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PLD User Manual - High Country Tek

1. V30D V Controller 24 250mA_ 750mA 80 100Hz 20 40 Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 8 PowerLine User Guide Coil E Dither Dither Valve Type Voltage as ae Frequency Amplitude V Hz WE ne SS Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required E HYDRA FORCE Coil Dither Dither Valve Type Frequency Amplitude Hz Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required Coil Min IMax Diner SES Valve Type Voltage V mA mA ier SR ERC LL 18 LL 22020 70 TI 50 100 12 4 4DP02 single OR dual coil 2200 2700 50 100 4DP02 single OR dual coil 4DP01 single OR dual coil 1100 1300 50 100 3DP03 single OR dual coil 200 1500 1700 250 TI 50 100 550 750 50 100 1250 1500 50 100 3DP06 single OR dual coil 12 400 1500 1700 50 100 3DP06 single OR dual coil 550 750 50 100 Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required 3DP03 single OR dual coil Part No 021 00155 RevD7 PowerLine System Controller Us
2. C Troubleshooting General Considerations The PWR Ok LED must be steadily on not flashing for correct unit operation This LED will be off if the power supply is too low and flashing if the power supply is too high Intermittent low power supply conditions also cause flashing Large noise spikes on the power supply can cause the unit to temporarily shut down due to over voltage The INPUT ERROR LED flashes if there is a fault with the COMMAND IN or PULSE IN inputs The PWM A and B LED S are on when their coil is driven They range from red driving 0 through green driving 100 The LED S flash red off for shorted coils and green off for open coils COIL leads shorted to power or ground may be interpreted as either a short or open COIL leads shorted to power or ground will be indicated as a short or open on whichever coil is driven first NOTE The unit WILL NOT drive coils after a short or open until the controllers power is cycled or disabled then re enabled by the ENABLE IN signal The trouble shooting mode of Manual PWM is available to drive the coils without reference to the pulse input This allows using a Virtual Pot on the computer to control the coil current Valve selection for coil A or B is obtained though the use of a Soft Switch next to the virtual pot Manual PWM applies 0 to 100 of the power supply to the selected coil output and does not regulate current against power supply variations or
3. 24 20mA_ 650mA 50 150Hz 20 40 EMP 21V10 IS 400mA 1380mA 50 150Hz 20 40 EMP Vin 24 200mA 690mA 50 150Hz 20 40 EMP31S 0 12 240mA 1200mA 50 150Hz 20 40 EMP31S 24 120mA_ 600mA 50 150Hz 20 40 EMP31V_ 12 400mA 1 000mA_ 50 150Hz 20 40 EMP31V_ IL 24 200mA_ 500mA 50 150Hz 20 40 EMP31810 ISL i50mA 1 200mA_ 50 150Hz 20 40 EMP ae LI 24 Dm 600mA 50 150Hz 20 40 EMP av 12 400mA 1560mA 50 150Hz 20 40 EMP av LI 24 200mA 780mA 50 150Hz 20 40 EMP4S 12 i00mA 870mA 50 150Hz 20 40 EMP4S 0 24 200mA_ 1750mA_ 50 150Hz 20 40 EMP4V 12 100mA 870mA 50 150Hz 20 40 EMP4V 24 200mA_ 1750mA_ 50 150Hz 20 40 PMV L 200mA 1260mA 60 150Hz 20 40 PN 90 00mA 630mA 60 150Hz 20 40 PDM PDV 12 i90mA_ 1200mA_ 50 150Hz 20 40 PDM PDV 24 i0mA 680mA 50 150Hz 20 40 PMZ LL 12 200mA 1260mA 50 150Hz 20 40 PMZ Li 24 OA 630mA 50 150Hz 20 40 SE Sizes2 amp 3 12 380mA 1 900mA 60 150Hz 20 40 SE Sizes2 amp 3 24 190mA 950mA 60 150Hz 20 40 SEH Sizes2 amp 3 12 250mA 1 260mA 60 150Hz 20 40 SEH Sizes2 amp 3 24 i30mA 630mA 60 150Hz 20 40 SWS2 12 400mA 1350mA 50 150Hz 20 40 SWS2 24 260mA 880mA 50 150Hz 20 40
4. Status Anti Stall Mode Enable Switch ON Normal Operation Coil A Digital Inputs Enable High ek acd fe CurrentTarget Amps 1 188 Coil Current Amps 1 205 Command Volts ban Supply 13 68 Sample B Log D Output Current A p Current B MAX Slow RPM deadband Stop RPM Center Command Input IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 22 e C Proportional Valve Driver Mode Selection from Menu gt Control Logic gt Valve Control Mode This mode allows you to adjust the coil current based on the command input This method is typically used in situations where the output current needs to be controlled directly using a joystick The valve driver can operate in either dual coil or single coil mode Figure A shows the characteristics of the valve driver mode in dual coil mode which is ideal for directional valve control or for pump swash control Figure 8 shows single coil characteristic which is ideal for flow or pressure control operation Output Current B MAX deadband Center Command Input Figure A Coil Current vs Command Voltages in Valve Driver Mode with dual coils
5. Max 40 to 85 Deg C max Page 14 et PowerLine User Guide C i G f tf Opto 3000 USB serial Interface The Opto 3000 is the newest way to interface with any PC running Windows XP Professional and Vista Business or Ultimate to program or observe operation of the PowerLine module The unit is USB compatible comes with all the cables needed to start work immediately The Opto 3000 gets power from the PC USB port so the user should take care to select a port that can support 5VDC output beware of USB expansion hubs with maximum load limitations The unit has TX and RX LED s available to allow the user to observe activity on the communications cable The kit has all the parts you will need to connect and or externally power the interface as required To begin using the Opto 3000 Locate a free USB communications port on your computer Connect and secure one end of the supplied USB cable into the port of the computer the other end into the Opto3000 connector Optically Coupled Communication Port Opto3000 SN A00001 NA i Hel o www higheounirylok com Ka e Ze Important NOTE The optical interface head that mechanically connects to the PowerLine module has a RED mark on one end This mark should be facing towards the PWR OK indicator Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 15 et PowerLine User Guide C Software PowerLine Insta
6. show an error led and will output PWM current equivalent to the Imax setting The module which should be protected by an AGC5 fuse as reccomended will be regulating and will not damage itself in this mode but the issue can only be diagnosed by using the GUI and observing that the current is changing but the PWM is only moving to a max of 5 of max output If power is applied to the controller while connected to an existing open circuit the module will not detect this or show an error led until the PWM output is commanded to control current Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 7 AM PowerLine User Guide Hcl Module Compatibility and Valve Settings To HA WS HYDRAULICS Coil Dither Dither Valve Type Voltage Frequency Amplitude V Hz PSV Size 2 12 450mA 1160mA 40 70 Hz 55 20 35 PSL V Size 2 24 225mA 580mA 4070 Hz 55 20 35 PSL V F Sizes 3 amp 5 12 620mA_ 1 960 mA 4070 Hz 55 20 35 PSL V F Sizes 3 amp 5 24 310 mA 630 mA 40 70 Hz 55 20 35 EM 21 DISIE 12 BU mA f 1200mA 50 150Hz 20 40 EM 21 DISIE 24 e MA 630mA 50 150 Hz 20 40 EMP ZS 12 550mA 1100mA 50 150Hz 20 40 EMP21S 24 240mA_ 480mA 50 150Hz 20 40 EMP21V_ 12 500mA f 1 000mA 50 150Hz 20 40 EMP21V_ 24 200mA_ 500mA 50 150Hz 20 40 EMP Zem ISL 40mA 1300mA 50 150Hz 20 40 EMP Zem
7. 1 530 265 3236 or E mail us through our website at www hctcontrols com giving details of your issue and how we can contact you Introduction This manual is designed to provide information needed for the installation and use of the Power Line Valve Controller Its intended user is qualified trained service personnel that understand the hazards involved in an electromechanical environment It is recommended that this manual be read in its entirety before installation is begun with particular attention paid to caution and safety information Cautions Changing setup values and limits under computer control while the machine is operating may cause sudden machine movement which may lead to possible injury or death It is strongly recommended that any moving parts are disabled prior to any alignment procedure whenever possible In any case caution should be exercised during any procedure and work should be completed only by qualified trained personnel Warranty Information High Country Tek Inc Guarantees this product to be free of defects in materials and workmanship for a period of one year extending from the date the unit was shipped from the factory Within this time frame High Country Tek will provide evaluation of warranted items free of charge Warranty repair or replacement will be at the factory s discretion If necessary contact the factory for return authorization by phone 530 265 3236 Fax 530 265 3275 E Mail Service hctconirols
8. A If UP setting A 11 te T H ee CT Auto Reverse y ime Di Ramp PWM B PWM B E 2 PWM B Full OFF Ramp PWM B 100mS Geesse 7 400ms Dwell Dwell setting IMPORTANT NOTE Reverse feature ON OFF setting The reverse feature is turned OFF by setting the Auto Reverse Time to 0 ZERO seconds The auto reverse feature is turned ON if there is any time entered in the Auto Reverse Time box The minimum reverse time is 0 5 seconds while the max is 85 seconds Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 21 e Horse Power Limiter amp Anti Stall with Max Command Selection from Menu gt Control Logic gt Anti Stall w Max Command Anti Stall w Max Command is the same as tT T PowerLine User Guide Anti Stall except for the addition of the COMMAND input that adjusts the MAX current The effect of the COMMAND input is exactly the same as changing the MAX current setting with the adjustment range of the analog input being the MIN to MAX current values set by the Opto 3000 See the graph in figure 7 Anti Stall w Max Command mode can be used to give the operator a joystick controlled load horsepower or load speed adjustment in addition to the automatic load reduction process that prevents stalling the engine Figure 3 Coil Current V s Command Voltages in Anti Stall w Max Command Mode File ControlLogic Setup Help
9. Areas where other AC or DC coils HAVE NOT been fully Suppressed Use a power supply that is not rated for the correct required O P current under full load Allow wires TO or FROM the unit to short circuit to each other or chassis cabinet e t c Attempt to use this unit in areas of intense RF without adequate screening measures Disconnect or connect wires to or from this unit unless it isolated from the power supply Use this unit in temperatures that exceed those specified as operation may be effected Start this unit without ensuring ALL work areas are clear of personnel Software Safety The software has been carefully written to give the user the maximum system configuration flexibility while being transparent in operation and easy to use even for novice system builders and operators To ensure safety when using the software and to prevent accidental connection to another module that is not a PowerLine rules have been written into the software to ensure correct operation at all times When the PC running the GUI is first connected to a powered PowerLine and before any data exchange can be allowed a Handshake takes place that confirms the internal software BIOS is compatible the serial number and the PowerLine part number The GUI then checks to ensure that its own revision is compatible with the module software and only then allows the PC and the module to communicate and share data lf at any point during the process abo
10. PowerLine User Guide PowerLine v1 50 BIOS Ver 6 90 High Country Tek Inc 208 gold Flat court Nevada city CA 95959 U S A Website www highcountrytek com Copyright 2007 National Instruments Corporation Current T All nights reserved Log p Always use this method of terminating the PowerLine PC program This cleanly exits the program and also releases any communications port s in use for other applications Log Data A data logging feature is available to log the RPM Coil Current and RPM set point This feature is useful for system troubleshooting and remote debugging The Log Data button is used to start the data log process The user is prompted for a file name and location after the data has been collected The data log contains 250 samples The timer period of the data log is less than a half of a minute on a fast computer to several minutes on a slow computer The log file is text and may be read into a spreadsheet and graphed Part No 021 00155 RevD7 Choose or Enter Path of File PowerLine System Controller User Guide ave in O Manual PLD data W 021 00076 Rev B doc 64 anti stall PLD A docx WPL User Guide Rev AO doc p Power Line Manual Mrkup pdf EF PowerLine GUI changes doc E PowerLine V1 5 screen shots doc E PowerLine v1 50 aliases fe PowerLine v1 50 exe PowerLine v1 50 ini File name All Files Save as type Page 32 et PowerLine User Guide
11. Will transition through Orange e Coil A PWM B Coil B Output B LED Coil A Green full ON INPUT ERROR Coil B Red full OFF Power Line Power COM 12 way input Will transition through Orange Sig COM output connector CMD INPUT S N A00001 Input or Feedback Error SMN 400001 Pulse INPUT indicator LED Ref O P Ze Enable I P Mounting through www highcountrytek com Direction 8 E Mounting through hole 8 screw hole 8 screw Wiring Use 16 AWG wire for power and coil wiring Use of shrouded coil connectors is always recommended Shielded cables are preferred for the pulse and command inputs as these are typically low level analog signals This will minimize potential cross talk between cables that are bundled or in a cable harness Additional noise protection can be obtained by shielding the coil and power cables The shields should be grounded only at the unit end of the cable Long cable runs with any other cables especially high voltage or those carrying switching type signals in close proximity of each other should be avoided Take extra care to isolate any cable that are connected to high voltage AC electric motors variable frequency or variable voltage drives Protecting the unt e pulse input from external noise is very important and can save a lot of time in troubleshooting NOTE The unit MUST be installed with an in line fuse in the positive supply cable Use only an AGC 5 fuse Locate the fuse
12. a short circuit to either power or ground NOTE lf a COIL or COIL is short circuited or open circuited while being driven the controller will shut down its outputs until the user cycles controller power or disables then re enables the module Check the card at full on and full off Do not try the full on test if the power supply is higher than the coil s rated voltage To test the card at full on use the control software to go to Open Loop PWM mode and set the PWM to 100 Full ON Measure the voltage across the COIL and COIL and from POWER to POWER COM The voltage difference should be no more than approx one 1 volt if the card is operating correctly Full OFF To check the card at full off Enter the GUI and go to the Manual PWM screen and set the PWM to 0 in open loop mode Measure across the COIL to COIL voltage which should be zero volts Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 34 AM PowerLine User Guide Hel Valve not being driven to maximum lf the card passes the full on test above the problem is potentially in the system or wiring 1 Check the controllers Max settings through the GUI and make sure they are correct 2 Dry test the valves Turn off the hydraulics pump Ensure there is NO system flow or trapped pressure Make the equipment safe to work on for you and others Command the valves using GUI manual mode to maximum Measure the voltage at the power s
13. applying the load Slow RPM Figure 2 Coil Current vs Demand in Part No 021 00155 RevD7 PowerLine System Controller User Guide Anti Stall Mode Page 20 et PowerLine User Guide C Horse Power Limiter amp Anti Stall Mode with Reverse Selection from Menu gt Control Logic gt Anti Stall Mode with Reverse The PowerLine controller has a new useful function that combines Arnti stall with a reverse feature PowerLine v1 50 BIOS Ver 6 90 File ControlLogic Setup Help This feature will allow the user to set up the anti stall as normal with SLOW and STOP limits with the difference being that if the monitored RPM reaches the STOP limit the controller will turn the PWM A Output fully off then turn the PWM B on to offer a reverse feature _CoilB Coil Open Digital Inputs Enable High eas IRE PERV RET VI The ramps used for the PWM A and ge Current Target PWM B are set in the process setup Mil ren Setup window as shown here SET 7 More Current More Speed Ramp A Down P0 Sec V Enable Active High Ramp B Up S Ser Enable Enable Ramp B Down GE Sec _ Enable Direction P Sho C Ramp to 0 if Disabled Gei z _ Anti Stall Current to 0 etpoin GEES Normal RPM level RPM STOP l oN fy Setpoint T Ramp set by rate of RPM decline PWM A Full ON ki PWM A l Output Ato H f NT Ramp ZERO PWM
14. coil resistance changes Note Care should be exercised when driving coils that are rated for lower voltages than the controllers supply voltage i e 12V coil with 24V supply Over Driving a valve coil may will damage the coil by overheating The switch inputs have on screen indicators that toggle when that switch function is enabled Running graphs allows the viewing of several input and output signals The PULSE IN voltage display is useful to verify that the pulse sensor is providing the expected voltage swing Note that this signal does not show pulse shapes but does indicate the range of amplitudes detected by the unit These graphs can also be used to aid in tuning the dynamics of the system regulation A LOG button allows saving the unit settings and sampling the inputs to the PC for later analysis multiple logs can be saved into the same file Logs should always accompany trouble reports to the factory if possible Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 33 et PowerLine User Guide C On Site Testing If the set up procedure does not achieve the desired results double check the wiring and perform the following tests Record the test results Tools required A PC running Windows XP and an Opto 3000 are required for initial set up programming or observation of the controllers operation through the RS232 port The PC can also be used for uploading the configured program to new PowerLine modul
15. com or by writing our service department at High Country Tek Service Dept 208 Gold Flat Court Nevada City CA 95959 To help us serve you better please have the units full Model Part Number and Serial Number available when contacting the factory for any reason Do not return products to the factory without prior authorization and a RMA number attached Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 2 AM PowerLine User Guide Hel Manual Index OER felt de 1 ME 2 KEE EE 2 Waranty WMO VU ereechen 2 TAD UAW Vue TC EE 3 Product Application Guidelines sss sssssssss sss sese esse essen enesenn enen ennenen enen 4 PowerLine flexible configurations sss ssssssssssss esse sees s ees ees esse nenes eenn nenen ennenen ene 5 M d le TUE a E 6 Module Compatibility and Valve SetiingdS sssss sss ssss sss sese s ese esec ese eee enen 8 Module Connections ccccceccsccsscnecneensenecneeneeceeeseeseuseuseuseuueusenseueeneeueseeseeseaueueeuseneeeeeeeenenes 11 PowerLine Dimensional Information sss sssssss svec esse sse eves sese esea enean e neeaae 12 Electrical Specification Overview sss ssss esse esse sees sees esse eee enen eena 14 Opto 3000 USB serial Interface s sssssssss sese ess sese esse ennenen ennenen enean ennenen 15 Software PowerLine Installation ssssssss sss ss ssss sss esse e enean aenean ennenen 16 SYSIEM e EE 16 Using The PowerLine application ccccccescsescsesceeseeseeessensensenseasee
16. deg settings are used when the Command Center gl Z3 Error Detection check box has been checked Auto Center OFF Auto Center en High Command Input Error reported when Auto Calibrate all SR reference volts are greater than High Low Command Input Error reported when Min 32 00 Low Sin op Low 34 33 reference volts are less than Low Auto Center The voltage from the joystick is used during power up as the center command voltage if it is within the Auto Center limits set below Check this box to enable auto center detect on power up Auto Center This setting is used to calculate how far a joystick can be out of the center set point in the command range On power up and sets limits for the Auto Center feature Deadband This setting installs a Deadband over the center portion of the command voltage range that is plus and minus percent from Command center When the Command Input Voltage is in this range the coil outputs are disabled Auto Calibrate oe Command Input Setup This feature is used to gather information about the input command signal The command range C Command Error Detection Command Selection te Du ei command error limits and reference error limits Bs eee ee Command Error Default 00 are set automatically The user moves the input command to minimum and maximum pausing momentarily then returns to center and presses the Ok button The values are then stored in the control
17. range Coil B current setting range Coil A amp B Protection Ramp A max setting range Ramp B max setting range Dither frequency Hz range Dither amplitude max Process P term scale factor range Process I term scale factor range Industry Compliance Environmental IP rating NEMA rating Humidity Storage Temp range Operating temp range PowerLine System Controller User Guide PowerLine User Guide High Country Tek unique size and mounting 12 way heavy duty screw terminal 9 30VDC absolute maximums 400mA quiescent valve currents User supplied in line fuse AGC5 5VDC 10 short circuit protected 5mA Absolute maximum current limited DC Voltage and pulse 0 5VDC or 0 10VDC 4 20mA 100 Ohm resistor load 0 30 KHz 0 30V absolute max 0 5V or module supply 10 KOhm All through graphical user interface software 0 3000mA with current feedback circuit 0 3000mA with current feedback circuit Open and short circuit detect circuit 0 10 seconds up and down 0 10 seconds up and down 0 250Hz 0 5V Pk Pk 0 7 0 7 Designed to meet latest CE certification standards Totally encapsulated unit for mechanical protection IP68 Module only derate for connectors as required 6P Module only derate for connectors as required 95 100 Non condensing 60 to 90 Deg C
18. to LV e change from minimum output current to maximum output current Le 0 100 Ramp A Up OQ Se Smaller changes within this window will be a Ramp A Down 93 v Enable Active High ratio of this value Commands to change coils Ramp B Up gt 7 Enable Enable will be delayed by the ramping process Ramp B Down SZ e _ Enable Direction In RPM regulation mode the user can adjust P i _ Ramp to 0 if Disabled the speed of the change in the set point due to 2 _ Anti Stall Current to 0 changing command input This does not affect Time ms 5 Command Reverse Acting the speed of process regulation at a given set Sia point REM Siw In load limiting and horsepower limiting mode Auto Reverse Time the user can adjust the speed of the change in current due to changing command input Process P I and I Time These settings are used to tune the units response to input and output changes The P and I values have a range of 0 to 255 with default values of P 10 and I 2 The Process time range is 4 to 512ms default value 50ms The default values typically produce a slow response time in the system A detailed explanation of these settings can be found in this user guide under the heading PID The Basic Technique for Feedback Control The user can adjust the process control parameters here to tune the rate and aggressiveness of the speed change relative to feedback as well as system under overshoot for the speed regulatio
19. 21 00155 RevD7 PowerLine System Controller User Guide Page 37 PowerLine User Guide Hc Ordering Guide pL oi G Valve Coils D Dual standard The standard is for DUAL coil output V User special option with single coil control being selected through the set up software Current Range O to 80mA EDC Valve 0 to 90mA 2 x 240 EDC valves in series Die Se de E S m to m wit m resolution V option is user specific 90 to 150mA 1 x 240 EDC valve W O to 63mA please contact factory X O to 125mA Y 0 to 250mA Connector Z 0 to 500mA l The PowerLine comes with the E O to 1 0 Amp i integral 12 way terminal block as K O to 1 67 Amps standard G 0 to 3 0 Amps The Q option offers a 12 way v User special option WeatherPak connector on 6 inch leads The V option is a user specific connector please contact factory Blank Terminal Block Standard Q WeatherpaK Connector V User special option PowerLine PowerLine controller controller shown with optional here with Weatherpack connectors use the Q connector option when ordering standard 12 way screw terminal connector z SCDE onee ssia M NOTE Manual Control Potentiometers The PowerLine controller is no longer supplied with a potentiometer Please contact our customer service department to order these items separately Potentiometers available are N Conductive film poten
20. B tick box when using a dual coil valve or bi directional motor or closed circuit pump Dither Amplitude and frequency Hz Dither is commonly used to reduce the effects of valve hysteresis and stiction These parameters can be adjusted to suit the hydraulic product being controlled Optimized values can typically be found in the manufacturers datasheets IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 31 Ze Help The Help dropdown menu offers two choices The first opens a window that gives the user information on the controller Application and BIOS versions as well as contact information for High Country Tek Inc The second option View Help will open a PDF file of this manual to allow the user immediate access to information regarding the controller application set up and troubleshooting Software Controls Exit the program GUI PowerLine v1 50 BIOS Ver 6 90 File Control Logic Setup Help About Controller Status Enable Switch ON Normal Operation 100 Coil Digital Inputs Enable High Ds EE Click the Exit button on the man screen lower right hand corner NOTE View Help PWM
21. Coil A Connector terminal 2 1 This terminal should be connected to the A coils positive connection It is switched ON or OFF to decide which if any coil will be driven These terminals should not be connected to Power Coil B Connector terminal 3 This terminal should be connected to the B coils positive connection It is switched ON or OFF to decide which if any coil will be driven These terminals should not be connected to Power Coil A Connector terminal 4 Both Coil A and Coil B are internally connected together on the card and should be connected to the negative coil leads These are used to sense coil current control the internal feedback circuit that maintains and regulates current to the coils to recover from heating effects and should never be grounded Coil B Connector terminal 5 Both Coil A and Coil B are internally connected together on the card and should be connected to the negative coil leads These are used to sense coil current control the internal feedback circuit that maintains and regulates current to the coils to recover from heating effects and should never be grounded Power Com Connector terminal 6 This is the main 0 Volts GND power supply connection for the module Sig Com Connector terminal 7 This terminal is internally tied to Power Common Power Com on the card To provide the best possible noise resistance Sig Com should be used as the only grou
22. Enable Active High P T Ramp to 0 if Disabled x Ramp to 0 if Disabled Anti Stall Current to 0 Time ms Command Reverse Acting e More Current More speed This option RPM Stop mandatory in Anti Stall Mode and is automatically RPM Slow set to True then locked by the application software Wao raae TE Anti Stall Current to 0 Completely shuts coil off when RPM is below the Stop Set Point RPM Stop and RPM Slow are set to 1500 and 2100 RPM respectively This sets the Control Range Decoupling the load from the Prime Mover Enable Direction is set to False and direction is determined by comparing the Command input voltage to the Center Volts Setting in the Command Range Auto Reverse is set to zero see the Power Line User Guide for more information about the Auto Reverse feature Coil Setup Sets Maximum and Minimum Coil Current to 1200mA and P coil Setup 120mA respectively Sets Dither to 125Hz 0 Amplitude off Coil A Min 3 12 Amps Dither Hz Bis Col A Max X tude En COANE iI lamps Dither Amplitude Ep Coil B Min En E GE e EDZ Type Coil 4 19 Amps Coil B Max GK Disable ColB Anti Stall with Max Command Default File AntiAnti StallwMaxCommand 2Coil r0 dat Sets module to Anti Stall with Max Command Mode This mode and file is the same as Anti Stall Mode except that the Maximum Current is limited by the Command Input For example if the Command Input voltage were 3 37 volts with the above se
23. High Country Tek Inc PowerLine system Controller User Guide PWM A x x 2 PWM4 B CG D INPUT ERROR Power Line cores ie PLDK PWR COM G N A000032 SIG COM COMMA RIC IN PULSE IN ANA POT REF OUT HET ENABLE IN www highcountrytek com DIRECTION Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 1 et PowerLine User Guide C Welcome to the High Country Tek Inc HCT PowerLine system controller user guide and thank you for selecting this HCT controller to use in your application The following information is designed to allow you to connect set up and optimize the PowerLine module If you have used HCT products before you will recognize some of the instructions and settings For those of you that are new to HCT please read the directions with care and be sure that if you have any questions regarding this industry unique controller then please contact us using one of the numbers given on the back page of this manual We value our customers their experience and abilities and ask that if you would like to see any additions subtractions or find any errors in this publication that you contact HCT s customer service so that we can correct the information and make sure that our programming community is using the latest information If you require urgent support more information or would like specific programming areas clarified you can contact us on the customer support number at
24. Output Current A PowerLine v1 50 BIOS Ver 6 90 PowerLine User Guide File ControlLogic Setup Help Status Valve Control Mode Enable Switch ON Normal Operation Coil Digital Inputs Enable High pm ee Cire yj assa v Output Current ALE MIAA Current Target Amps D 700 Coil Current Amps 0 700 Command Volts 1 06 Supply 13 85 Sample Po Log p Command Input Figure B Coil Current vs Command Voltages in Valve Driver Mode with single coil IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 23 AM PowerLine User Guide Hcl Setup NOTE It is strongly reccomended that the user cycles power to the PowerLine module after saving any program changes to ensure that the setting alterations take place and any old setting data is erased by the controller Ei PowerLine v1 50 BIOS Ver 6 90 File Control Logic Setup Help Pulse Input Setup Command Input Setup Advanced Settings Enable SV process Setup Normal Col Setup Status cB Digital Inputs Enable High bam Valve Current ei Full Scale ei 1 4 LOG DATA From this screen the user has access to all of the setup sub screens and drop downs
25. as close to the power supply as possible to provide protection to both the wiring and the unit Failure to use a fuse invalidates the warranty can be dangerous to the system and also the PowerLine unit Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 6 et PowerLine User Guide INPUT ERROR LED blink code descriptions OFF Input or feedback signal operation is normal Check command or feedback signal for Blinking Error detected or loss of feedback connection signal level and polarity and correct as required Power LED blink code description OFF Power Supply below 9VDC Increase power supply to gt 9VDC ON Power supply between 9VDC and 30VDC NO action normal operation Blinking Power supply above 30VDC Reduce power supply to lt 30VDC PWM A and PWM B Output LED blink code description OFF NO output or not in use Check power supply or module fuse GREEN Respective output fully ON RED Respective output fully OFF ORANGE Respective output in transition or under control Respective output SHORT circuited module turns OFF PWM Turn OFF power and clear short circuit output turn power back on Turn OFF power and re connect open circuit turn power back on Flash RED 2Hz Flash GREEN 1Hz Respective output OPEN circuited turns OFF PWM output SHORT and OPEN CIRCUIT ERROR DETECTION If power is applied to the controller while connected to an existing short circuit the module will not detect this or
26. asenseoeseoeseoeseoeseoeseaeaess 17 File Memory Options E 17 COMO e Le 18 Man al TV E 19 Horse Power Limiter amp Anti Stall Mode sss see 20 Horse Power Limiter amp Anti Stall Mode with Reverse sse eee 21 Horse Power Limiter amp Anti Stall with Max Commande 22 Proportional Valve Driver Mode sss sse eee ee 23 SOU GEN 24 wll KEE 32 ES oun ee le b EE ER TROUDICS INO OU isien EAEE EEEE EREA A aa 33 Application Connection Examples ccccssscccseecceseecenseeceseeeessesenseceeseecensesonseeeeneesonseses 36 Ordering GU HHT 38 Default Files and Set up HDS sss ssss esse sees sese sese ennenen enen nenen eee 39 Valve Driver SONG E 40 Doak ol yawe Bd EE 40 Command e E 40 FOS EE 41 e KE KEE 41 Single Coil Valve Driver 42 Command Input Command Input 42 Srel EE 42 Ry ON EE Ee EE 42 Horse Power Limiter amp Anti Stall Mode ccccsecsescsscneceseesenscusenseeeeeseeseaeeeseeseaueasenesnens 43 KIR Go HR 43 SR e 8 EE 43 Command UM ON GE 43 FOC le E 44 OOS E 44 Anti Stall with Max Command KEE 44 Need More Information EE 45 Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 3 et PowerLine User Guide C Product Application Guidelines ALWAYS do the following Take a few minutes to FULLY read THESE information data sheets BEFORE starting Keep High Voltage AC cables separate from Low Voltage DC signal and supply cables Make sure the unit supply voltage is the same as the
27. coils on the valve being driven Ensure that you are aware of the adjustments and consequences on the electronics and hydraulics Make sure you have the correct tools to do the intended job i e Opto unit P C software e t c Isolate this unit from all other equipment BEFORE any form of welding takes place Check ALL connections to and from this unit to ensure NO short or OPEN circuits Check the units supply voltage is CORRECT ELECTRICALLY CLEAN and STABLE Operate the units within specified operating temperature for best amp reliable performance Ensure that any unused wires terminals are terminated safely and not shorted together Use screened cables wherever possible for best immunity to external interference Use cables that are capable of carrying the required voltage and current for your products and application Isolate the controller if ANY form of battery charging or battery boosting takes place on the vehicle Ensure ALL valve connectors are wired correctly secure locked and connected to correct coils Observe the set up procedures in this manual for best operational results Follow and abide by local and country health amp safety standards protect yourself and others NEVER do the following Arc Weld or Charge Batteries with this driver unit connected as damage can occur Attempt to use this unit if you are unsure of electrical OR hydraulic connections or expected operation Attempt to use this unit in
28. d causes max current Note The Enable Enable check box must be checked for enable active to operate properly Enable the Enable Input When this box is checked the PowerLine will look at the Enable In input to enable the controller When this box is unchecked the PowerLine is always enabled Enable Direction Use of the Direction input allows the user to use the full range resolution of the command input in each direction when applicable This check box enables the Direction Coil B H In input to the controller When selected Coil B will be active when the input is pulled high Ramp to 0 Zero if Disabled This check box determines the units behavior when the enable input is used and changes state When this box is checked the ramp value and method in use with the selected algorithm is applied to turning off the output When this box is unchecked the unit immediately turns off the output Anti Stall Current to 0 Zero When the input RPM is less than the STOP RPM the current will stay at MIN unless this box is checked in which case the current drops to zero from Imin without ramping This option is only active in Anti Stall mode Command Reverse Acting This feature is available in Anti Stall w Max Command mode only When checked the Command Volts Min in single coil operation demands 100 percent current and Command Volts Max demands 0 percent current Warning It is dangerous to do this in dual coil operati
29. e poss 50 La a Housing Type Housing Material Housing Color Surface Finish Housing Thickness Unit size Unit Weight Wire entry Encapsulation Mounting Temperature range Part No 021 00155 RevD7 Sig COM Sone Pulse INPUT JNA Ref O P Heft Enable Up www highcountrytek com Direction High Country Tek unique encapsulated block None solid flameproof epoxy resin block Black dark Grey Gloss 12mm main module 25mm incl Connectors See above size detail drawings Approx 400 grams including Encapsulation material Via heavy duty screw type connector Flame Resistant Black Two Part Epoxy Resin Via through holed 3 suitable for No 8 5mm screw 40 to 85 degrees Centigrade operational PowerLine System Controller User Guide Page 13 H O On On Un BWN ka Q W N N N N N N N N N N kM RP RP RP RP k RP PPR k e G WQ D dd VW P WM ka OD D zl Oh W P W N k O Part No 021 00155 RevD7 AM CI Electrical Specification Overview Board Style Connector Type Input Supply Voltage Input supply current Input supply protection User Reference Voltage User Reference Voltage current Command Input types DCV Command input value range DC Current Command Input Range Pulse Command input value range Pulse command voltage range Enable input value range Enable input impedance Parameter Adjustments Coil A current setting
30. e erratic behavior if the field is strong enough Observe the control inputs on the PC GUI If the electrical noise greater than a few percent of full scale is noticed on an unchanging PULSE IN or COMMAND IN input or if the digital inputs are switching randomly try changing the routing of the control wires to see if the problem changes The use of shielded signal cables is strongly reccomended to avoid the affects of induced input errors Power supply interference or brown outs power supply voltage dips as loading increases or when starting an engine e t c can also cause erratic behavior Observe the power supply on the graph on the PC GUI If large dips are noticed test for a poor supply by running the card off its own fully charged battery Further information Visit our website www highcountrytek com for additional documentation and assistance Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 35 Hcl Application Connection Examples VDC Power Supply Single coil i proportional valve Pressure or i em em em mm mm mm mm pm om mm mm em pm om em pm mm om em pm am m sm A Command Signal Potentiometer or Joystick l OVDC Power Supply I Single coil I proportional S i Pre valve Coll A N Coll B Coil A Gail B d Power COM sig COM GND INPUT Pulse INPUT Ref op Enable LP Direction Pres
31. en to the left This option can be used for coil and system setup and is ideal for troubleshooting NOTE for information The Current LOS Current status message is always displayed not seen on this screen shot on the GUI when using or in this controller mode IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 19 AM PowerLine User Guide Hcl Horse Power Limiter amp Anti Stall Mode NOTE It is strongly reccomended that the user cycles power to the PowerLine module after saving any program changes to ensure that the setting alterations take place and any old setting data is erased by the controller Selection from Menu gt Control Logic gt Anti Stall Single Coil Operation The PowerLine will adjust its outputs as a LEE function of the RPM of a device Anti stall Us eaea setup Help or load limiting progressively de couples the load as RPM decreases to avoid Stalling the prime mover electric motor or engine This method is typically used in situations where the throttle of the engine is controlled by the operator and the load changes independently such as a 82 as Digital inputs propulsion circuit The Anti Stall action is Enable aia u
32. er Guide Page 9 Valve Type DAAL DBAL DLDA DMDA DNDA DNDC DTCA DTDA DWDA FMDA FMDB PRDL PRDM PRDN PRDP RBAN RBAP DAAL DBAL DLDA DMDA DNDA DNDC DTCA DTDA DWDA FMDA FMDB PRDL PRDM PRDN PRDP RBAN RBAP PowerLine User Guide Dither Dither Imin mA Imax mA Frequency Amplitude a ss 1150mA 250Hz dependant on valve size 590 250Hz dependant on valve size Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required Linde Coil l Dither Dither VEO Ue Voltage HO Max ma Frequency Amplitude HPV 02 EI 440 460 810 1200 100Hz HPV 02 E1 215 235 410 600 100Hz Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required 600 700 290 270 00 850 2 0 310 150 210 Note Final optimized settings are valve size and system application dependent Consult valve manufacturer for full details as required Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 10 et PowerLine User Guide C Module Connections Power connector terminal 1 This is the main Voltage power supply input for the module The PowerLine controller will accept 9 to 30VDC NOTE Make sure the unit has an in line fuse fitted to protect the system the module and the warranty
33. es for series production A battery operated multi meter is always a good idea for measuring and confirming analog signals and an oscilloscope would be useful for looking at fast moving or digital signals on the system as well as monitoring the system power input for transients that could cause intermittent operation Check the power input The module will not function correctly unless the POWER supply is at least 9 VDC when driving the coils If the supply voltage is below 9VDC there is a risk of a Module shutting down b Module continuously trying to reset or c Low drive current to valves If the supply voltage is more than 30 VDC there is a risk of a Blown in line AGC5 fuse b Module internal damaged or c Coil damage due to excessive drive voltage Check the control inputs Verify the control inputs are the correct polarity and are hooked up correctly to the correct module terminals by monitoring their status with the PowerLine software or testing with a voltmeter or oscilloscope Ensure that any external control or command inputs have their respective OV or GND connected to the modules power supply OV or GND terminal Verify the coil is not shorted or open Disconnect the wires going to the COIL and COIL terminals and measure the resistance between the wires Verify it is in the expected Ohmic range for the type and voltage of coil being driven Verify that there is no voltage between either wire and power or ground indicating
34. esired value it is responding to the accumulation of commands over the recent past and its own delay It can be assumed that the system is responding to commands issued one Update delay ago Simply freezing the controller s output when the system hits the commanded value will cause overshoot as the system catches up to the value that is now commanded and goes past the set point The process variable then overshoots the set point causing an error in the opposite direction This results in an oscillation of positive and negative error The PID constants determine the extent if any of this oscillation and how soon it dies out The smaller the P and I terms and the longer the time the slower the controller will respond and the less over shoot and oscillation will occur Critical damping can be achieved with the process brought smoothly up to the set point with no overshoot at all The tradeoff of achieving critical damping is a much slower system response to changes of load or set point In the opposite extreme it is possible to tune the system for continuous and violent oscillation The user must tradeoff system speed of response against the amplitude and decay time of the oscillation Now suppose the process responds quickly to the controllers corrective efforts The integral term in the equation will not play as dominant a role in the controller s response to changes since the errors will be so short lived Part No 0
35. he following illustration 5 of Command Selection is 25V with the center at 2 24V there will be no output drive until command volts is above 2 49V or below 1 99V i PowerLine v2 00 BIOS Ver 6 90 File ControlLogic Setup Help Status Valve Control Mode PWM 0 100 Enable Switch ON Command Error Normal Operation Digital Inputs Enable High 0 Valve Current wei FullScale e 00 T Current Target Amps pooo 0 Coil Current Amps Dong ZE Command Voltz _ commer umas re gd Supply haos wT Sample bi Ch Log Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 40 et PowerLine User Guide C 1 T Process Setup Sets the Ramp Rate for both coil A and B to 3 seconds Up or Down Process Setup Sets the following options to True SH More Current More Speed e Enable Enable Enable input pin is active dl X Enable Active High Ramp B Up Enable Enable e Enable Active High 12v at the enable input will Ramp B Down Za C Enable Direction enable unit p Ramp to D if Disabled e Anti Stall Current to 0 e Ramp to 0 if Disabled Ramps if disabled Timeme Be eee RPM MIN e More Current More speed This option should be RPM MAX set True whenever in Dual Coil Valve Driver Mode This is forced on in the Dual Coil Valve Driver mode Auto Reverse Time e Enable Direction is set to False The direction is determined by comparing the Command input voltage to the Ce
36. ing Control Logic B PowerLine v2 01 BIOS Ver 6 90 File Kemna Setup Help This drop down menu allows the user to _ Aan un T ie select what control mode the controller will oo mr mr operate in moma operatorn 80 60 1 Manual PWM control Set up Wa a 2 Anti Stall Reverse option available e cB Digital Inputs 3 Anti Stall with Max Command Enable High A Valve Control Single or dual coil 0 70 Valve Current v Full Scale v Current Target Amps Coil Current Amps Command volts Supply 6 16 Sample IO Log i IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 18 par C Manual PWM Selection from Menu gt Control Logic gt Manual PWM Mode PowerLine v1 50 BIOS Ver 6 90 Fie ControlLogic Setup Help Status Manual PWM Mode Enable Switch OFF Starting Coil Digital Inputs Den Valve Current ei Full Scale ei Coil Current Command Volts Supply Sample 0 Log p PowerLine User Guide This feature allows the user to manually control the output current to coils A and B PWM by the using the Virtual Potentiometer shown colored as Yellow on the scre
37. ing to manually determine the required values for a particular installation Caution Use of this selection temporarily prevents the unit from working in the system Do not select this option while the machine is operating Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 17 AM PowerLine User Guide Hcl Selection from Menu gt Restore Temporary Memory from Permanent Memory Restores settings stored in permanent memory to temporary operational memory Caution Use of this selection temporarily prevents the unit from working in the system Do not select this option while the machine is operating Ei Powerline vi Sp BIOS Wor 40 E pls rie Coepdlog Sete Help nave Ierger Mamory Fo Permanent Meer EE Su T rary Pet hal ma Sit empora Memory b Perag Memory Barbe a mt C C A Restore Temporary Memory fom Permanent Memory ap SCH Lo Restore Temporary A Pemereg Memory from a Fike e R Selection from Menu gt Restore Temporary amp Permanent Memory from a File When this selection is made the user is prompted for a file name and location from which to retrieve settings The restored values are placed in temporary and permanent memory GT Digital neu ani Enable igh ba Wave Greg ei HA Sema ei Core Target Amps 0 195 Cod Curent beans 03 Caution Use of this selection temporarily prevents the unit from working in the system Do not select this option while the machine is operat
38. lers temporary memory The user must then select the Save Temporary Memory to Permanent Memory menu option to permanently save the calibration settings Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 27 et PowerLine User Guide C Advanced Settings Selection from Menu gt Advanced Settings Process P and Term Scale These values allow for scaling the P and term scale These values are only editable when the controller is in RPM Regulation Mode These values represent the number of times to divide the effect of the P or term by two Therefore larger shift values will increasingly reduce the effects of the P and terms The P shift value can be from 0 to 7 default 5 The I shift value can be from O to 7 default 7 These setting should only be changed Process P Term Scale Factor when the use of process P and time values were not able to tune the process Refer to Tuning a PID controller Process I Term Scale Factor Ln K Current P Term baal aie La Lale Laie Current I Term Ki NOTE These settings are pre set for optimal response and are only available with the correct password please contact HCT factory for further information Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 28 et PowerLine User Guide C Process Setup Selection from Menu gt Process Setup Ramp Up and Ramp Down The units seconds are the time taken
39. llation You are now ready to install and start the PowerLine program by Inserting the software CD and running the setup exe program follow the on screen instructions After installation the program will be found in the Start menu group called HCT Products Gi Find Opto Link Once the software has been installed restart your computer Before you find and run the PowerLine software program ensure all mechanical and electrical connections are secure between the PC and the Opto 3000 and that the PowerLine module is connected to a correct power supply and turned ON When the software is started and depending on your PC software set up the first thing it will do is to find the connected Opto 3000 and may display the screen on the left while it is doing this operation After a few seconds the available Communications COM ports will show up as Green Select the port being used for communications If you are correct the screen left will disappear and the main program screen will replace it congratulations you are now communicating with the PowerLine controller In most instances when using the Opto 3000 the PC will detect the unit as soon as it is connected and automatically select a port and start the PowerLine user interface System Requirements Windows XP Professional Vista Business or Ultimate sas 256MB RAM or greater GC E Serial Port RS232 or USB Adapter aes Opto 3000 and USB cable Soe Normal Opera
40. lve or pump control effectively de coupling the load from the motor The active nature of this mode allows the machine to find the optimized work rate and still support healthy engine RPM 2a Horse Power Limiter amp Anti Stall with Reverse Ideal for system such as auto feed wood chippers or any applications that need a reverse feature if the engine starts to stall because of a forced load 3 Horse Power Limiter amp Anti Stall with Max Command Used to protect an engine from stalling by progressively reducing the hydraulic load either by valve or pump control effectively de coupling the load from the motor Extra Features are provided to allow the user to vary the maximum command signal with a pot or joystick during Anti Stall operations 4 Valve Driver Direct open loop control of single or dual coil valves or pump controls The last mode provides a quick easy method of controlling single or dual coil valves or pump strokers This unit will drive all the major OEM products and can be set easily to interface with a simple joystick or work from an external command signal of either voltage or current Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 5 et PowerLine User Guide C Module Familiarity Power ON led Clear optical communications LED Opto2000 or Opto3000 Mechanical mount Mounting through hole 8 screw Output A LED Green full ON Red full OFF PWM A S Power
41. n mode Note that the process setup settings directly affect the output current value to the coil Minimum Maximum RPM or Stop Slow The user can adjust the minimum and maximum RPM that is selected by the command input as it goes from its minimum to maximum value in RPM Regulation mode In Anti Stall mode this is the Stop RPM and Slow RPM set point Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 29 et PowerLine User Guide More Current More Speed EE SEA This software selectable feature allows the use of reverse acting single coil valves When this E o 1 More Current More Speed box is unchecked the PowerLine will apply A Down Zb SE Enable Active High Ramp E Up 3 Enable Enable d to 0 if Disabled less current to get higher system speed This feature is only available if Disable Coil B is selected The current when the coil is off will be the MAX current in reverse acting L Anti Stall Current to 0 mode Command Reverse Acting Enable Active High active when enable enable true When this box is checked the PowerLine logic is enabled when there is a high or gt 5 VDC on the enable input pin When the check box is unchecked the unit is enabled when there is a low or 0 volts on the enable input pin The unit is disabled when enable pin is not in the enabled state This prevents driving the outputs unless More Current More Speed is unchecked If unchecked disable
42. nd for the pulse and command sensors Command In Connector terminal 8 This is the analog command input for the controller The Graphical User Interface GUI allows the user through software to choose from several selectable ranges including 0 to 5 Volts 0 to 10 Volts and 4 20mA There is also the facility that lets the user choose Uni or Bi directional operation by setting the inputs so their respective mid points become the zero crossover point i e 0 5V becomes 0 2 5 5 with 2 5V representing NO drive to the valve coils This input has an impedance of 100 KOhms when Voltage Mode is selected and is internally pulled low to allow for error detection and avoid spurious signals if not used Pulse In Connector terminal 9 This is a programmable range input that accepts pulses above up to 30KHz Pulses must cross the midpoint of the range selected to be detected and may exceed the range without damage to the unit if less than 30 Volts Peak Selectable ranges include 1 to 1V 0 to 1 25V 0 to 2 5V 0 to 5V and 0 to 10V A GUI software switch is provided to allow the user to activate an internal 10KOhm pull down resistor on this input Activation of the pull down resistor is intended to provide loading for inductive sourcing or open emitter sensors Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 11 AM PowerLine User Guide Hel Module Connections Cont NOTE sinking or open collector sens
43. nter Volts Setting in the Command Range e All other process options are grayed out and disabled while in Valve Driver mode Coil Setup Sets Maximum and Minimum Coil Current to 1200mA and E coil Setup 120mA respectively Oo Im o mps itner Hz In this instance the Dither has been disabled with a value of UR T 0 Coil A Max Snai Amps Dither Amplitude Yo Sp Coil B Min En H rr EE MS EDC Type Cail _ i Amps Coll B Max 21 19 tests cals m Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 41 et PowerLine User Guide C 1 09 Fi a i LT Single Coil Valve Driver Default File ValveDriver 1Coil r0 dat Sets module to Valve Control Mode using the following settings Command Input Command Input Command Input Setup Sets up the Command Input to act as a 0 5 Volt input Command Error Detection Command Selection lke Ge e with a valid range of 0 1 4 47 Volts Command Error coils off Command Error Default zs Error detection for the Command Input and Reference Command Range Command Error Limits Refernce Error Limits Output are active with a Command Error turning off the Max Si maan High Sin i a coil Center wc Min 0 10 Low 30 04 Low 34 39 Auto Center OFF Auto Center h CMD Deadband o Auto Calibrate SIS SE Deadband is redundant in Single Coil Mode Process Setup Sets the Ramp Rate to 3 seconds Up or Down Process Setup Sets the following options
44. on the Center Voltage will command 100 percent output Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 30 AM PowerLine User Guide Hcl Coil Setup Selection from Menu gt Coil Setup Minimum and Maximum current The user can adjust the minimum and maximum current on a per coil basis The current output will not be commanded outside of these ranges when the coil is on This feature is useful as it allows for Coi AMin 50 20 Amps Dither Hz Bu valve deadband to be reduced making the Coil A Max Bi 29 am Dither Amplitude A mL amps i J system more responsive to small commands around the zero position or point of a command Coil B Min In Amps source i e Joystick e t c The software has a e limit of zero 0 for minimum and a limit of Coil B Max Eh 29 Amps Disable Gan C 3000MA for maximum current Coil Setup EDC Electronic Displacement Control Type Coil This soft switch changes the PWM frequency to a lower setting for use with low current coils to allow for better current regulation Check this box when using EDC coils Note Adjusting the max current above recommended OEM values may damage the coil and will reduce the resolution of the process control Disable Coil B This software switch disables coil B output Check this box when using as a single coil valve or uni direction motor or open circuit pump NOTE Always make sure to uncheck the Disable Coil
45. ors may require an external pull up resistor Pot Ref Out Connector terminal 10 Pot Ref Out provides 5VDC through a 1KQ current limit resistor 5mA max and is typically used for local connection to a 10K potentiometer or Joystick NOTE This outout should not be used as a sensor power supply as it will not supply sufficient current Enable In Connector terminal 11 This is a sinking switch input Activation is achieved by pulling the input high to either 5 Volts or to the module power supply connection This input nominal impedance is 10 KOhms NOTE This input is internally pulled low to prevent a floating input when deactivated or not in use Direction Connector terminal 12 This is a sinking switch input that may be used to activate Coil B remotely This innovative feature allows the user to have full resolution of the command source by choosing when to select the coil B drive output rather than offsetting the command input to mid point Activation is achieved by pulling the input high to either 5 Volts or to the modules power supply connection This input nominal impedance is 10 KOhms NOTE This input is internally pulled low to prevent a floating input when deactivated or not in use Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 12 far 4 j T j PowerLine Dimensional Information Label Inches PowerLine User Guide 3 x 8 screw Coil A Coil B
46. over a recent time interval and the derivative of the error signal to calculate how much of a correction to apply These calculations are done once every I Time but are fast enough to appear to be continuous to the system These three quantities are each multiplied by tuning constants and added together to produce the controller output Error target feedback Pterm P error 24Process_P_Scale_Factor lterm lI Sum_of_error 2 Process scale_factor Output Pterm Iterm Note The derivative or D term is not implemented at this time Tuning a PID Controller How to best tune a PID controller depends upon how the process responds to the controller s corrective efforts Consider a sluggish system that tends to respond slowly If an error is introduced abruptly as when the set point is changed the controller s initial reaction will be determined primarily by the proportional term After a while the integral term will also begin to contribute to the controllers output as the error accumulates over time In fact the integral term will eventually come to dominate the output signal since the error decreases so slowly in a slow moving process The controller s output will lead the process This means that the controller will continue to command ever higher outputs while the process slowly tries to follow Overshoot of the system can occur if the controller is set up to be much faster than the system When the system reaches the d
47. se to select the best range for the application If more than one range works select the lowest range that fits your application Configuration Steps 1 Enter the number of teeth or pulses per revolution maximum 255 2 Enter LOS Loss Of Signal Current 3 Select voltage range of the pulse input under Feedback Selection 4 Select a RPM range that best fits the application choose the range with the highest lower RPM value that will work Application Tips Inductive Pickup Use 1 to 1v for Feedback Selection value Hall Effect Pickup Use 0 5v or 0 10v for Feedback Selection value Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 25 et PowerLine User Guide C Command Input Setup Selection from Menu gt Command Input Setup Command Error Detection S Command Input Setu el Enabled when checked disabled when he P H Seles unchecked Command Error Detection Command Selection U to ov ei Command Error coils off _ Command Error coils off Command Error Default 0 00 active if command error detection true Command Range Command Error Limits Refernce Error Limits activates when a command error is detected Max 34 53 High 44 76 High 93 75 Center 22 29 Coils turned off when checked command Low 40 00 Low 44 33 hats lie e E Error Default Volts Pee BE EE when unchecked ge 5 Command Range Max voltage to determine end of joystick travel Center Pot joy
48. sed to prevent a sudden increase in load from causing the engine to stall before the eae a Feel operator has a chance to increase the e E throttle or decrease the load or to Si EE automatically adjust the load without a Supply a operator intervention sed When the prime mover RPM is less than et the STOP RPM setting the PowerLine outputs MIN current and the load will be completely removed When the RPM is more than the SLOW RPM the PowerLine will output Max current Setting the MAX current value too high can delay the start of load de coupling until an RPM less than the SLOW RPM set point has been reached The separation between the SLOW RPM and Output STOP RPM determines how aggressively the i i i load is reduced This algorithm can be used as Lued Single Coil Operation a continuously variable transmission controller when connected to a variable displacement MAX pump or motor Ramps are provided to tune the response time PID constants do not affect this process This algorithm can cause oscillations if the ramp times are too short in some systems Ramps are easy to tune as there is only one number to adjust per ramp and there are only four independently tunable ramps The ramps are simply increased from zero until the oscillation if any stops or the desired smoothness is achieved Because the ramp settings are independent the rate of reducing the load can be set differently than the rate for re
49. stick center point voltage Min voltage to determine end of joystick travel Command Selection 0 to 5V or 0 to 10V or 4 to20mA options Command Error Default Volts active if command error detection true activates when a command error is detected If the unit Senses a command error this voltage value will be read by the card as the command voltage until the error is corrected Command Error Limits active if command error detection true The Command Error Limits feature will detect and report errors on the Command Input that exceed the user defined set points NOTE lf the command input value is outside the High and Low values entered here the modules outputs will be determined by the Command Input Error settings These settings are used when the Command Error Detection check box has been checked High Command Input Error reported when command volts are greater than High Low Command Input Error reported when command volts are less than Low Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 26 et PowerLine User Guide fap pure oat Reference Error Limits active if command error detection true M erin Command Selection Dia 5v el The Reference Error Limits feature will L_ Command Error coils off Command Error Default 0 00 detect and report errors on the Command ers SS Reference Output of the module that SS p exceed the user defined set points These vax gass Weg
50. sure or Remote command signal source OVDC Power Supply VDC Power Supply Dual coil _ A Rr proportional valve or pump control d Power COM C O Ci OSOSC S CMD INPUT Pulse INPUT Ref O P Enabie LP Direction Remotecommand OVDC Power Supply signal source Part No 021 00155 RevD7 PowerLine System Controller User Guide PowerLine User Guide This first example shows how the controller can be used ina single proportional valve control application The command is coming from a manual source either a potentiometer or joystick as shown here This example shows how the controller can be used in a single proportional valve control application The command is coming from a remote signal source possibly another machine controller This example shows how the controller can be used in a Dual proportional valve control application The command is coming from a remote signal source possibly another machine controller IMPORTANT NOTE DUAL COIL OPERATION The output of either A or B output will go from the respective I Min setting to ZERO OmA when crossing through command mid point The valve outputs do NOT jump from one Min to the other Page 36 et PowerLine User Guide C PID The Basic Technique for Feedback Control The Proportional Integral Derivative or PID controller looks at the present value of the error the integral of the error
51. that will enable the configuration of the particular control logic mode that has been selected The following pages describe the setting available their limits and what the effect is on the application being worked on NOTE Each Graphical User Interface screen may have grayed out settings or look different to the pictures shown in this manual This is due to the settings regarding the mode of operation and or other user settings that may render them invalid or require them to be set to a mandatory set point Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 24 et PowerLine User Guide C Pulse Input Setup Selection from Menu gt Pulse Input Setup Enable Pull Down Resistor Pulse Input Setup vi This check box is used to enable a 10k resistor from the pulse input to ground for use on systems with open emitter _ Enable ik ohm Pull Down Resistor Sensors Pulses Per Rev seo Pulses Per Rev ETER sai Number of pulses per revolution Feedback Selection 0 to L25v LOS Current amps Loss Of Signal Current The user can set the coil current to drive when a loss of signal is detected RPM Range Select the lowest working Range for your Feedback Selection oe Used to select a voltage range for the Pulse Input Pulses 7 20 8 to 416K RPM must cross the midpoint of the range selected to be detected and may exceed the range without damage to the unit if less than 30 Volts RPM Range U
52. tiometer 10KQ non weatherproof plain plastic adjustment knob X Conductive film potentiometer 10KQ weatherproof numbered bezel and adjustment knob Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 38 fos PowerLine User Guide Default Files and Set up tips Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 39 et PowerLine User Guide C Valve Driver Settings Dual Coil Valve Driver Default File ValveDriver 2Coil r0 dat After installation your GUI will display the following settings in the various windows Command Input Command Input is set at 0 5 Volt input with a valid command range of 0 1 4 47 Volts Ei Command Input Setup Valve B range is 10 to 2 24 volts Seet Been EE ecient Mele ee Valve A range is 2 24 to 4 47 volts _ Command Error coils off Command Error Default ee z In this example Cenierie at 24 voll and Command Command Range Command Error Limits Refernce Error Limits Input error detection is ON Max 4447 High SH High 61 Center SKS Command Error Default Exceeding the limits will set the Min SD 10 Low 30 04 Low 4 39 command input to 2 37 volts this value falls within the deadband variance around center that is dead and therefore O current is supplied to coil A CMD deadband is the deadband around center 2 24 volts or 0 current Auto Center OFF Auto Center CMO Deadband Auto Calibrate SIS ab In t
53. tion e The PowerLine Graphical User Interface part number is P N 023 00206 e Ensure you have the latest version of software for KR Geng this module by contacting our customer service x x 88 Valve Current w Full Vv and support personel if required fe Seer wj ee yi e Run Setup exe from the install CD e Follow the on screen instructions as you are prompted Figure 1 Main Screen Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 16 AM PowerLine User Guide Hel Using The PowerLine application File Memory Options Selection from Menu gt Save Temporary Memory to Permanent Memory NOTE It is strongly reccomended that the user cycles power to the PowerLine module after saving any program changes to ensure that the setting alterations take place and any old setting data is erased by the controller The unit stores all user programmable LE settings both in temporary and permanent ui ie Sete Fee Save Temporary Memory to Permanent Memory memory The unit reads the values from Save Temporary Memory to Permanent Memory amp a File 7 S Ce Restore Temporary Memory from Permanent Memory permanent memory In the PowerLine EE Restore Temporary amp Permanent Memory from a File prom into temporary memory only at power up or when the Restore Temporary Memory from Permanent Memory menu item is selected The temporary memory values settings are used in opera
54. tion coi Digital inputs The PowerLine control program allows KE altering the values in temporary memory ES we eet el Flscle e which immediately and temporarily affects the unit s operation The control E nail program also allows saving the parameters 3 Command volts in temporary memory into the unis e ga permanent memory by selecting Save 2 e E Temporary to Permanent Memory a Changes that are not saved will be lost when power is turned off or if the Restore Temporary Memory from Permanent Memory is selected Caution The unit does not function while settings are being saved Use of this selection temporarily prevents the unit from working in the system Do not select this option while the machine is operating Selection from Menu gt Save Temporary Memory to Permanent Memory amp File The control program can save and restore all unit settings to or from a file The temporary and permanent memory values in the unit are made to be identical during operations to avoid confusion about what was saved or restored When the Save Temporary Memory to Permanent Memory amp a File is selected the temporary settings are saved to permanent memory Next the user is prompted for a file name and location to save the new settings to This file can be used to program other units identically or act as a backup while adjusting the unit This feature also allows a replacement unit to be set up identically to the original without hav
55. to True see previous page for more information Ramp A Up More Current More Speed e Enable the Enable select box e SECH Ramp B Up 7 Enable Enable e Enable Active High Ramp B Down i C Enable Direction F Ramp to 0 if Disabled e Ramp to 0 if Disabled l S 21 Anti Stall Current to 0 Time me _ Command Reverse Acting e More Current More speed GE MIIN All other process options are disabled while in Single PAME Valve Driver mode Auto Reverse Time Coil Setup Coil Setup Disable Coil B is set to True Puts the module into Single Coil Valve Mode Coil Min 0 12 Amps Dither Hz F Sets Maximum and Minimum Coil Current to 1200mA and Coil A Max 4h 19 a 120mA respectively D CKE amps Toe KE l Coil B Min Z0 12 A In this instance the Dither has been disabled with a value un EDC Type Coil _ of 0 j SL a ADS coil B Max 2 19 Disable Coil E Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 42 far Horse Power Limiter amp Anti Stall Mode Dual Coil Driver Default File Anti Stall 2Coil rt dat Sets module to Anti Stall Mode using the following settings Pulse Input Sets module to Anti Stall Mode using the following settings The Pulse Input is set for use with a 0 5 Volt Sensor 120 pulses per revolution and an operational range of 21 to 4160 RPM The 1K ohm Pull down is deactivated but may be set to True for use with sensors using an open collector type ou
56. tput Loss of Signal Current is set to 390mMA Command Input Sets up the Command Input to act as a 0 5 Volt input with a valid range of 0 1 4 47 Volts Center Volts is set to 2 24 Volts Error detection for the Command Input and Reference Output are active with the Command Error Default set to 2 37 Volts Sets Coil A to Min Current during input error Deadband is 5 or 0 125 Volts Part No 021 00155 RevD7 Command Error Detection PowerLine User Guide Pulse Input Setup vi Seles Enable ik ohm Pull Down Resistor Pulses Per Rey 2120 N LOS Current amps 20 Feedback Selection Oto Sy ei RPM Range Select the lowest working Range For your Application 6 20 6 to 4 16k RPM Command Input Setup Command Selection Oto Sv ei Command Error coils off Command Error Default E Ga Command Range Max 29 47 Center 27 29 Min 0 10 Auto Center OFF Auto Calibrate PowerLine System Controller User Guide Command Error Limits Refernce Error Limits High SE Low 0 04 Low ab Auto Center CMD Deadband GC St ab High SR Page 43 et PowerLine User Guide C Process Setup Sets the Ramp Rate for both coil A and B to 3 seconds TF MA Up or Down eg Sets the following options to True eh 3 More Current More Speed Ramp A Down ia Enable Active High e Enable the Enable select box Ramp B Up Enable Enable Ramp B Down Enable Direction e
57. ttings in the Command Input and Coil Setup screens the max current delivered to the coil when RPM is above the Slow Set Point would be 50 of Maximum current to Minimum Current or 660mA Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 44 PowerLine User Guide Hel Electro Hydraulic Control Solutions We currently supply to virtually all areas of the fluid power industry increasing product integration and growing our customers business by allowing them to approach new profitable electro hydraulic markets successfully Please contact us to discuss your next project product training or system application we would be pleased to work with you and your team Need More Information For customer service and application support contact us through E mail at info hctcontrols com Electro Hydraulic Control Solutions High Country Tek Inc 208 Gold Flat Court Nevada City CA 95959 www hctcontrols com mz Phone 1 530 265 3236 Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 45
58. upply or battery and ensure this is at least 20 above the specified coil voltage that you are driving see note 1 below If there is a difference of gt 1VDC at full load between the measurement at the power supply and at the module power input there is excessive voltage drop in the connection wires and they should be shortened or replaced by bigger wires larger cross sectional area g Also check for bad OV or ground connections as this can also cause large voltage drops DD D h Note 1 Ohms Law says that when a coil heats up in use it increases Ohmic resistance which de creases the current flow Most manufacturers coils even when hot should still be able to fully shift the valve 100 if their rated voltage is supplied to them In some instances a voltage slightly greater than the coils rating is needed to maintain the valve 100 position On a mobile application nominal system voltage is quoted as being 12VDC When the alternator is running the fully charged battery voltage should be in the 13 8 14 3VDC region This extra voltage should be sufficient to enable the valve to drive to 100 When an increased supply voltage is not a possible option you must use a coil rated for less voltage The controller will have no trouble driving a 12 V coil from a 24 V supply or a 10 V coil from a 12 V supply for example If the valve shift is erratic Electrical interference on the command wires connected to the controller can also caus
59. ve an error or mis match is detected the GUI software will NOT allow communications and will inform the user of the problem via a clear message in the Status window Part No 021 00155 RevD7 PowerLine System Controller User Guide Page 4 et PowerLine User Guide C PowerLine flexible configurations The PowerLine module is ideally suited for today s hydraulic OEM distributor or system builder With both mechanical and electrical robustness paramount in the design priority Windows compatible easy to use set up software and full CE compliance means this one product can through the many configurations and features available be used across multiple platforms markets and applications This units cost effectiveness will become quickly apparent through the reduction in inventory costs and stocking needs as well as in the reduced costly engineering time taken usually associated with the design to delivery cycle The PowerLine has five 5 basic configurable modes of operation available within the one module 1 Manual control of the output current through the graphical user interface This mode is typically used during system start up and commissioning Used to prove control and direction of motion as well as correct hoses and fittings are leak free 2 Horse Power Limiter amp Anti Stall automotive style prime mover protection Used to protect an engine from stalling by progressively reducing the hydraulic load either by va

PLD User Manual - High Country Tek

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