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Gold Cup Digital HI-IQ Control Electronic Control User Manual

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3. Umax n i 040 co 4 900 HE 4 Kd 000 Dmax 4 Limit gt lt Uminus 100 Wawas Uplus 10 p 4 Ramps T Cmd 00 4 Read T 001 Cancel The parameter settings for the pump control loop can be changed on this global screen in the same way that they are changed on the smaller individual screens Selecting the Write to RAM button sends all of the new values to the driver card The parameter settings for the valve control loop can only be viewed on this screen and cannot be changed Changes to the valve control loop parameters can only be made by a qualified Denison Hydraulics technical service representative 24 www comoso com ANALOG INPUT AND OUTPUT SIGNALS The format of the analog input signals e g 4 20 mA 10 vdc determine the electrical connector pin assignments for the driver card The pin assignments have been preset by Denison with the proper configuration for particular applications The following paragraphs describe how to view and change these pin assignments if required Changes to these pin assignments can dramatically affect the performance of the pump control system Changes should only be made by trained personnel and with extreme care The analog input and output connector pin assignments can be accessed by selecting the Process menu options Master Layout or X Pump as shown below The Y Valve menu option can only be accessed by
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5. 43 www comoso com SAVING SYSTEM PARAMETER SETTINGS IN A PC FILE Select the File Save menu option as shown below to transfer the parameter settings currently active in the Denison User Interface Software into a file stored on the PC hard drive floppy disk CD or any other file storage device connected to your PC Terminal Programm Version 2 2 b00002 Ele Parameter Process Setup Graphics Extras Windows Help Open F3 ONLINE _ Denison C Back up pictures Custamers Save as type Data ect Cancel Open read only The file can be saved in same manner as any standard PC file It must be saved with the default 0 file extension to be compatible with the Denison User Interface Software This feature allows archive copies to be stored of various versions of the control system parameter settings This file storage option is useful when maintaining special control system parameter settings that are different from the Denison GoldCup Digital HI IQ pump default settings This feature permits storing control system parameters that are uniquely adjusted for a particular customer machine 44 www comoso com RETREIVING SYSTEM PARAMETER SETTINGS FROM A PC FILE Select the File Open menu option as shown below to transfer an ec0 file from your PC into the Denison GoldCup HI IQ User Interface Software Terminal Programm Version 2 2 b00002 Parameter
6. DIGITAL INPUT DIGITAL OUTPUT AND CONTROL LOOP STATUS INDICATORS page 22 ENTERING A PASSWORD eege page 23 PARAMETER MENU OPTION D page 23 GLOBAL PARAMETER SETTING LIST F10 page 24 ANALOG INPUT AND OUTPUT 5 page 25 SIGNAL BAR GRAPHS AND GRAPHICS WINDOW U nennen nenne nennen nnn page 30 ONLINE AND OFFLINE GRAPHICS MODES U i arc Eire ecd C randa page 31 FUNCTION GENERATOR page 33 Continued on next page www comoso com TABLE OF CONTENTS continued DISPLAY OF GRAPHICS WINDOW MASTER LAYOUT AND X PUMP BLOCK page 35 PUMP CONTROL SYSTEM PARAMETER SETTINGS U n II III enn nnne nnn page 36 GAIN X BLOCK PUMP DISPLACEMENT FEEDBACK 0 2 22 page 37 LIMIT X BLOCK PUMP MAXIMUM DISPLACEMENT LIMITER U page 37 RAMP X BLOCK PUMP RAMP GENERATOR page 38 Ki X BLOCK PUMP LARGE SIGNAL INTEGRATOR page 38 Kis X BLOCK PUMP SMALL SIGNAL INTEGRATOR page 39 Kp X BLOCK PUMP PROPORTIONAL GAIN sensere III III I Innen hne nnne
7. The Graphics Options menu option allows these values to be changed Adjustments for the scaling and units are provided to make the graphics display screens easier to read 25 www comoso com Selecting the Y Cmd menu option displays the following screen Select Input Channel We EE EDS zogen TEES ATIS S A L 2 e ETT 3 s ut The Y Cmd signal is predetermined by Denison and can not be changed Signals that can not be changed on these screens are shown in grey colored font Selecting the Y Out menu option displays the following screen Select Input Channel We S 2 F LESS S65 DEDE FADE E M ADS 4 20 F LES punkie Pater The Y Out signal is predetermined by Denison and can not changed 26 www comoso com Selecting the X Fdback menu option displays the following screen Select Input Channel 7 L rim F oe e o e e e e 2 e This screen corresponds with the wiring diagram for the pump that shows the displacement feedback signal being connected to driver card pin B8 If the pump displacement feedback sensor would be changed to a sensor with a 4 to 20 mA output then this signal could be connected to pin B14 This screen would then be used to interpret the signal at pin B14 as the X Fdback signal in the control system block diagram Selecting the X
8. ed UN N L g 7 y N Z LJ lt 13 www comoso com EC01 DRIVER CARD WIRING NOTES 1 The driver card has two electrical connectors The main input output connector is located at the rear of the card and the serial port connector is located on the front panel The rear connector is a heavy duty DIN 41612 F 48 pin and the serial port connector is a standard 9 pin D type The 0 V zero volt line of the power supply pins and B30 is not the same as the signal GND ground at pins B6 Z28 and Z30 A current compensation coil separates them The Digital Inputs connected to pins B16 enable D16 pump feedback polarity reversal and B20 digital input ground can be wired as electrically isolated inputs The Digital Input signal reference potential must be connected to pin B20 digital input ground to obtain electrical isolation of the digital input signals Pin B20 digital input ground must be connected to the signal ground using either pin Z28 Z30 or B6 as shown in the above wiring diagram when electrical isolation is not required The current consumption for each Digital Input is 3 mA 15 vdc The Digital Output signals
9. Cmd menu option displays the following screen Select Input Channel Fin ee AU nos E Eua AUS H ma Ae res OP 1 L L M Pateri Pe E Er RI E The X Cmd signal has been predetermined by Denison for this application and can not be changed 2f www comoso com Selecting the X Cmd Main menu option displays the following screen Select Channel Fine L L The X Main signal is obtained from pin D12 B12 if it is 10 vdc signal and from pin D8 if it is a 4 20 mA signal This screen shows that it is also possible to connect the internal function generator to provide the X Cmd Main signal For example the pump response can be evaluated with a square wave input and displayed on the Graphics window using this approach Selecting the X Cmd Aux menu option displays the following screen select Input Channel KP aale Laeken elie earl e e o e 22 e L ptn ay De The X Cmd Aux is shown on the SK 16101 driver card wiring diagram connected to an optional external command input potentiometer at pin B10 D10 This external input signal is summed on the driver card with the pump displacement command to form the input command to the control system 28 www comoso com The Process Y Valve menu option is shown in grey font and can not be accessed or changed The X Pump menu option displays many of the s
10. Kis X BLOCK PUMP SMALL SIGNAL INTEGRATOR GAIN There are two integrator blocks in the control loop The Kis X block allows you to set an integrator that operates at high gain on small signals The integrator improves the accuracy of the pump to follow the displacement commands This integrator gain Kis is active when dX lt U lt dX and is limited to Umin lt integrator output lt Umax Double clicking the Kis X block in the X Pump block diagram displays the following window Integral Controller k Pump d T m K F Umin 200 Umas 200 ta Cancel Selecting the boxes labeled dX Ki Umin and Umax allows a new values to be entered for the gain of the integrator and the range over which it operates Selecting the Write to RAM button sends the new values to the driver card The Ki gain of the integrator has a significant influence on the stability of the control system and should be used carefully Kp X BLOCK PUMP PROPORTIONAL GAIN The Kp X block sets the proportional gain for the pump controller This proportional gain has a major influence on the response and stability of the pump control system Adjustments to Kp X should be made with extreme caution Double clicking the Kp X block in the X Pump block diagram displays the following window Proportional Controller wl Pump Write to Cancel Selecting the box labeled Kp allows a value to be entered to set the proportional pump
11. an authorized Denison Hydraulics technical representative Terminal Programm Version 2 2 b00002 Eile Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics Y Fdback Y valve Y Cmd T Time 1907 Pump t Out Y F sch 31 Fdback Yu 0 ns _ X F sch 00 eX Aux The analog input output channel selection screens can be accessed from the Process menu as described above They can also be accessed by double clicking the color coded boxes on the block diagrams for the corresponding signals Selecting the Y Fdback menu option displays the following screen Select Input Channel x 00 Channel C ADT 4 20 m C 26 102010 ADS 100 V D122B12 AD4 10 0 Y Fdback Min Unit D14 Ce ADS 4 20 ua 100 F B14 C ADE 4 20 m X Main Eunktlsen Patch Write to nter Cancel UJU The Y Fdback signal is connected to driver card rear connector pin 014 for this HI IQ application and should not be changed The Min and Max scaling and the Units are shown on this and on subsequent Process screens for information purposes The Min Max and Units values only affect the display scaling of the Bar Graphs and the Graphics Screen and do not affect the operation of the pump control loops They can not be changed on this screen and are shown in grey font
12. card Do not allow the cable shield to contact the connector Use shrink tubing at the solder joints to avoid short circuits and to provide additional strain relief for the wires s Cable Dia DHI P N 721 30059 0 10 www comoso com DIP SWITCH JUMPER AND POTENTIOMETER SETTINGS FOR THE EC01 DRIVER CARD The following information is for reference only The EC01 driver card hardware is factory set for the GoldCup Digital HI IQ application No user adjustment of the hardware settings is required Refer to this information to verify settings or to restore an altered card to the original factory settings JUMPERS JP1 Programming bootstrap jumper for downloading software program to micro controller FLASH memory The link should be stored on one of the JP1 pins when not in use JP2 Not used Factory use only No link provided JP3 Not used Factory use only No link provided JP4 JP5 Not used in the application One link supplied and stored on one pin when not in use These settings configure the D12 B12 inputs for a 0 4 20mA command signal See Publication 9 EN 6060 A for detailed information JUMPERS ON DIGITAL SUB BOARD The 5 position Jumper JP2 on the digital sub board makes connection to a ROM RAM emulator This jumper is only for certain test and development purposes and should not be cha
13. card The parameter settings stored in the RAM can be changed with a PC that contains the Denison GoldCup Digital HI IQ User Interface Software This allows the user to evaluate various control system parameter settings in the RAM until the parameter settings are optimized The optimized settings must then be stored in the EEPROM on the card to be sure that these values are restored when the main electrical power is removed and then reapplied to the card SAVING SYSTEM PARAMETER SETTINGS IN EEPROM Select the Save to EEPROM option from the Setup menu as shown below to store the parameter settings in EEPROM This procedure transfers the parameter settings from the card RAM into the EEPROM amp Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics Save to EEPROM 3E Read from RAM 1 bi m FG Measurement Setup F ECH Setup Shift F7 Y Cmd Do PM o m COM Setup Ctrl F X Fdback 888 Start Measurement F4 X Cmd 885 Stop Measurement ESC X Cmd Main 885 E E Last Dialog FS Password RETRIEVING SYSTEM PARAMETER SETTINGS FROM DRIVER CARD RAM Select the Read from RAM option from the Setup menu as shown above to retrieve the settings from the driver card RAM This procedure transfers all parameter settings from the driver card RAM into the PC User Interface ooftware This allows the parameter settings to be examined on the PC
14. control inputs i e PLC If voltage isolation is not necessary the 24Vout voltage Pins D6 D32 or 15VDC Pin B2 can be used for the digital control inputs When using the driver card 24Vout or 15V a connection from B20 Dig INGND to one of the GND Pins Z28 Z30 or B6 is required for the card to work correctly The digital input voltage level must be between 4V and 32VDC The current consumption for each digital input at 24V is approximately 5mA ENABLE The digital input E7 pin B16 is the driver card ENABLE function Connecting a positive voltage to pin B16 will ENABLE the driver card at the X Cmd logic block The driver card must be ENABLED before the system will respond to the external commands for pump displacement If OV or no voltage is connected to the ENABLE input the pump controller X Cmd logic block output is zero and all external commands to the driver card are ignored NOTE Even if the ENABLE function is off the controller still stays powered up and only the external commands are blocked from controlling the pump displacement B16 Vdigital Logic 1 ENABLE ON Logic 0 ENABLE OFF B20 GNDpigital CHANGE SIGN FEEDB The digital input E1 at pin D16 changes the sign of the pump displacement feedback signal Connecting a positive voltage Logic 1 will invert the sign of the pump displacement feedback signal This allows the user to easily change the pump displacement feedback polarity for pro
15. for a copy of the GoldCup Digital HI IQ User Interface Software and the installation instructions The computer serial COM PORT 9 pin D connector must be connected to the driver card with a standard serial port extension cable There are two standard types of serial port cables one that reverses the connection between pins 2 and 3 and a second extension cable that passes all pin connections directly through the cable with no pins reversed as shown below It is recommended that the shortest available extension type cable be used to communicate with the driver card Computer Driver Card Computer socket ECO1 Card Pins 2 O 2 i D Note The complete GoldCup Digital HI IQ transmission pump system may be powered up electrically but not hydraulically to check the wiring of the driver card control valve solenoids control valve LVDT sensor pump displacement sensor and the serial communications between the PC and the driver card 17 www comoso com OPERATION OF THE GOLDCUP DIGITAL HI IQ USER INTERFACE SOFTWARE Apply 24 VDC power to the driver card Connect a PC containing the Denison GoldCup Digital HI IQ User Interface ooftware to the driver card using a serial port extension cable as previously described and run the program named 726000072 exe on the PC COM PORT SETUP When running this program for the first time on a PC the serial communication port address must be established before communication can occur be
16. screw Ring 8 pinch ring shielding ring bos t OE mom rana iram NONAS A H w ESA KN E d E EEN The proper parts orientation for the cable strain relief and seal is shown above Do not connect the cable shield at the connector end Connect the shield to the earth ground only at the control card The housing cover with the o ring seal is not shown Make sure the housing o ring is in place www comoso com Wiring of the control valve spool position sensor mating connector Refer to installation drawing SK 16099 or SK 16101 to wire from this connector to the EC01 driver card Wire Gage 24 20 AWG 0 25 0 75 mm entrance Not Used 4 4 20mA Signal 3 UB amp Signal Ground Position Key 2 UB Supply at Assembly Voltage Wiring of the valve solenoid coil mating connectors Refer to installation drawing SK 16099 or SK 16101 to wire from this connector to the EC01 driver card Assemble the parts on the cable as shown The rubber seal has removable concentric rings to accommodate larger cable sizes Do not connect the cable shield at the connector end Seal adjust to fit cable dia Cable Dia _ D n 4 5 10mm 16AWG Metal Max Washer Wiring of the pump displacement sensor mating connector Refer to installation drawing 5 16099 or SK 16101 to wire from this connector to the ECO driver
17. the mouse button or by holding the Ctrl key and pressing the F7 function key Config Com Port Baud Rate Com Status v 9500 Online t Offline C 18200 C 37400 Write to 57600 C 115800 The serial communication port on your PC that is connected to the driver card has an address defined by the internal configuration of the PC The COM port selected on this menu must be a physical port with a hardware connector and not an internal port It must also be available on the PC and not in use by external modems plotters or any other equipment Select a suitable COM port address for your PC If you don t know the address of the COM port use a trial and error process starting with Com1 trying each of the four menu choices until communication is established Select an initial Baud Rate data transfer speed of 9600 bps bits per second A low Baud Rate will result in the most reliable comunications You can try to increase the Baud Rate later to determine if higher communication speed is possible with your PC Click the Write to RAM button on the menu A message box will appear on the PC screen with the words Com Port new initialised when the communications port address has been chosen correctly G Port new initialised 19 www comoso com This message indicates the PC is communicating with the EC01 driver card and the Denison GoldCup Digital HI IQ User Interface Software is operationa
18. 000 LI width n 1000 4 Dam a 2200 2 Dr LI a TED 00 w 2 Y Offset min 512 Umas ds 2000 c 4 Kis Ki 35 CU 20 Umas __ 200 C di 40 c 4 1800 4 2000 SST 26 sss 4 Limit gt LI rins 100 Uplus 10 4 Ramp T sii Read from T Cmd Www Cancel 58 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P11 AND P14 PUMPS WITH DC RVDT DISPLACEMENT SENSOR GLOBAL x 2 Ki REH T Cmd Umir J 2000 T Cmd 01 Umas omn 4 Offset d 20 4 Overlap Y U plus 2 400 U minus n 2 10 U width TFD 1000 4 2475 2 DHU Kd ni 2 jd Offset Kx T 5 Umin RER E Umar ET d 2000 4 a d 055 Umin 200 c Umas Waw dx 10 s 4 1800 www 4 Kd 2000 d Uminus 100 LIplus 100 a d Ramp T 1 55 Read from T r 1 59 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P24 AND P30 PUMPS WITH POTENTIOMETER DISPLACEMENT SENSOR GLOBAL 2 T Cmd ROFSIIOGMiI IEEGUGAIIAI Urin 2000 T Cmd 1 Umas onn 4 amp Offs
19. 00002 File Parameter Process Setup Graphics DENIS Global F10 Master Layout nr m TTm Y Valve Y 88 Kis X Y Out 36 px X Faback BRE E X 29 0 HB X Cmd Main 290 X Cmd Ae oo WE x offset Overlap Y These same screens can be accessed by double clicking the various blocks in the Master Layout or X Pump block diagrams shown below Master Layout Eamp X Ee Ke x 36 www comoso com The pump operates in a PID proportional integral and derivative control configuration with a Gain X adjustment to scale the pump displacement feedback There are also blocks in the control system that provide options for limiting the maximum displacement of the pump ramps to limit the rate of change of pump displacement and overlap compensation for the control valve The following paragraphs describe how the parameters contained in these blocks are set GAIN X BLOCK PUMP DISPLACEMENT FEEDBACK GAIN The Gain X block calibrates the pump displacement feedback sensor signal for flow being delivered from either the A or B port of the pump Double clicking the Gain X block in the X Pump block diagram displays the following window Proportional Controller gt Pump K i 210 Write ta Cancel Selecting the box labeled allows value to be entered to calibrate the pump displacement sensor Selecting the Wri
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21. D12 10 input range 200KO input impedance This input is dedicated to the pump command input either main or auxiliary Term 08 4 20mA current input into a 2500 current sensing resistor Used as main pump command when a current input signal is used It is a 12 8mA signal when it is used as a pump displacement command signal loss of signal detector is activated in the software when the D8 input is selected Term D14 4 20mA current input into a 2500 current sensing resistor This input is dedicated to the valve spool position feedback signal The 1055 of signal or broken wire detector is activated in the software when the 014 input is selected Term B14 4 20mA current input into a 2500 current sensing resistor This input is not used in the standard HI IQ application It can be used as an alternate pump command input or as the valve spool position feedback input in case either is defective When the B14 input is selected a 1055 of signal or broken wire detector is activated in the software 55 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P6 P7 AND P8 PUMPS WITH POTENTIOMETER DISPLACEMENT SENSOR GLOBAL xd 2 T Cmd 1 LIrnin 2000 T Cmd ESSE Limax 000 4 Offset n d 2000 4 Overlap U plus p 20 400 U minus n 2 kdi Y 1000 U width 0 THD 0 4 Gain gt 2 DAU Kd eeng E I TED E 2 Y Offset n LI s
22. DENISON HYDRAULICS GoldCup Digital HI IQ Control Electronic Control Card User Manual Software Version 2 2b Publication Number LT3 00055 1 4 June 2002 ISO 9001 eem http I Www com www comoso com TABLE OF CONTENTS DESCRIPTION OF GOLDCUP DIGITAL HI IQ PUMP CONTROL SYSTEM page 5 EC01 DRIVER CARD CODE 2 6 INSTALLATION AND WIRING OF THE EC01 DRIVER nennen nnne page 6 DIP SWITCH JUMPER AND POTENTIOMETER SETTINGS FOR THE EC01 DRIVER CARD page 11 EXTERNAL DC POWER SUPPLY REQUIREMENTS page 15 DRIVER CARD POWER SUPPLY REFERENCE VOLTAGES page 15 ENABLE DIGITAL INPU RE page 15 READY DIGITAL OUTPUT rc 9 page 15 CONTROL ERROR DIGITAL OUTPU Eegen page 15 DRIVER CARD RESET SWITGBL EE page 16 ESTABLISHING COMMUNICATIONS BETWEEN THE EC01 DRIVER CARD AND YOUR page 17 OPERATION OF THE GOLDCUP DIGITAL HI IQ USER INTERFACE SOFTWARE page 18 COM PORT Eege EE page 18 CHOICE OF ENGLISH OR GERMAN LANGUAGE page 21 THE HELP MENU OPTIONS EE page 21
23. GNDDigital 53 www comoso com DIGITAL OUTPUTS The driver card has four digital outputs but only A1 Pin Z16 and A2 Pin Z18 are used in the Standard HI IQ application Each output is isolated by means of an on board optocoupler to provide fully isolated output switching When using an external voltage source for the supply of the optocouplers the plus voltage line of the source must be connected to Pin B32 VEXT and the 0V line of the source MUST be connected to Pin B22 Dig OUTGND of the driver card If isolation is not necessary the 24Vout voltage available on pins D6 amp D32 can be used to power the opto couplers When using the internal 24Vout a connection from pins D6 032 to pin B32 Vext and a connection from Pin B22 Dig OUTGND to one of the Pins Z28 Z30 or B6 is required for correct operation The outputs from opto couplers are standard high side output type with internal overload and short circuit protection with a maximum switching capability of 500mA However if the internal 24Vout pins 06 032 is used the output current is limited to 80mA total and should only be used to drive LED indicators with appropriate resistor in series or to interface with the main system buffered inputs If higher currents are required i e up to 500mA an external voltage supply with corresponding current ability must be connected to pins B32 as indicated above The 24V supply voltage for the driver card can also be u
24. Process Setup Graphics Extras Windows Help Open Save F2 ONLINE 1 qms Exit s BEL 71x Look in E Documents cl AutoCad _ Electronics Ne Back up Forms ne _1 Catalogs OL Competitors Internet Mail and News Correspondence Kits Cpg Customers Modular Pricing ali Denison 1 Monthly Reports COISE 1 pictures eBooks Files af type Daten ec0 Cancel 2 LOADING THE GOLDCUP DIGITAL HI IQ CONTROL ALGORITHM INTO THE DRIVER CARD The software that has been uniquely developed to control the Denison GoldCup HI IQ pump is stored in the digital driver card EEPROM in a bin file The software in the bin file contains the control system algorithm responsible for the closed loop PID control of the GoldCup pump Contact a Denison Hydraulics technical service representative to install the correct bin file on your driver card 45 www comoso com CONNECTOR PIN DETAILS ECO1 HI IQ PIN ASSIGNMENT 24XOUT 04 2 6V AD1 MAIN PUMP CMD AD2 Pump Displmnt CO e CO CONot Used AUX PUMP CMD Analog1 OUT C 0 4 20mMA 0 4 20MA Not Used ADS Valve Spool AD6 Opt I P Analog2 OUT T 1 Dig1_Out SignF eedbk Enable Not Used I 1 2 0192 ESCH Dig8 In A2C Dig2_Out Sign Command Ramp No Error MEC M E ASC 01 5 Out Sign D10 B10 Di
25. SW1 1 4 off Do not change The 4 poles of switch SW1 must be set as shown the picture the right SW1 switch configures the input impedance of the D8 and B8 inputs This is not a user selectable option for the HI IQ application 4 SW2 1 2 3 4 5 6 7 8 Factory SW2 4 on and SW2 1 2 3 5 6 7 8 off TheSW2 switch is used to configure the D12 B12 input for various command signals It is a user selectable option See Publ 9 EN6060A for complete details SW3 1 2 3 4 Factory set SW3 4 on and SW3 1 2 3 off The SW3 switch sets the AT 4DC01 control valve A solenoid maximum operating current 0 SWA 1 2 3 4 Factory set SW4 4 on and SW4 1 2 3 off The SWA switch sets the 40 01 control valve B solenoid maximum operating current SW5 1 2 Factory set SW5 2 on and SW5 1 off SW5 1 changes the over current adjust ment range of RT3 SW5 2 changes the hardware dither frequency range of adjuster This setting is not used in the HI IQ application SW6 1 2 3 4 Factory set SW6 4 and SW6 1 2 3 off Selects the frequency of the dither Only one switch must be on When RTR5 is not installed the SW6 setting is not relevant 12 www comoso com JP4 JP5 ON S WG N ES
26. ame screens described above for the Master Layout menu option and is shown on the following screen S Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics Master Layout Y Fdback X Fdback Y 139 gt Y Cut 08 Hain X F sch 828 BX Cmd Aux 506 29 www comoso com SIGNAL BAR GRAPHS AND GRAPHICS WINDOW The magnitude and sign of seven important analog signals are always displayed in the upper left corner of the screen as shown below Terminal Programm Version 2 2 600002 Eile Parameter Process Setup Graphics ONLINE T Time 2907 ms Y Fdback 78 z EE Y Cmd 86 BS EN Y Out ai Ee X Fdback 759 i X 76 5 X Cmd Main T6 5 KO X Aux oo IR The choice of the seven signals that are displayed is fixed by the software and can not be changed The colored bar is small and centered when the signal is zero The colored bar increases in length in proportion to the increase in the signal The bar moves to the right of center when it is positive and to the left of center when it is negative The color coding of the bars correspond to the color of the box in the control system block diagram window for each of the seven signals The same color code is used for the Graphics window that resembles an oscilloscope screen This
27. amp MECHANICAL SPECIFICATIONS page 51 DIGITAL INPUTS u R page 52 DIGITAL OUTPUTS R 54 RP iEetil gpe page 55 DENISON DEFAULT PARAMETER SETTINGS FOR P6 P7 AND P8 PUNPS page 56 DENISON DEFAULT PARAMETER SETTINGS FOR P11 AND P14 5 page 58 DENISON DEFAULT PARAMETER SETTINGS FOR P24 AND P30 page 60 4 www comoso com DESCRIPTION OF GOLDCUP DIGITAL HI IQ PUMP CONTROL SYSTEM The Denison GoldCup Digital HI IQ transmission pump is an electronically controlled hydraulic transmission pump capable of precise high speed quiet efficient closed loop positioning of a hydraulic cylinder typical control system is shown in the following circuit diagram customer hydraulic cylinder customer PLC feedback cylinder position feedback HI IQ cylinder position command 1 GoldCup 5 350 bar maximum pressure capability provides exceptionally high power density a rugged compact and efficient package The pump also performs the dual role of the flow source and the flow control for the hydraulic cylinder The Denison GoldCup Digital HI IQ transmiss
28. anced Too much error between valve command and valve feedback EC01 card not securely plugged into mating connector Valve command and valve feedback is out of phase Valve feedback is missing incorrect or erratic Air trapped in valve One or more of the selected 4 20 mA signals are missing 49 Recommendation Check phase relationship tables and set digital input E1 sign pump feedback as required Check EC01 Setup Error Handling settings Check pressure compensator setting and system load pressure Remove wiring at EC01 card and check reference voltages Replace ECO1 card if faulty If OK check wiring at connectors Check the valve loop error indicator WO If it is Pink the control valve may be sticking Return the control valve to Denison Remove any obstruction and then insert the card until the connector is fully engaged Valve solenoid cables are reversed Check the 24V output to the valve feedback sensor It must be greater than 19V Check for correct wiring and secure connections Operate the pump at zero flow and maximum pressure on the pressure limiter control Bleed aerated fluid from the control valve air bleed screws until the fluid is free of air Check wiring continuity of the 4 20 mA circuits Check the 4 20 mA sources of each circuit If they are OK the problem is in the 01 card Return the ECO card to Denison www comoso com mt Possible Reason Recommend
29. at pin Z18 control error signal and B22 digital output ground are shown in the above wiring diagram with no electrical isolation Connect pin B32 Vext digital output to pin D28 and also connect pin B22 digital output ground to pin B30 0 V supply to provide electrical power to the digital outputs when electrical isolation is not required The total current consumption for all Digital Outputs must be less than 80 mA The Digital Output signals can also be wired as electrically isolated outputs The Digital Output signal reference must be connected to pin B22 digital output ground to obtain electrical isolation of the digital outputs If higher currents are required up to 125 mA per output 500 mA total an external voltage supply with corresponding current ability must be connected to pins B32 as indicated in the above text The EARTH connection at pins Z2 and Z32 is required for EMC electromagnetic compatibility protection and compliance to regulations The EARTH pins Z2 and Z32 are not connected to pins B6 Z28 and Z30 ground or to pins D30 and B30 0 V supply on the driver card The complete GoldCup Digital transmission pump control system may be powered up electrically but not hydraulically to check the wiring of the driver card control valve solenoids control valve LVDT sensor and the pump displacement sensor Do not start the electric motor that drives the pump until all of the driver card wiring has been checke
30. ation Valve Y feedback bar graph Pump control is against the mechanical Reduce input command signal or adjust Limit X does nol return to zero displacement stop when the pump is operated near maximum displacement and Pump displacement sensor may not be command signals are properly centered equal Check pump displacement sensor zero adjustment See section on pump zero adjustment Maximum input displacement command and pump feedback signals are not balanced Determine maximum pump displacement feedback signal and set Gain X to the same level in millivolts Displacement input command signal may be too large on one side or the other due to pump displacement asymmetry Reduce maximum input command if possible or use the Limit X adjustment to compensate for the displacement asymmetry Pump X feedback bar graph Gain X parameter setting may be too low Determine maximum pump displacement feedback is at 100 but the actual signal and set Gain X to the same level in millivolts pump flow is lower than expected 50 www comoso com EC01 DC2 GENERAL ELECTRICAL amp MECHANICAL SPECIFICATIONS Dimensions Euro Card 160 x 100 mm Front panel dimensions 3U 8HP 128 5 x 40 4 mm Weight approximately 250g Connector DIN 41612 3 row FORM F male 48 pin B D Z Card Holder Code Number 701 00066 8 Supp
31. axis of the Graphics window can be adjusted by changing the values in the boxes labeled Scale X Axis The name of the signals are displayed below the horizontal axis of the Graphics screen the scaling and the color code as shown below to assist in interpreting the data Graphics 100 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 T U 2 0 ERU 10 Y Fdback 150 0 150 0 Fdback 130 0 130 0 X Cmd Aux ms 100 0 Y Cmd 150 0 150 0 100 0 100 0 Y Ont 100 0 BIBLE ONLINE AND OFFLINE GRAPHICS MODES The signals selected to be shown on the graph are automatically displayed and refreshed on the Graphics window screen in a continuous process when in the Online mode The resolution of the graphs produced in the Online mode is acceptable for a horizontal axis scaling of 10 seconds i e 10000 ms or greater However horizontal axis scaling of less than 10 seconds will have poor Graphics resolution because the PC and driver card communicate at a relatively low sampling rate so that the PC does not interfere with the operation of the pump and driver card Higher resolution of the Graphics window display screen can be achieved with horizontal axis scaling of less than 10 seconds using the Offline mode The Offline time scale can be adjusted in the lower of the two boxes under the Scale X Axis heading The Online and Offline status of the Graphics window can be selected by toggling the buttons lab
32. by double clicking the corresponding colored boxes on the Master Layout or X Pump block diagram screens Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics IMEEM Fdback Y Valve Y T Time 10 Pump K Out Y Fdback 31 Fdback Y Cmd 33 gt cma wan X F sch 00 Aux 33 www comoso com Selecting the X Cmd Main option brings up the following screen Select Input Channel EN C ADT 4 20 mA C 2 2 Bi Di C ADS 100v 012 812 04 10 0 Main Unit 014 ADS 4 20 rs 106 6 100 0 E B14 C ADG 4 20 Funkt Gen Patch Write ta t nter C The Funkt Gen option can be selected as shown above for the input to the X Cmd Main location of the block diagram which connects the function generator to this input command location Selecting the Write to RAM button connects the function generator to the X Cmd Main input and disconnects the previous input The function generator amplitude is automatically set to zero when initially connected to the control system to avoid unintended operation of the pump The amplitude and other function generator settings can be accessed and changed as previously described using the Setup FG Measurement Setup F7 menu option 34 ww
33. control gain Kp X Selecting the Write to RAM button sends the new Kp X value to the driver card 39 www comoso com Kd X BLOCK PUNP DERIVATIVE GAIN The Kd X block sets the derivative gain for the pump controller This derivative gain improves the response characteristics of the pump control system Double clicking the Kd X block in the X Pump block diagram displays the following window differential Controller Fi k Pump D Differentiation Step Td Td D Tsample iu ud Write to rite to 25 Max 31 Cancel Selecting box labeled Kd allows a value to be entered for the derivative gain Selecting the box labeled Dmax allows a value to be entered to limit the maximum time difference used to calculate the rate of change of the input signal Selecting the Write to RAM button sends the new Kd X and Dmax values to the driver card VALVE OVERLAP Y COMPENSATION BLOCK The Overlap Y block provides an overlap compensation system that electronically avoids operation of the control valve near zero command Overlap compensation is not required because the control valve on the GoldCup Digital HI IQ pump has nearly zero overlap Do not change these settings unless directed by a Denison Hydraulics technical expert Double clicking the Overlap Y block in the X Pump block diagram displays the following window Overlap Compensation x Fe Pump plus i Write t
34. d and is operating correctly 01 DRIVER CARD WIRING CHECK POINTS 1 Check that all 0 V GND and EARTH connections are wired correctly Check that the card output signals are connected to the correct solenoids A and B Check that all cables are soldered correctly with no short circuits on the terminations Check that the valve spool position sensor is wired correctly Check that the pump displacement sensor is wired correctly Check that the 24 VDC 3 A power supply is stable and smooth 14 www comoso com EXTERNAL DC POWER SUPPLY REQUIREMENTS The power supply for the electronic driver card must provide DC voltage only The DC voltage supplied to the card must be between 20 and 32 VDC for proper operation The reverse polarity protection diode on the card ensures there will be no damage if the supply voltage is connected with reverse polarity The driver card operates with a DC DC converter module supplying control valve solenoid power from the card The voltage applied to the solenoids is actually higher than the supply voltage to the card with the DC DC converter maintaining nearly equal input and output power The input current to the card is less than the current supplied to the solenoids by a factor approximately equal to the voltage amplification ratio of the DC DC converter DRIVER CARD POWER SUPPLY REFERENCE VOLTAGES There are several power supply voltages available on the driver card that can be used to supply low curre
35. ective Incorrect wiring Wrong wiring from driver card to solenoids Sub board defective ECO1 card valve driver output stage defective 48 Possible Reason Recommendation Check power supply Check power supply Check wiring and or resistance of the solenoid Check external devices transmitter electronic cards potentiometer Send the driver card back to Denison for repair Send the driver card back to Denison for repair Remove and store on only one pin Check wiring of Enable digital input Send the driver card back to the Denison for repair Check all wiring at ECO1 card connector pump valve and related electrical components Most start up problems are caused by wiring problems Check solenoid wiring Send the driver card back unit to Denison for repair Send the driver card back unit to Denison for repair www comoso com Digital output A2 is Red pin 218 is low and pump loop indicator W1 is Pink Digital output A2 indicator is Red and valve loop Indicator W0 is Pink Same as above but also erratic and noisy pump operation at start up or after valve replacement Digital output A2 indicator 15 Red and pin Z18 is low Bar graphs are in phase and W0 and W1 loop monitors are yellow Possible Reason Pump control loop error Bar graphs out of phase or too much amplitude difference Pump in pressure compensation mode Reference voltages to pump feedback sensor are missing or unbal
36. ecurrent Trace Start ms C Free Run Sample Rate Ce Wat 4 Trigger Act ms 250 ms 449 Channel v Cmd sl Period 4000 ms Amplitude 7 7 Delay J x f Sinus Offset x Fla Channel gt Cmd 1 Write to The wave form can chosen right of the function generator window either Sine Wave Sinus Triangular Wave Ramp or a Square Wave Step under the function generator Mode label The Period Amplitude and DC Offset of the wave can be adjusted by entering values into the boxes under the Adjustment label The settings on the left of the window perform like the trigger settings of a standard oscilloscope The trigger can be set to operate from any of the signals listed on the drop down menu labeled Channel The trigger settings can be used to adjust the appearance of the data recorded in the Graphics window in the Offline mode The Write to RAM button must be selected to activate the new function generator settings on the driver card The function generator can be connected to the many different locations in the control block diagram The X Cmd Main logic block can be connected to the function generator and disconnected from the driver card terminal B12 D12 The function generator can be connected to various block diagram locations using the Process Master Layout or X Pump menu options as shown below The same screens can also be accessed
37. eled Mode 31 www comoso com The Start Measurement or function key F4 option under the the Setup menu shown below is used to begin displaying the signals on the Graphics window in the Offline mode You will see the display box in the lower left corner of the screen change color indicating the measurement has been started f you need to stop the measurement before the time entered into the setup screen has elapsed use the Esc Stop Measurement key The PC mouse will respond slowly after starting an Offline measurement but the the Esc key will to stop the Offline measurement immediately Terminal Programm Version 2 2 b00002 Parameter Process Setup Graphics Extras Windows Help Save to EEPROM F12 Read from F11 FG Measurement Setup dd EC01 Setup Shift F7 Y Cmd 149 mi s sa COM Setup Ctrl F X Fdback 431 Start Measurement X 413 BN Stop Measurement X Cmd 413 m Last Dialog F8 Password Ctrl F9 32 www comoso com FUNCTION GENERATOR The user interface software provides a function generator that can be connected at various points on the driver card for diagnostic testing and tuning of the control system parameters The function generator screen shown below can be accessed from the Setup screen under FG Measurement Setup F7 menu option Function Generator gt x Trigger Measurement Function Generator Level pom slope R
38. et Offset r K 2000 4 Overlap Y LI plus n 2 Kp a00 U minus D 2 r 1000 O width TED 5 4 Gain S 2 Kd Tau ai TED r u rx ihMh 2 Y Offset Offset 5 Kx CF nt Umin L sis Umax wawa d so 4 gd 50 Umin E Umax 0 d SEH 4 2700 c 4 2000 max w asss 4 Lt gt Uminus 100 sss Uplus 100 Ir 4 T rd Read from T Cmd HET ces Cancel 60 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P24 AND P30 PUMPS WITH DC RVDT DISPLACEMENT SENSOR GLOBAL x 2 KY 75 T Cmd LI min 2000 T Cmd Umas oon 4 amp Offset Offset r j d 20 4 Overlap Y U plus 2 400 L minus n 2 Fd r Fd 1000 U width p 1000 4 Gain 247 2 DAU Kd TED ni 2 Offset Offset mi 53 a4 Kx NH wawww 50 Umas waw di 2000 4 A Umin Umas 200 di EH KpX Kp ETH BEN 4 Kd 2000 4 Limit gt Uminus 100 Uplus 4 Ramp 1 Read from RAM T Cmd 01 61 www comoso com Denison Worldwide Sales and Service Locations North amp South America Asia Pacific Canada Denison Hyd
39. g Mo Kio Ave 10 Unit 07 01D Techplace Singapore 569628 Tel 65 268 7840 Fax 65 268 7847 Taiwan Denison Hydraulics LTD 6F 10 No 79 Sec 2 Roosevelt Road Taipei Taiwan ROC Tel 886 2 23645101 Fax 886 2 23639025 To locate a Denison Hydraulics representative near you call toll free 800 551 5956 in North America or visit us at http www denisonhydraulics com DENISON Hydraulics Copyright 2002 Denison Hydraulics Incorporated All rights reserved 30 April 2002 62 www comoso com
40. gINGND Not Used E AC 2019411 O 4 DDig4_Out Not Used Not Used Not Used IES CODig5 In 26 24V0UT DIG OUT 46 www comoso com EC01 DC2 BLOCK DIAGRAM Command potentiometer B D30 10KOHM recomm 02 4 min 4 7K0hm 10V m Digital controler modi 12 132 AN3 V ext 852 B12 P28 C Dig 1 716 B12 diff input D8 Seer o mur 3 720 STOP 24V Isolated External ower Supply OV 8215 VAN B4 15V dell 24V uis 00 08207 esr TAG WT zs 016 bi ma ia D20 _ 024 CN D26 PIT I 724 816 Kid _ gt LT 726 Droen Ei B8 Sensor Jr ANI nr p OUT GND Dither PWM Gen 230 47 www comoso com Power Supply 24V Isolated External Power supply FAULT FINDING GUIDE Front panel LED CPU active is not lit and not flashing and LED on sub board is not lit Front panel LED CPU active is lit and flashing but card does not respond to command signal No current to valve solenoids Power supply not properly connected Power supply not within the specified range Short circuit of valve connection Short circuit at the reference voltage outputs DC DC converter on the board defective No program installed on EC01 card EC Burn boot strap jumper J1 installed Enable digital input not connected correctly Sub board def
41. ion pump provides smooth controlled acceleration and deceleration of the hydraulic cylinder without the throttling power losses and heat generation associated with conventional servo or proportional valve cylinder positioning systems It is also capable of regenerating the hydraulic power needed to decelerate the cylinder and converting it into electrical power through the primary drive electric motor This significantly reduces heat generation in the hydraulic fluid increasing the hydraulic fluid life and reducing the size and operating cost of the fluid cooling system The regenerated power can be used to drive other mechanical and electrical devices in the system Denison GoldCup pumps have earned a global reputation for their quiet reliability This control system strategy further reduces the overall hydraulic system noise by eliminating the throttling of the main system flow The fluid throttling noises associated with conventional valve controlled cylinder positioning systems have been completely eliminated Shock induced noises are also avoided when the cylinder motion is accurately and smoothly controlled omooth cylinder motion control also reduces wear extending the service life of the customer s machine Eliminating shocks also helps to prevent costly and troublesome hydraulic fluid leaks The GoldCup Digital HI IQ transmission pump truly represents a quantum leap forward in hydraulic cylinder motion control technology www comoso com The de
42. l The word ONLINE should appear next to the Denison logo and a green box should be displayed The should display several new windows as shown below gt Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help ONLINE jj T Time 2837 ms Y F back sum 1 ww Y Cmd SE E PE Y Out 38 Gi k X Fdback 02 94 Bees ki X Cmd 06 cpu X Main De E __ X Cmd Aux 00 i Graphics 00 100 lt gt 0033333 2 Bg Gen 10510 Axz20 Mot used 4 022 B Seres 4222 B Mot ued is R MEE PB cu joies M T P 16 READY z 28 EE 100 0 0 0 0 1 4 0 4 0 6 0 7 3 0 9 10 El Wo Y Foback 150 0 150 0 X Fdback 120 0 120 0 X Cmd Aux ms 100 0 Wl Y cmd 1500 150 0 X 100 0 100 0 Ge Y Chit WOO Cl 100 0 100 0 2 Z 243PM W Microsoft Terminal il Start Inbox The Master Layout X Pump and Graphics windows can be minimized using the standard windows icons located in the upper right hand corner of each window Use the Windows menu option to redisplay the windows after they have been minimized 20 www comoso com CHOICE OF ENGLISH OR GERMAN LANGUAGE The User Interface Software has the option of displaying the screen text in either English o
43. lectrical command to the pump driver card Slowly close the throttling valves in the A and B ports while observing the pressure at each port Access the X Offset adjustment screen and adjust it to obtain equal pressures at the A and B ports 41 www comoso com SETUP MENU SETTING PARAMETERS FOR THE CONTROL ERROR SIGNAL DIGITAL OUTPUT Z18 The driver card continuously monitors the performance of the pump displacement control loop The digital output at pin Z18 will be set to 0 vdc indicating a Control Error if the difference between commanded pump displacement and the actual pump displacement exceeds Error1 for a time duration longer than TimeErr1 Select the Setup EC01 Setup menu options to set these parameters as shown below Terminal Programm version 2 2 b00002 ECO1 Setup 42 www comoso com PARAMETER SETTINGS STORED IN RAM AND EEPROM ON THE DRIVER CARD There are two types of memory storage areas for the driver card parameter settings RAM random access memory and EEPROM electrically eraseable programmable read only memory All of the parameter settings stored in RAM are erased when the main electrical power is removed from the card The RAM is volatile memory that is lost when electrical power is removed All of the parameter settings are read from the EEPROM into the RAM when the main electrical power is applied to the card The EEPROM is non volatile memory that is retained when electrical power is removed from the
44. ly Voltage 24 V DC nominal 20 32VDC Limits Supply Type Bridge rectified and filtered DC ripple lt 5 Current Consumption Card only 350mA with accessories and valve current 1500mA Reference voltages 15V 45 50mA 10V 0 590 Q 10mA for accessories Storage Temperature 40 125 Operating Temperature AR GE 70 C Output Stages Two 24V PWM for Valve Solenoids Output Stage Current Maximum Current approximately 3000 mA Factory Set Dither Amplitude Software Setting Only Factory Set Dither Frequency Software Setting Only Factory Set Ramps Up Down Software Setting 1 50V s 420 Digital Inputs 5mA 24V Functions Defined by Application Software Digital Outputs Defined by Application Software Analog Inputs 3 Voltage 3 Current 51 www comoso com DIGITAL INPUTS The driver card is equipped with digital inputs for control The inputs are electrically isolated by means of onboard optocouplers providing isolated control of the digital input functions The 0V return line of the source must be connected to Pin B20 Dig INGND of the driver card when using an external voltage source for the digital
45. make changes to the pump control system parameters use the function generator and oscilloscope and can monitor the control system response characteristics You must contact Denison Hydraulics to obtain a password Selecting the Setup Password menu option displays the following window Password Password Canes Enter a Password and click OK to provide access to the corresponding system capabilities PARAMETER MENU OPTION The control system parameter screens can be accessed by double clicking the corresponding blocks in the Master Layout or X Pump block diagrams or they can be accessed by selecting the Parameter menu options Global Master Layout or X Pump as shown below S Terminal Programm Version 2 2 b00002 Eie Parameter Process Setup Graphics Extras Windows Help DENIS Global F10 Master Layout p M TTim Valve 4 23 www comoso com GLOBAL PARAMETER SETTING LIST F10 All of the control system parameter settings can be viewed on a single screen using the Parameter Global F10 menu option as shown below GLOBAL 2 T Cmd 1 Urin 2000 T Cmd 1 Umas onn 4 amp Offset Offset K 2000 4 Overlap r U plus r 2 Kp a00 U minus cu 2 kdi r 1000 U width r TED 100 4 Gain 2 Kd J REN 2 Offset n EE EJ Umin Umar awasi wawas dx 00 4 d Umin
46. nennen page 39 Kd X BLOCK PUMP DERIVATIVE 1 2 2 2 1 page 40 VALVE OVERLAP Y COMPENSATION BLOCK EEN page 40 VALVE CONTROL SYSTEM PARAMETER SETTINGS U page 40 X OFFSET COMPENSATING THE ZERO DISPLACEMENT ERROR OF THE PUMP page 41 SETTING PARAMETERS FOR THE CONTROL ERROR SIGNAL DIGITAL OUTPUT 218 page 42 PARAMETER SETTINGS STORED IN RAM AND EEPROM ON THE DRIVER page 43 SAVING SYSTEM PARAMETER SETTINGS IN EEPROM U page 43 RETRIEVING SYSTEM PARAMETER SETTINGS FROM DRIVER CARD page 43 SAVING SYSTEM PARAMETER SETTINGS IN A FILE U page 44 RETREIVING SYSTEM PARAMETER SETTINGS FROM PC page 45 LOADING THE GOLDCUP DIGITAL HI IQ CONTROL ALGORITHM INTO THE DRIVER CARD page 45 Continued on next page www comoso com TABLE OF CONTENTS continued CONNECTOR PINTO DETAILS u ui CE ERU M E EXE ERE page 46 ECUTDG2 BLOCK DIAGRAM u uuu u u u ME RING RAE MORE Dade page 47 FAULT FINDING GUIDE ci u d oa page 48 ECO DC2 GENERAL ELECTRICAL
47. nged by the user Normally there must be no link fitted POTENTIOMETERS RTR1 Factory set The associated circuit is not used in the HI IQ application RTR2 Factory set The associated circuit is not used in the HI IQ application RTR3 Factory set Sets the over current limit for both A and B solenoid of the proportional control valve The setting is determined by the specifications of the valve used in the application The proportional valve used for the HI IQ application is the 4DCO1 RTR4 Sets the variable dither frequency The hardware dither has been disabled on the latest version of the ECO1 card by removing the dither amplitude potentiometer RTR5 RTR5 was used on older versions of the card If RTR5 is present adjust 4 to the maximum clockwise position for maximum frequency and RTR5 to the maximum clockwise position for minimum amplitude These settings will minimize the effect of the hardware dither RTR5 Not installed on the latest version of the ECO1 card used for the HI IQ application This potentiometer was used on earlier versions of the ECO card The RTR5 potentiometer was used to set the amplitude of the hardware generated dither If RTR5 is present turn potentiometer to the maximum clockwise position for minimum amplitude The ECO1 card now uses software generated dither for the HI IQ application 11 www comoso com DRIVER CARD DIP SWITCH SETTINGS SW1 1 2 3 4 Factory set SW1 2 3 on
48. nt external command potentiometers external transmitters or external electronic units e g a 5 channel command card The available power supply voltages are 15 V and 10 V They are generated on the driver card with an internal switched mode DC DC converter The supply voltages are available at the following connector pins B2 15 V unregulated 50 mA maximum B4 15 V unregulated 50 mA maximum D2 10 V regulated 10 mA maximum D4 10 V regulated 10 mA maximum ENABLE DIGITAL INPUT The driver card must be enabled to activate the card for normal operation of the pump controller Applying a 15 vdc signal to pin B16 enables the driver card Removing the 15 vdc digital input signal disables the driver card The pump displacement input command is internally set to a zero value when the driver card is disabled The driver card continues to provide electrical power to all external devices and all sensor and diagnostic information remains available when the driver card is disabled READY DIGITAL OUTPUT The READY digital output on pin Z16 is not used for the GoldCup Digital HI IQ pump application CONTROL ERROR DIGITAL OUTPUT The CONTROL ERROR digital output is on pin Z18 Pin Z18 operates at 24 vdc when no errors are present in the pump controller Pin Z18 operates at approximately O vdc when an error is present t is the responsibility of the user to determine the actions that are taken when a control error is detected For exam
49. o O minus T width VALVE CONTROL SYSTEM PARAMETER SETTINGS The valve control system parameter settings can not be accessed by this User Interface Software Please contact Denison Hydraulics if you want to make changes to the parameter settings for the valve control loop 40 www comoso com X OFFSET COMPENSATING THE ZERO DISPLACEMENT ERROR OF THE PUMP The signal from the pump displacement sensor should be zero when the pump is at zero displacement However there is always a small the electrical output signal from the feedback sensor at zero pump displacement A small zero displacement error can be eliminated on the driver card using the X Offset adjustment when commissioning a new pump or when servicing an existing pump To access the screen to adjust the X Offset either double click the X Offset colored box on the X Pump block diagram screen or access it through the Parameter X Pump X Offset menu option Double clicking the X Offset colored box on the pump block diagram window will display the following screen Offset j Pump Range of values 512 0 511 Inc Offset Write ta the X Offset adjustment Place two throttling valves in series with the flow from the A and B ports Place suitable pressure gages at both the A and B ports of the pump Operate the pump at the normal idling condition on the machine Send a zero displacement e
50. per closed loop operation See Phase Charts to determine the correct D16 setting for pump flow type of feedback assembly potentiometer or DC RVDT and the location of the feedback sensor A or B port side of the pump D16 Vdigital Logic 1 Invert Feedback Sign Logic 0 Non invert Sign B20 GNDDigital CHANGE SIGN COMMAND The sign of the sum of the input commands at the X Cmd logic block output is inverted when a positive voltage is applied to the digital input E2 at pin D18 This inversion changes the pump output flow to ports A or B for a given input command polarity This function can be used to change the polarity of an outer loop or to produce the desired system reaction for a given polarity command signal D18 Vdigital Logic 1 Invert Command Sign Logic 0 Non invert Sign B20 GNDDigital 52 www comoso com CHANGE SIGN B10 D10 The sign of the command input from terminal B10 D10 is inverted when a positive voltage is applied to digital input E3 at pin D20 B10 D10 is a unipolar positive input To permit negative or opposite pump response the E3 Sign B10 D10 inverts the polarity in the software logic This inversion is in addition to any inversion by the E2 function D20 Vdigital Logic 1 Invert Sign B10 D10 Logic 0 Non invert Sign B20 GNDDigital RAMP Applying a positive voltage to digital input E8 at pin B18 turns on the RAMP function B18 Vdigital Logic 1 RAMP ON Logic 0 RAMP OFF B20
51. ple The user may decide to illuminate an error lamp when an error is detected The user may also decide to remove the ENABLE signal to pin B16 when a pump controller error is detected The user must determine the consequences of the control error and decide what action is best for the overall operation of their machine 15 www comoso com DRIVER CARD RESET SWITCH A red LED light emitting diode located on the front panel of the driver card flashes at 2 Hz when the driver card is operating correctly There is a problem with the internal operation of the driver card when the red LED remains continuously illuminated The driver card has a Reset switch located behind the front panel that can be accessed through a small hole to the left of the red LED This switch is not intended for normal use and should only be operated when there is a problem with the card The Reset switch is a momentary switch that requires only a light push hold for 2 seconds and then release for the Reset to occur Follow this Reset procedure when the red LED is illuminated continuously 16 www comoso com ESTABLISHING COMMUNICATIONS BETWEEN THE EC01 DRIVER CARD AND YOUR PC The overall operation of the GoldCup Digital HI IQ pump can be monitored and the control system parameter settings can be examined and changed using a personal computer PC that has the Denison GoldCup Digital HI IQ User Interface Software installed on the hard drive Contact Denison Hydraulics
52. pump displacement Connect the system as described in the SK 16099 for a 4 20 mA input command www comoso com m o eui u u9D AGL Wwe s uondunsuoo iueuno z 5 UMOUS SD 99 0 peioeuuoo eq siy ul uMous sp 027 JO 55 228 inoBig eui XliddnsA 80798 QN9 o eq Ee N 1024 pejoeuuoo eq upo 228 Purua ay jou s uonp os j oi Pasinbes jou s uonp ios p yo uuoS eq snu Dnuejod 1 91 NVIS NVSOVIO 2 J S3ndino peipjos 210 228 ONS y uonbjos boujoe e 104 sjndu bouoeje 2 812 pubis oug al eJ 0 lt 9 UD 910918 Z um AlddnS AO MO QNO 102 uonpsuedujgoo uano 760 2 SV 3NVS JHL LON D DIA pejbuedes 210 ONS oui ep julod Sn week JONVIIdWNOO INS en jou s Ajddns en jO 2 7 27 G3YINOSY 0 25 N d 31495 98 28 SILON A18N3SSV dnd 0109 20 25 Xoveq33J A1HN3SSV 3XOV8G334 HO ASV N9 ASH QNO od ona UA 802 Galo3NNOO ISNW SVNINH3L
53. r German language Select the Extras Options menu option to select the language as follows i Terminal Programm Version 2 2 500002 Pie Parameter Process Setup Graphics Extras Windows Help options ONLINE Cancel Englisch THE HELP MENU OPTION Selecting the Help About menu option displays the software version 2 2b00002 that must be used on a PC to communicate with the ECO1 driver card as shown below It also displays the PC User Interface Software file name card model number card hardware code number system binary file code number application software code number system parameter setting file code number and operating system kernel software code number You must have the corresponding version of the User Interface Software to be able to communicate with the driver card using a PC This information is helpful when ordering additional products from Denison and for diagnosing problems These numbers uniquely describe the capability of the driver card The control system parameters can be changed by the user as described in subsequent sections of this manual Storage and retrieval of the control system parameter settings are described in subsequent sections of this manual gt Terminal Programm Version 2 2 b00002 Eile Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics Documentation n Lo EU About x DENISON Hydraulik GmbH Version 2 2 0002 Copy
54. raulics Canada Inc 2880 Brighton Road Unit 1 Oakville ON L6H 553 Canada Tel 1 905 829 5800 Fax 1 905 829 5805 Mexico Central America South America amp Caribbean Denison Hydraulics Inc 7850 NW 146 Street Suite 512 Miami Lakes FL 33016 USA Tel 1 305 362 2246 Fax 1 305 362 6220 USA Denison Hydraulics Inc 14249 Industrial Parkway Marysville OH 43040 USA Tel 1 937 644 3915 Fax 1 937 642 3738 Austria Denison Hydraulics GmbH Zweigneiderlassung Linz Haidbachstrake 69 4061 Pasching Austria Tel 43 72 29 6 48 87 Fax 43 72 29 6 30 92 Benelux Denison Hydraulics Benelux B V Pascalstraat 100 3316 GR Dordrecht Holland Tel 31 78 6543 070 Fax 31 78 6175 755 Denmark Denison Hydraulics Denmark A S Industrikrogen 2 2635 Ish j Denmark Tel 45 4371 15 00 Fax 45 4371 15 16 Finland Denison Lokomec Oy Polunmaenkatu 22 P O Box 116 33721 Tampere Finland Tel 358 3 357 51 00 Fax 358 3 357 51 11 France Denison Hydraulics S A 14 route du bois blanc BP 539 18105 Vierzon France Tel 33 2 48 53 01 20 Fax 33 2 48 75 02 91 Great Britain Denison Hydraulics UK LTD Kenmore road Wakefield 41 Industrial Park Wakefield WF2 OXE West Yorkshire England Tel 44 1924 826 021 Fax 44 1924 826 146 Germany Denison Hydraulics GmbH Auf dem Sand 14 40721 Hilden Germany Tel 49 0 2103 940 3 Fax 49 0 2103 940 5
55. right DENISON Hydraulics 1998 LegalTrademarks This product is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program any portion of it may result in severe civil and criminal penalties For news and updates visit us in the http daat denisan de 2500007 2 DAC 0100801 8 Bin File Mo B 26000311 Applicationna 36000201 Parameterna 736001181 Kernelno 1 21 www comoso com DIGITAL INPUT DIGITAL OUTPUT AND CONTROL LOOP STATUS INDICATORS The lower left corner of the screen has several colored boxes that indicate the status of the digital inputs digital outputs proportional valve control loop and the pump displacement control loop The digital inputs are identified with the boxes labeled E1 through E8 The digital outputs are identified with the boxes labeled A1 through A4 The rear connector terminal strip number for the digital inputs and outputs is also shown in parentheses next to the indicator label The pump displacement control loop is identified with a colored box labeled W1 and the proportional control valve loop is identified with a colored box labeled WO The following table identifies the functions being monitored and the signal status that they represent Status Box Color Description O Bei Y E Invert sign of X Fdback No
56. s DENEN J Fee Umin EE Umax em di 3000 4 Kis Ki E Umin ECH Umax ECH EE di EH 4 Kp __ 4 Kd 2008 Dmax 40 Limit LIminus 100 Uplus 100 4 HampX T 01 EE Read from RAM T WW iS Cancel 56 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P6 P7 AND P8 PUMPS WITH DC RVDT DISPLACEMENT SENSOR GLOBAL x 2 Ki Ki yh T Lrnd eai LI min 1 2000 T Umas anon 4 amp Offset Offset d 2000 4 Overlap Y U plus J n 2 40 U minus 2 1000 U width r 7 A100 4 Kp 2355 2 DAU Kd THO 2 Offset n ss j NI s Umin mz E was EN dx 000 4 Kis Ki 25 Umin RECH E mas 10 di a9 4 Kp 2 4 Kd SD 25 4 Limit gt lt LI rninius cqr 100 Cc e c Uplus 100 cc 4 Ramp x T cr rT Read from T s Cancel 57 www comoso com DENISON DEFAULT PARAMETER SETTINGS FOR P11 AND P14 PUMPS WITH POTENTIOMETER DISPLACEMENT SENSOR GLOBAL wl 2 Ki T Lrnd 111 1 LI min 2000 T Crd 201 Umax on 4 Of set Offset d 2000 4 Overlap r LI plus n 2 LI minus es 2 kdi Ed 1
57. screen is used to view the various signals as a function of time It is particularly useful in monitoring the performance of the pump control system and for tuning the control system parameters The colors of the bars can be changed by selecting the Graphics menu option followed by the Options or pressing F6 function key option as shown in the following figures Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help ONLINE Graphics Options wl Active Channel Color er Fdback from Scale Axis Lm Ce Online Offline Sample Time Screen Screen 100 m ok Cancel 30 www comoso com The signal can be selected from the drop down menu labeled Channel The color can be selected by placing the mouse pointer on the desired color in the 4 x 4 color pallette matrix and pressing the left mouse button The Active box can be toggled from a blank to a check mark in a similar manner using the mouse Placing a check mark in the Active box displays that signal on the Graphics window oscilloscope screen The Graphics window display of the various signals can be scaled by selecting the values in the boxes labeled from and to with the mouse and entering new values The default values are displayed in 9o of full scale under the Unit heading The bar graph display can be customized to display other engineering units e g volts mA cc The scale of the horizontal time
58. sed as Vext source See INSTALLATION AND WIRING OF THE EC01 DRIVER CARD Ready A1 Dig 1Out The digital output 1 Dig 1OUT 216 is not intended for general customer use in the HI IQ application GREEN NO ERROR RED ERROR A2 Dig 2Out The digital output A2 Dig 2OUT pin Z18 is configured and used for ERROR detection This digital output is set to logic 1 green no error when no errors are detected in either the pump or valve control loops If an error is detected the output is set to logic 0 red error to indicate that an error has occurred The Z18 output can be connected to the master control system logic to provide a safety interlock See the sections on fault analysis and digital input and digital output display for more information o4 www comoso com ANALOG INPUTS The driver card has 6 analog inputs Three are voltage inputs and three are 4 20mA current inputs The function of these analog inputs is defined by Denison for the HI IQ application The following defines the function and electrical specifications of the analog inputs Term B8 2 6 input range 10MO input impedance OpAmp buffered This input is dedicated to the pump displacement feedback signal Term B10 D10 Differential 0 10V unipolar input gt 10MQ input impedance OpAmp buffered This input is dedicated to auxiliary command input The polarity can be changed by the software logic and digital input E3 at Pin D20 Term B12
59. sign of the Digital Electronic Driver Card is the key to making the GoldCup Digital HI IQ system easy to use The EC01 DC2 driver card employs advanced digital technology providing unmatched ease of use performance and reliability The cards are shipped from Denison with all of the customer control system parameters preset and stored in the memory of the card This dramatically reduces new machine commissioning time and saves time in servicing existing machines The digital electronic controller also provides the ability to monitor the operation of the system and to diagnose and solve problems before they result in machine downtime Access to all of the critical control system parameters is provided through a Windows based Denison User Interface Software package that can be installed on your PC This PC software adjustment system for the electronic driver card prohibits unauthorized personnel from making changes to critical control system parameter settings A Denison supplied password is required to make any changes to the driver card settings Only authorized users with the Denison User Interface Software properly installed on their PC and supplied with the appropriate Denison password are able to make adjustments to the control system parameter settings This User Manual describes the general operation of the digital electronic driver card and the hardware software and procedures to evaluate the performance of the pump It also describes how to make adju
60. stments to the pump electronic control system parameters in the field 01 DRIVER CARD CODE NUMBERS The control system parameters are stored in the ECO1 card memory customizing each card for the particular GoldCup pump model and configuration that it operates The following table provides the existing standard ECO1 Card Code Numbers The ECO1 Card Code Number is displayed on a printed label located on the side of the rear electrical connector of the card Two cards are shown at the bottom of the table that have zero values stored in the memory These two cards can be configured to operate with any pump model and configuration using the Denison GoldCup Digital HI IQ User Interface Software version 2 2b to manually set the control system parameters and store them the card memory Contact Denison for the ECO Card Code Numbers for pumps that operate with with a servo pressure higher than 41 bar Pump Model Sensor Type Command Servo Pressure Code Number 726 00030 3 726 00031 3 726 00034 3 rpnn O OPY IT tc lt a s P6 P7 or P8 potentiometer 4 20 mA 726 00100 3 P11 or P14 potentiometer 4 20 mA 726 00102 3 P24 P30 potentiometer 420mA per s ns aO m 726 00020 3 4 20 mA 726 00050 3 INSTALLATION AND WIRING OF THE EC01 DRIVER CARD Connect the electronic driver card pump and control valve as described in the SK 16101 electrical connection diagram for a 10 vdc input command for
61. te to RAM button sends the new Gain X value to the driver card A Kp value of 2100 mV is required to scale the optional potentiometer feedback device and a Kp value of 2400 mV is used to scale the optional DC RVDT feedback device The Kp value represents the full scale signal in mV and is not a true proportional gain block LIMIT X BLOCK PUMP MAXIMUM DISPLACEMENT LIMITER The Limit X block allows you to set a limit for the maximum displacement of the pump from either the or B port Double clicking the Limit X block in the X Pump block diagram displays the following window Limiter E Pump 100 to 100 Cancel Selecting the boxes labeled Uminus Uplus allows new value to be entered to limit the maximum pump displacement for pump flow in either direction Selecting the Write to RAM button sends the new Uminus and Uplus values to the driver card The value entered for Uminus and Uplus is the percentage of maximum displacement to either the or B port 37 www comoso com RAMP X BLOCK PUMP RAMP GENERATOR The Ramp X block allows you to set two different ramp times in milliseconds for flow to the or B port of the pump Double clicking the Ramp X block in the X Pump block diagram displays the following window k T Cmd accel ms H TT nte to T decel me 1 T Cmd decel ms 1 Cancel T Cmd accel ms 1 Selecting the bo
62. tinvrted 2 lvetsgnofXCmd inverted Notinverted Invertsign of D10 B10 input Inverted Notinvrted E Notused 25242 42 ES 4 ___ ___ E6 Mme 42 00 00 O E8 Ramp Rampenabed Ramp disabled 444 A1 4 2 0 2 A3 4 0 7 O Status Box Color Description Yellow WO Valve watch dog timer no error error W Pump watch dog timer no error error The two boxes below the A4 box labeled Ready are indicators for the Graphics mode The boxes are yellow when taking measurements in the Online graphics mode They change to a pink color when collecting and storing data in the Offline graphics mode 22 www comoso com ENTERING A PASSWORD Access to the advanced capabilities of the GoldCup Digital HI IQ electronic control system are protected by the use of passwords There are three levels of passwords At the first password level the user can monitor the operation of the control system change the variables and the color coding used for the Graphics display screen change between English and German language for the screen text and select the COM port At the second password level the user has the capability provided by the first password level and can also make changes to the electrical input and output connections to the ECO1 driver card At the third password level the user has the capability provided by the second password level and can also
63. tween the PC and the driver card The word OFFLINE will appear next to the Denison logo and a red box will be displayed until the serial communications port address is assigned A window will also appear warning that Communication is offline This indicates that the PC has not established communication with the ECO1 driver card Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help G Communication is offline OFFLINE Ig The User Interface Software will automatically try to establish communication with the driver card and will display the following window if it has been successful This process will take a few seconds G Port reinitialised The serial communication port address of the PC may have to be manually selected if communications with the card has not been automatically established within a few seconds To select the serial communications port address of the PC select the Setup option on the menu bar to open the following window Terminal Programm Version 2 2 b00002 Ele Parameter Process Setup Graphics Extras Windows Help Save to EEPROM F12 Read from RAM F11 auc d FG Measurement Setup Mau 41 BB Shift F7 SEE COM Sct X Fdback 02 Start Measurement F4 X Cmd 06 Stop Measurement ESC X Cm Main Oe m Last Dialog F8 Password 18 www comoso com Select the COM Setup option by a left click of
64. w comoso com DISPLAY OF GRAPHICS WINDOW MASTER LAYOUT Y VALVE AND X PUMP BLOCK DIAGRAMS The Graphics window Master Layout block diagram and X Pump block diagram can be displayed by selecting the Windows menu options shown below Terminal Programm Version 2 2 b00002 File Parameter Process Setup Graphics Extras Windows Help DENISON Hydraulics Show Graphics ONERE Master Layout T Time 5546 ms alye X Pump Y Fdback 7E Y 3 5 X Pump block diagram also be displayed by double clicking the X Pump box the Master Layout window shown below Master Layout ojx Offset 8 The recommended control system parameter settings for all of these blocks are stored in the card memory by Denison for the various models and configurations of GoldCup Digital HI IQ pumps as shown in the table on page 6 The following paragraphs describe how to monitor and change these values if required These control system parameter settings can dramatically affect the response and stability characteristics of the pump They should only be changed by trained technical service personnel and with extreme care 35 www comoso com PUMP CONTROL SYSTEM PARAMETER SETTINGS The pump control system parameter settings can be accessed by selecting the Parameter menu options and either the Global Master Layout or X Pump options as shown below S Terminal Programm Version 2 2 b
65. xes labeled T Cmd accel T decel T Cmd decel and T Cmd accel allows new values to be entered to limit the maximum rate of change of the pump displacement for flow in either direction and for increasing or decreasing flow conditions Selecting the Write to RAM button sends the new ramp values to the driver card The Ramp Enable signal must be applied to pin B18 to activate the ramp The Ramp Enable signal is identified as Digital Input E8 on the PC screen Ki X BLOCK PUMP LARGE SIGNAL INTEGRATOR GAIN There are two integrator blocks in the control loop The Ki X block allows you to set an integrator that operates at low gain on large signals The integrator improves the accuracy of the pump to follow the displacement commands This integrator gain Ki is active when dX U lt dX and is limited to Umin lt integrator output lt Umax Double clicking the Ki X block in the X Pump block diagram displays the following window Integral Controller k da 2000 Ki 1 LImin PI Liman 511 write ta RAM Selecting boxes labeled dX Ki Umin and Umax allows new values to be entered for the gain of integrator and the range over which it operates Selecting the Write to RAM button sends the new values to the driver card The Ki gain of the integrator has a significant influence on the stability of the control system and should be used carefully 38 www comoso com

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