, WPC-300 or online via the Profibus. A diagnostic LED indicates the online status.

6.2 Installation

A typical screened Profibus plug (D-Sub 9pol with switchable termination) is mandatory. Every Profibus segment must be provided with an active bus termination at the beginning and at the end. The termination is already integrated in all common Profibus plugs and can be activated by DIL switches. The Profibus ca-ble must be screened. PIN 17 have to be connected with PE (low impedance).

6.3 GSD Configuration File

The GSD data file is available on our homepage: http://www.w-e-st.de/files/software/hms_1810.gsd

The communication parameters are 16 bytes (8 words) for IN/OUT variables.


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6.4 Description Profibus DP interface

The pressure command and feedback values were preset and send in 0,1 bar units.

The flow rate command and feedback values are interpreted as percent ones. 0x3fff (16373) corresponds to 100%.

The module will be controlled by the control word, with the following bits:

• ENABLE: Must be activated in addition to the hardware signal

• P CTRL: The pressure controller (open or closed loop controlled) gets activated by this signal. If the control structure TYPE is P or Q, the pressure valve is controlled by 100% when the bit is de-activated. If the TYPE is F, this function is not enabled.

• RAMP: Activation of the internal preset ramps.

• MODE: Kind of pump (PVSEL) and structure of controlling (TYPE) can be changed via Profibus if this bit is activated.

• TYPE: Within those two bits the kind of control structure (F, P, Q) can be defined via Profibus.

Attention: If pump or control structure is changed, the table of the wpc-300 program has to be updated for displaying the changing and right parameters.

The description of the command values, feedback values and status report you find in the description of the communication.

Note: Default for Profibus address is 126. This address allows changing it via the Profibus without chang-ing in the parameterlist of the module. The shown address in the list is still 126 then, but active is the cho-sen address by Profibus. See also 5.2.4 PBADR.


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6.5 Commands via PROFIBUS

6.5.1 Command map

16 data bytes are sent to the module.

Nr. Byte Function Remake

1 0 Control word Hi unsigned int

2 1 Control word Lo

3 2 Command value displacement Hi Signal resolution:

0x3fff = 100 % 4 3 Command value displacement Lo

5 4 Command value pressure Hi Signal resolution:

0,1 bar 6 5 Command value pressure Lo

7 6 Command value power limitation Hi Signal resolution:

0x3fff = 100 % 8 7 Command value power limitation Lo

9 8

10 9

11 10

12 11

13 12 PVSEL Hi

(only active if bit MODE = 1)

Selecting pump type

14 13 PVSEL Lo

(only active if bit MODE = 1)

15 14

16 15


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6.5.2 Definition of the control bits:

Byte 0 – Control word Hi-Byte

Nr. Bit Function

1 0 TYPE F/PQ

(only active if

MODE = 1)

0: Only displacement control (TYPE F)

1: Pressure valve is active, too (TYPE P or Q)

2 1 TYPE P/Q

(only active if

MODE = 1)

0: Open loop pressure control (TYPE P).

1: Closed loop pressure control (TYPE Q).

3 2

4 3 MODE 0: TYPE and PVSEL settings in module.

1: TYPE and PVSEL settings via Profibus

5 4

6 5 RAMP 0: Ramp function is not active.

1: Ramp function is active (recommended).

7 6 P CTRL

(only active if

TYPE F/PQ = 1)

0: Pressure controller not active, valve is controlled by 100%.

1: Pressure controller is active.

8 7 ENABLE1 0: Module is not activated, output is deactivated.

1: Module is activated, if hardware ENABLE is available, too.

Byte 1 – Control word Lo-Byte

Nr. Bit Function

1 0

2 1

3 2

4 3

5 4

6 5

7 6

8 7


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6.6 DATA send to PROFIBUS

6.6.1 Feedback map

Totally, 16 Bytes will be sent to the Profibus.

Nr. Byte Function Remark

1 0 Status word Hi unsigned int

2 1 Status word Lo

3 2 Feedback displacement Hi Signal resolution: 0x3fff = 100%

4 3 Feedback displacement Lo

5 4 Feedback pressure Hi Signal resolution: 0,1 bar

6 5 Feedback pressure Lo

7 6

8 7

9 8

10 9

11 10

12 11

13 12

14 13

15 14

16 15


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6.6.2 Definition of the status bits:

Byte 0 – Control word Hi-Byte

Nr. Bit Function

1 0 Pressure sensor 1: No feedback error.

0: Feedback error ( signal below 4… 20 mA).

2 1 Pressure valve 1: No solenoid error.

0: Broken wire to the solenoid.

3 2 Power limitation 1: Displacement valve is limited by power limitation.

0: Displacement control is not limited.

4 3

5 4 Displacement sensor Q 1: No feedback error.

0: Feedback error, signal is out of range.

6 5 Displacement valve Q 1: No solenoid error.

0: Broken wire to the solenoid.

7 6

8 7 READY 1: No error, system is enabled.

0: An error is detected or ENABLE signal is not available.

Byte 1 – Control word Lo-Byte

Nr. Bit Function

1 0

2 1

3 2 D-error 1: No data error.

0: Data error in EPROM detected.

4 3

5 4

6 5

7 6

8 7


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6.7 ST (Status request)


ST - Bit|Hex

This command is only available in terminal mode. Typing in and sending reads back control word, status word and command values.

The display looks like the following:

High Byte / Low Byte

Control word: 1000 0011 / 0000 0000

Status word: 0011 0011 / 0000 0100

Command Value Q: 2333

Command Value P: 9f6

Command Value L: 3ffe

Control word and status word are shown in single bits, beginning with the highest one.

The command values are displayed hexadecimal; a “0” at first place will not be shown.

7 Appendix

7.1 Failure monitoring

Following possible error sources are monitored continuously:

Source Fault Characteristic

Feedback signal PIN 6 Out of range. The output will be switched off.

Feedback signal PIN 14

4… 20 mA

Out of range or broken wire. The output will be switched off.

Solenoid P on PIN 17 + 19

Solenoid Q on PIN 18 + 20

Wrong cabling, broken wire. The power stage gets deactivated.

EEPROM (at switching on)

Data error The output is deactivated.

The module can be activated by saving new parameters (pressing of the SAVE Button).


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7.2 Troubleshooting

It is assumed that the device is in an operable state and there is communication between the module and the WPC-300. Furthermore, the valve control parameterization has been set with the assistance of the valve data sheets. The RC in monitor mode can be used to analyze faults.

CAUTION: All safety aspects must be thoroughly checked when working with the RC (Remote Control) mode. In this mode the module is controlled directly and the machine control cannot influence the module.

FAULT CAUSE / SOLUTION

ENABLE is active, the module does not respond, and the READY LED is off.

There is presumably no power supply or the ENABLE signal (PIN 8) is not present.

If there is no power supply there is also no communication via our operating program. If a connection has been made to the WPC-300, then a power supply is also available and you can see in the minitor if ENABLE is available.

ENABLE is active, the READY LED is flashing.

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 14 ( 4… 20 mA)

• Signal out of range at the input PIN 6

• A broken cable or short cut to the solenoids

• Internal data error: press the command/SAVE button to delete the data error. The system reloads the DEFAULT data.

With the WPC-300 operating program the fault can be localized directly via the monitor.

ENABLE is active, the READY LED is on, controller is unstable.

Often it is a hydraulic problem.

Electronic problems may be:

• Power supply has intence disturbences.

• Very long cables (> 40m) to the solenoids (->unstable current control loop) 2

• Unstable current control loop because of the solenoid controlling. In some cases the settings of PWM and DITHER is problematic.

o High PWM frequency (e.g. 2600 hz), a dither is needed, parameterized as good as possible adapted to the valve.

o Low PWM frequency (100… 400 hz), the DITHER amplitude has to be switched off, means setting it to “0”.

• Unstable PID control loop (Displacement control).

The P-, I- and D-gain have to be checked. First steps trying to locate the problem:

o Decreasing P-gain (maybe to the half of the actual selected value)

o Increasing I-gain (relative long reset time)

o Decreasing D-gain

o Observing the behaviour of the controller and evaluate how it has changed. Depending on the results further optimization procedures can be reflected.

2 Maybe the current control loop (PPWM and IPWM) has to be optimized. This is rare neccessary. Possible settings in

critical cases are: PPWM = 3 (1… 3) and IPWM = 100.


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8 Notes

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