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1. 53 5 2 1 Run Fault LED 54 5 2 2 Valve Current LED 54 5 2 3 Feedback LED 54 5 2 4 Testpoint 54 5 3 Basic Diagnostics with PC Interface 55 5 4 Programmable Outputs Diagnostic 56 5 5 Advanced Diagnostics 56 5 5 1 Module Faults 56 5 5 2 System Messages 57 6 Technical Data
2. 26 4 3 Pump Controller Configuration 30 4 3 1 Overview 30 4 3 2 Configuration 30 4 3 2 1 Function Zero Stroke Command 31 4 3 2 2 Stroke Controller 31 4 3 2 3 HP Limiter 32 4 3 2 4 Output Polarity 32 4 3 2 5 Output Current Limit 33 4 3 2 6 Dither 33 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Sit
3. 6 0 107 50 98 3 400 1500 0 85 43 From the Advanced Configuration form the user enters each of the variables in the desired system of units Once this is done the use presses the HP Theory command button to create a new value for the HP factor 49 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 4 5 2 Ramp Configuration The EPC module provides one ramp module and is configured by program items 870 through 874 The ramp can be configured from the Advanced Configuration Form select Diagnostics and then Advanced Program Item Range Description 870 0 to 4 Ramp 1 Source 871 1 to 255 Ramp 1 Acceleration Rate 872 1 to 255 Ramp 1 Acceleration Step 873 1 to 255 Ramp 1 Deceleration Rate 874 1 to 255 Ramp 1 Deceleration Step Table 17 Ramp Configuration Source The Source selects the Analog Input used as the ramp input Valid entries are 0 No Ramp 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 or 4 LVDT Analog Input 4 If No Ramp is selected the ramp module will be disabled and the ramp function will be equal to 2048 DAC counts Rate and Step The Ramp module provides different ramping rates for acceleration and decele
4. 43 4 4 5 2 Adjustment Algorithm 44 4 5 Advanced Configuration 46 4 5 1 Horsepower Limit Factor Calculation 46 4 5 1 1 Experimental HP Limit Factor 47 4 5 1 2 Theoretical HP Limit Factor 48 4 5 2 Ramp Configuration 50 5 Module Diagnostics 5 3 5 1 Diagnostic Representation of Numbers 53 5 1 1 DAC Counts 53 5 1 2 Voltage and Percentages 53 5 2 Basic Diagnostics on Front Panel
5. Program items 8xx Diagnostics General Purpose Input Configuration Analog IO Configuration Fine Adjustable Input Configuration LVDT Diagnostics Servo Driver Configuration Programmable Output Selections Program items 84x 85x 86x 88x and 93x Diagnostics Ramp Configuration and Advanced HP Limit Setup Advanced Configuration program items 87x and 810 Language Select English German or Italian Help User Help Items are programmable either through Numeric Input boxes or Drop Down List boxes EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 4 Module Configuration 4 1 General Configuration General Configuration parameters include Password Mode and Communication Setup Parameters 4 1 1 Password Protection 000 Program Item Range Description 000 0 to 255 Password Table 1 Password Protection The EPC has a simple lockout password that can be used to protect the program configuration from accidental changes The password is entered through program item 000 in the General Configuration Form If the password is set to 249 the user will be able to modify any editable entry Any other password will place the device in read only mode The user will not be able to modify any entry in this mode
6. 4 1 2 Operating Modes 200 Program Item Range Description 200 0 to 7 Operating Mode 0 Dynamic Function Selection with Fault Monitor 1 Dynamic Function Selection with Watchdog Monitor 2 Static Function Selection with Watchdog Daisy Chain 3 Dynamic Function Selection with Limit Monitor 4 Static Function Selection with Fault Monitor 5 Static Function Selection with Watchdog Monitor 6 Static Function Selection with Watchdog Daisy Chain 7 Static Function Selection with Limit Monitor Table 2 Operating Modes The EPC has eight 8 operating modes For Dynamic Modes the EPC will dynamically select the active function program based on the state of the digital input and the Program Block settings For Static Modes the EPC has only function block 1 active and the digital input may be used for an alternative purpose defined by that particular mode described in the following sections The digital output is always controlled by the mode specification Note Firmware versions prior to 1 10 only support Modes 0 1 and 2 6 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 7 4 1 2 1 Dynamic Function Selection with Fault Monitor This operating mode is selected by setting program item 200 to 0 by choosing Mode 0 Dy
7. 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If Open Loop is chosen the stroke controller is disabled and the command is passed directly through to the output KP and KI KP and KI provide the proportional and integral constants respectively for the PI control algorithm Both terms are expressed as 0 to 100 of a maximum value The PI control loop can be made a P only control loop by setting the KI term to 0 Likewise the PI control loop can be made an I only control loop by setting the KP term to 0 The command to the stroke controller is from either the Active Program or the Function Zero Stroke Command or by the HP limited adjustment of this command please refer to Section 4 3 2 3 An error signal is produced by comparison of this command to the stroke feedback signal The PI loop produces Yp and Yi determined by the error signal and the KP and KI constants respectively The stroke controller output is made by the summation of Yp and Yi The Stroke Controller is disabled if the Stroke Feedback Source program item 800 is selected as Open Loop The Pump controller relies on the stroke feedback device being configured correctly Please refer to Section 4 4 5 regarding the LVDT Adjustment Algorithm EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bullet
8. Setting is applied immediately AFTER the Polarity setting and BEFORE the Servo Driver Offset Setting The Servo Driver Offset parameter menu item 966 applies an offset voltage to the servo driver signal Valid entries are from 10 0VDC to 10 0VDC at 0 1VDC increments The Offset Setting is applied immediately AFTER the Attenuation setting and BEFORE the Current Limit Setting The Servo Valve Driver current is shown in voltage units The driver range of 10V to 10V is a scaled value of the output current Depending on the EPC part number the output current may be different for the same output voltage See the table 16 for more information EPC P N Driver Current Current Current Current Current L723888 Current 10V 5V 0V 5V 10V 310 800mA 800mA 400mA 0mA 400mA 800mA 311 800mA 800mA 400mA 0mA 400mA 800mA 312 700mA 0mA 0mA 0mA 300mA 700mA 314 250mA 250mA 125mA 0mA 125mA 250mA Table 16 Driver Output EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 41 4 4 4 2 Stroke Feedback Device The Stroke Feedback Device information is displayed in both a bar graph and numerical form The Feedback Device is determined by menu item 800 located in the Pump Controller Form
9. The Polarity setting is set to either 0 Normal or 1 Inverted Inverting the input in this way would be equivalent to reversing wire leads to the module In fact a better long term solution to using the invert setting would be to reverse the wire leads to the module Current Fault Enable The Current Fault is set to either Disabled or Enabled and is designed for use when a 4 to 20mA input device is used The EPC module requires a 500 resistor across in parallel the Analog Input terminal pins see Figure 20 If used a 4 to 20mA input device will result in a voltage from 2VDC 4mA to 10VDC 20mA to the module If the Current Fault is enabled the module will set a System Message if this voltage falls below 1 5VDC approximately 3mA The four configuration settings are used together to configure the general purpose analog inputs The order of monitoring configuration is 1 A Fault is reported if the Current Mode Fault is enabled and the current supplied to the module falls below 3mA 2 Offset Voltage by Offset Setting 3 Multiply Voltage by Gain Setting 4 Invert Analog Input if Polarity Invert set EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 37 Example 1 A user wants a 4 20mA signal at Analog Inpu
10. c Ramp Rate 0 4988 Volts second 15mV step every 29 milliseconds d Ramp Rate 0 5001 Volts second 39mV step every 78 milliseconds The optimal setting depends on the ramp requirements and system dynamics If time is not critical the settings for a which have the smallest step size would be optimal If time is critical and the system dynamics allow for a larger step size the settings in d should be used since the ramping is closer to the desired value 0 5001 V s rather than 0 5210 V s Deductive reasoning can be used to find the rate and step values for a desired ramp EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 52 Example 4 What settings would be used to produce a 5 second ramp for a 0 to 10 Volt step command A 10 Volt 5 second 2 Volt second ramp is desired Since both the Rate and Step have values from 1 to 255 an arbitrary value of 10 is chosen for the Step and the Rate value is calculated Ramp Rate Closed Loop Response 0 004884 Step Rate Rate Closed Loop Response 0 004884 Step Ramp Rate 1600 0 004884 10 2 39 A step of 10 and rate of 39 make a 2 0037 Volt second ramp 48 mV step every 24 milliseconds Because 10 39 is approximately 1 4 we
11. 10VDC signal EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 19 Pressure Point 2 Source The Pressure Point 2 Source selects the source of the pressure point 2 signal for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Pressure Point 2 Preset is used as the delta pressure point 2 command Delta Pressure Source The Delta Pressure Source selects the source of the delta pressure signal for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Delta Pressure Preset is used as the delta pressure command Pressure Limit Source The Pressure Limit Source selects the source of the pressure limit command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Pressure Limit Preset is used as the pressure limit command Pressure Point 1 Source The Pressure Point 1 Source selects the source of the pressure feedback for the program Valid
12. 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E Figure 3 General Configuration Form Example 1 Operating Mode program item 200 is set to 0 Dynamic Function Selection with Fault Monitor Program Selection for Program Block 1 program item 210 is set to 1 Pressure Control and Program Selection for Program Block 2 program item 211 is set to 3 Flow with Pressure Limit Control See Figure 3 If the digital input is low lt 5 VDC Program Block 1 is made active and the active program is Program 1 Pressure Control If the digital input is high gt 5VDC Program Block 2 is made active and the active program is Program 3 Flow with Pressure Limit Control Example 2 Again operating Mode is set to 0 Program Selection for Program Block 1 program item 210 is set to 1 Pressure Control and Program Selection for Program Block 2 program item 211 is set to 0 No Program If the digital input is low lt 5 VDC Program Block 1 is made active and the active program is Program 1 Pressure Control If the digital input is high gt 5VDC Program Block 2 is made active but since no program is activated the module uses a special zero function command to command the pump controller refer to Section 4 3 2 1 for configuration of the Function Zero Stroke Command Mode 2 For operating mode 2 Static Function Selection with Watchdog Daisy Chain the
13. Dynamic Mode Program Overview The Advanced Control with Feed Forward Program in Closed Loop is a PI control with an adjustable Feed Forward signal Comparing the command to the feedback values produces an error value The error is multiplied by the KP and KI constants to produce the YP and YI contributions of the PI controller This signal is then summed with the feed forward signal to produce the output signal The Advanced Control with Feed Forward Program in Open Loop simply modifies a command with an offset and gain producing a output signal The PI control is not used If using EPC software version prior to 1 10 this program is not available EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 28 Figure 11 Advanced Control with Feed Forward Program in Closed Loop Example Figure 11 shows Program 11 Form for Advanced Control with Feed Forward in Closed Loop The Command Source is Analog Input 1 program item 501 1 The Command Preset is set to 10 program item 500 10 although the Command Preset is not used in this example The Feedback Source is Analog Input 2 program item 502 2 The error signal is produced by comparing the Command Source to the Feedback signal 1 00V 1 30V 0 30V The Yi and Yp signals are pro
14. E Mail Support OTG_electronic compuserve com EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 8 Ordering Information EPC Modules are available in three standard options Non Configured Modules Standard Configured Modules and Small Engineered System Units Non Configured Modules are intended for customer engineered systems and OEM applications It is expected that the user has completed Oilgear training or has significant experience with hydraulic systems and Oilgear electronics Wiring diagrams and installation drawings are not provided beyond the standard bulletin and or PC Interface Software online help both items ordered separately All accessory items should be ordered as separate line items please see the Accessories Section for more information Standard Configured Modules are intended for standard single unit applications or replacement parts for Small Engineered Systems The modules are pre programmed by Oilgear prior to shipping but may require some field adjustment Wiring diagrams and installation drawings are not provided beyond the standard bulletin and or PC Interface Software online help both items ordered separately All accessory items should be ordered as separate line items please see the Accessories Section for
15. EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 1 EPC 300 Series 3xx User Manual EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 2 Table of Contents 1 Introduction 4 2 Basic System Overview 4 3 General Instructions 5 3 1 Password Protection 5 3 2 PC Interface Groupings 5 4 Module Configuration
16. Generation 2 48x 49x Program Item Range Description 480 0 to 100 Program 9 Flow Command Preset 481 1 to 100 Program 9 Pressure Command Preset 482 0 to 5 Program 9 Flow Command Source 483 0 to 5 Program 9 Pressure Command Source 484 1 to 5 Program 9 Pressure Feedback Source 485 0 to 1 Program 9 Program Output Destination 486 0 to 100 Program 9 KP 487 0 to 100 Program 9 KI 488 0 to 100 Program 9 Q to P Control Switch Preset 489 0 to 7 Program 9 Q to P Control Switch Source 490 0 to 100 Program 10 Flow Command Preset 491 1 to 100 Program 10 Pressure Command Preset 492 0 to 5 Program 10 Flow Command Source 493 0 to 5 Program 10 Pressure Command Source 494 1 to 5 Program 10 Pressure Feedback Source 495 0 to 1 Program 10 Program Output Destination 496 0 to 100 Program 10 KP 497 0 to 100 Program 10 KI 498 0 to 100 Program 10 Q to P Control Switch Preset 499 0 to 7 Program 10 Q to P Control Switch Source Table 8 Pressure Control with Flow Preset Programs Function Programs 9 and 10 provide for Pressure Control with Flow Preset Program 9 is configured in program items 480 through 489 in the Program 9 Form Program 10 is configured in program items 490 through 499 in the Program 10 Form Flow Command Preset The Flow Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being e
17. HP Limiter is inactive and the pump controller command will be passed directly to the stroke controller KP and KI KP and KI provide the proportional and integral constants respectively for the PI control algorithm Both terms are expressed as 0 to 100 of a maximum value The PI control loop can be made a P only control loop by setting the KI term to 0 Likewise the PI control loop can be made an I only control loop by setting the KP term to 0 The product of Pressure and Stroke signals is compared to the HP Limit Factor program item 810 If the product is greater than the factor the feedback HP is greater than the allowed HP and the pump controller command is adjusted through the Yp and Yi contributions of the HP Limiter PI controller The HP Limiter works only as a limiter the pump controller command is not manipulated if the HP Limit Factor is greater than the calculated HP The HP Limiter relies on the HP Limit Factor being configured correctly Please refer to Section 4 5 1 regarding the HP Limit Factor Calculation 4 3 2 4 Output Polarity Module Polarity is selected from program item 802 from the Pump Controller Form Polarity program item 802 is either 0 Normal or 1 Inverted EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 8
18. If using EPC software version 1 06 or earlier see Appendix A for Generation 1 control EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 24 Figure 9 Pressure Control with Flow Preset Program in Pressure Mode Example Figure 9 shows Program 9 Form for Pressure Control with Flow Preset in Pressure Mode The Flow Command Source is Analog Input 1 program item 482 1 The Flow Command Preset is set to 10 program item 480 10 although the Flow Command Preset is not used in this example The Pressure Command Source command is the Preset Value program item 483 0 therefore the pressure limit command is set at a 50 level program item 481 50 The Pressure Feedback Source is Analog Input 2 program item 484 2 The Q to P Control Switch Source is Limit Offset program item 489 6 The Q to P Control Switch Preset is set to 10 program item 488 10 therefore the Q to P Toggle Point is 5 00V 1 00V 4 00V The error signal is produced by comparing the Pressure Command Source to the Feedback signal 5 00V 4 40V 0 60V The Yi and Yp signals are produced from the PI controller and the Pressure command is roughly equal to their sum 2 50V 2 36V 4 86V Since the Pressure Feedback 4 40V is greater than the Q to P Control Swi
19. Pressure Limit Preset is used as the pressure limit command EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 16 Pressure Feedback Source The Pressure Feedback Source selects the source of the pressure feedback for the program Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller module and is passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination KP KP provides the proportional gain setting to control the pressure limit slope KP is configured as a percentage with 0 to no proportional gain and 100 equivalent to maximum proportional gain Pressure Breakpoint Preset The Pressure Breakpoint Preset allows for direct numeric input The preset has a slightly different characteristics depending on the value of its entry If the Pressure Breakpoint Source is set to
20. Software Information 11 4 1 5 USB Communication 12 4 1 6 Update Rate 12 4 2 Program Configuration 12 4 2 1 Overview 12 4 2 2 PI Control Algorithms 12 4 2 3 Pressure Control Programs 40x 41x 13 4 2 4 Flow with Pressure Limit Programs Generation 2 42x 43x 15 4 2 5 Load Sense Control Programs 44x 45x 18 4 2 6 Simple Flow Control Programs 46x 47x 21 4 2 7 Pressure Control with Flow Preset Programs Generation 2 48x 49x 22 4 2 8 Advanced Control with Feed Forward Programs 50x 51x
21. USA 53219 Bulletin 836260E 34 4 3 3 Configuration Example Figure 13 Pump Controller Configuration Figure 13 shows the Pump Controller Module Form The Diagnostic screen shows that Program 3 is active and passes the command of 7 11V to the Pump Controller The Function Zero Stroke is set to 50 program item 801 50 so if no program was active a neutral stroke would be the Pump Controller command signal The Pressure Feedback Source is Analog Input 1 program item 811 1 and the Stroke Feedback Source is LVDT program item 800 4 The internal HP calculation based on these pressure and stroke signals results in a value of 4 56V The HP Limit Factor of 28 results in a value of 2 80V so the actual HP is greater than the allowed HP The error signal is the difference of these calculated numbers is 2 80V 4 56V 1 76V The HP Limit is made up of the Yi and Yp contributions computed from the HP Limiter PI controller The resulting Command with HP Limit is 7 11V 0 69V 6 42V This command along with the Stroke Feedback signal is passed to the Stroke Controller where the error signal is 6 42V 8 31V 1 89V This error signal is used for the Stroke Controller PI calculations and the output is equal to the Yi and Yp contributions is 0 00V 5 90V 5 90V Module Polarity is set to Invert the module output program item 802 1 so the 5 90V signal becomes 5 90V Finally the current is limited to 50 of maximum so the 5
22. control is to maintain a pressure difference across an orifice refer to Figure 6 Typically two pressure transducers would be used to monitor two points in the hydraulic circuit The pump flow would be controlled such that P P1 P2 In addition to this basic control a pressure limiter is added to ensure that the down flow pressure at P2 does not reach a critical point The controller command is the sum of the Point 2 Pressure and Delta Pressure signals limited by the Pressure Limit Command Comparing this command with the Point 1 Pressure signal results in an error value The error is multiplied by the KP and KI constants to produce the Yp and Yi contributions to the program output signal Figure 7 Load Sense Program Example Figure 7 shows Program 5 Form for Load Sense The Delta Pressure Source is set to the Delta Pressure Preset Value of 10 program item 444 0 and program item 441 10 The Pressure Point 2 Source is Analog Input 1 program item 443 1 therefore the command is 1 00V 1 54V 2 54V The Pressure Limit Source is set to the Pressure Limit Preset Value of 50 program item 445 0 and program item 442 50 In this case the previous command value is not limited since the command 2 54V is less than the Pressure Limit Command 5 00V The error signal is produced by comparing the Command to the Pressure Point 1 signals 2 54V 2 24V 0 30V The Yi and Yp signals are produced from the PI controller and the Progr
23. items 850 through 853 are used to configure Analog Input 1 program items 860 through 863 are used to configure Analog Input 2 and program items 880 through 883 are used to configure Analog Input 3 The Analog Inputs are configured from the Analog Input Configuration Form select menu Diagnostics and then Analog IO Configuration Offset A voltage offset can be applied to the Analog Input The voltage offset can be in the range of 10VDC to 10VDC at 0 1VDC increments The Analog IO Configuration Form allows for the direct entry of a voltage offset EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 36 Gain A limited gain factor can be applied to the Analog Inputs Values in the range of a 0 125 attenuation to a 4 gain at 0 125 increments are available The Analog IO Configuration Form allows for the direct entry of a gain Table 13 lists the 32 gains available Gain Gain Gain Gain 0 125 1 125 2 125 3 125 0 250 1 250 2 250 3 250 0 375 1 375 2 375 3 375 0 500 1 500 2 500 3 500 0 625 1 625 2 625 3 625 0 750 1 750 2 750 3 750 0 875 1 875 2 875 3 875 1 000 2 000 3 000 4 000 Table 13 Analog Input Gain Settings The resulting voltage is limited to the 10VDC to 10VDC range Polarity
24. lt 5 VDC Program Block 1 is made active and the program defined in program item 210 is used If the digital input is high gt 5VDC Program Block 2 is made active and the program defined in program item 211 is used Refer to Section 4 1 3 for discussion of Program Block Configuration 21x The digital output provides a signal as to whether the stroke command is being limited due to an over Power or over Pressure condition The over Power condition is specified from the Horsepower Limiter The only supported over Pressure condition is specified by the Flow with Pressure Limit Control algorithm Generation 2 If either limiting condition is taking place the digital output will be low 0 VDC If no limiting situation is taking place the digital output will be high Vsupply If the Horsepower limiter is disabled and a program other than a Flow with Pressure Limit Control program Generation 2 is active the digital output will be high 4 1 2 5 Static Function Selection with Fault Monitor This operating mode is selected by setting program item 200 to 4 by choosing Mode 4 Static Function Selection with Fault Monitor from the General Configuration Form of the PC Interface In this operating mode Program Block 1 is always active and the program defined in menu 210 is used Program Block 2 is always inactive and menu item 211 has no function The digital output provides standard condition status If no faults are present the digital
25. the maximum rated current At this point the user notes the DAC reading for pressure and stroke The HP factor is determined by the formula 20480 2048 2048 2046 100 The PC interface allows a one touch solution from the Advanced Configuration Form The user simply presses the HP Experiment push button once the maximum current is reached EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 4 5 1 2 Theoretical HP Limit Factor The HP limit factor can also be determined by the theoretical formulas For metric units the horsepower factor is determined by the equation 6 0 107 Where Power is the motor rating in kW DMAX is the maximum displacement of the Pump in ml rev PXDCR is the maximum measured pressure in Bars i e the pressure corresponding to a 10VDC or 20mA reading N is the speed in rpm is the pump efficiency The user may also use conventional English units 4 0 107 Where Power is th
26. www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 51 The Potential Step can be computed from the Step setting Example 1 A Rate of 255 and a Step of 1 is used for a 1600 Hz module The Ramp Rate in Volts second is Ramp Rate 1600 x 0 004884 x 1 255 0 03064 Volts second so a 10 Volt step would ramp over a period of 326 seconds 5 minutes 26 seconds The setting of Rate 255 and Step 1 results in the slowest ramping rate Example 2 A Rate of 1 and a Step of 255 is used for a 1600 Hz module The Ramp Rate in Volts second is Ramp Rate 1600 x 0 004884 x 255 1 1993 Volts second so a 10 Volt step would ramp in only 5 milliseconds The setting of Rate 1 and Step 255 results in the quickest ramping rate A user should select a ramp rate that is close to a desired value while not producing an undesirable step Generally the lower the values for rate and step the smaller the step Example 3 Which of the following are the optimal settings for a 0 5 Volt second ramp a Rate 15 Step 1 b Rate 31 Step 2 c Rate 47 Step 3 d Rate 125 Step 8 Assuming a 1600 Hz closed loop response the settings for a result in Ramp Rate 1600 x 0 004884 x 1 15 0 5210 Volts second or a 1 x 0 004884 5mV step every 15 1600 9 milliseconds Similarly the settings for b c and d result in b Ramp Rate 0 5042 Volts second 10mV step every 19 milliseconds
27. 0 Preset Value the preset is configured as a percentage with 0 equivalent to a 0VDC input signal and 100 equivalent to a 10VDC signal This value is used as the Pressure Breakpoint command If the Pressure Breakpoint Source is set to 6 Limit Offset the preset is configured as a percentage with 0 equivalent to a 0VDC input signal and 100 equivalent to a 10VDC offset signal The offset value is added to the Pressure Limit Source signal to make the Pressure Breakpoint command Finally if the Pressure Breakpoint Source is set to 7 Limit Attenuation the preset is configured as a percentage of the Pressure Limit Source with 0 equivalent to a 0VDC input signal and 100 equivalent to the Pressure Limit Source This value is used as the Pressure Breakpoint command Pressure Breakpoint Source The Pressure Breakpoint Source selects the source of Pressure Breakpoint command Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 5 Ramp 1 6 Limit Offset 7 Limit Attenuation 8 Reference Offset or 9 Reference Attenuation Program Overview The Flow with Pressure Limit Control Program is a sloping pressure limiting control program similar to the control schemes used in Oilgear Analog Rack systems The algorithm will begin to limit the Flow command once the Pressure Feedback value is greater than the Pressure Breakpoint command Comparing the Breakpoint command to the Feedback
28. 0 Program 4 Pressure Breakpoint Preset 439 0 to 7 Program 4 Pressure Breakpoint Source Table 5 Flow with Pressure Limit Programs Function Programs 3 and 4 provide for Flow with Pressure Limit Control Program 3 is configured in program items 420 through 429 in the Program 3 Form Program 4 is configured in program items 430 through 439 in the Program 4 Form Flow Command Preset The Flow Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Pressure Limit Preset The Pressure Limit Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Flow Command Source The Flow Command Source selects the source of the flow command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Flow Command Preset is used as the flow command Pressure Limit Source The Pressure Limit Source selects the source of the pressure limit command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the
29. 100 Program 5 KI 450 1 to 100 Program 6 Pressure Point 2 Preset 451 1 to 100 Program 6 Delta Pressure Preset 452 1 to 100 Program 6 Pressure Limit Preset 453 0 to 5 Program 6 Pressure Point 2 Source 454 0 to 5 Program 6 Delta Pressure Source 455 0 to 5 Program 6 Pressure Limit Source 456 1 to 5 Program 6 Pressure Point 1 Source 457 0 to 1 Program 6 Program Output Destination 458 0 to 100 Program 6 KP 459 0 to 100 Program 6 KI Table 6 Load Sense Programs Configuration Function Programs 5 and 6 provide for Load Sense Control Program 5 is configured in program items 440 through 449 from the Program 5 Form Program 6 is configured in program items 450 through 459 from the Program 6 Form Pressure Point 2 Preset The Pressure Point 2 Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Delta Pressure Preset The Delta Pressure Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Pressure Limit Preset The Pressure Limit Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a
30. 2 Form Command Preset The Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Command Source The Command Source selects the source of the command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Command Preset is used as the Command Feedback Source The Feedback Source selects the source of feedback for the program Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller module and is passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulleti
31. 36260E 33 4 3 2 5 Output Current Limit The Module can be current limited to protect the valve or limit stroke The current limit is selected from program item 803 of the Pump Controller Form and is expressed as 0 to 100 of the maximum current of the module 250mA Current is limited in each direction so a Current Limit of 50 will limit the current to 50 to 50 of the maximum 4 3 2 6 Dither The EPC provides for a dither signal that is superimposed on the final output to the current driver The dither is set from the Pump Controller Form the dither option is only available for EPC modules with software version of 1 05 or later The dither frequency is fixed at 200Hz The amplitude of the dither signal is expressed in DAC counts with 0 equal to no dither and 255 equal to maximum dither approximately 12 5 of maximum controller current Table 11 below shows several examples of dither values in DAC counts converted into percent and current mA for EPC3 The maximum current for EPC3 is 250mA Dither DAC count Dither Dither mA 0 0 0 0 00mA 51 2 5 6 26mA 102 5 0 12 52mA 154 7 5 18 75mA 208 10 0 25 00mA 255 12 5 31 25mA Table 11 Dither Examples EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI
32. 5 8 6 1 Module Pinout 58 6 3 Specifications 59 6 4 IO Summary 59 6 5 Cable Recommendations and Terminal Information 59 7 Technical Support 6 0 8 Ordering Information 6 1 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 1 Introduction The EPC is a fully programmable microcontroller operated controller and amplifier for servo controlled hydraulic pumps and valves The unit can be configured for several types of control applications including Flow Control Pressure Control or Load Control Flow Control with Pressure Limit PQ
33. 6 4 1 General Configuration 6 4 1 1 Password Protection 000 6 4 1 2 Operating Modes 200 6 4 1 2 1 Dynamic Function Selection with Fault Monitor 7 4 1 2 2 Dynamic Function Selection with Watchdog Monitor 7 4 1 2 3 Static Function Selection with Watchdog Daisy Chain 7 4 1 2 4 Dynamic Function Selection with Limit Monitor 8 4 1 2 5 Static Function Selection with Fault Monitor 8 4 1 2 6 Static Function Selection with Watchdog Monitor 8 4 1 2 7 Static Function Selection with Watchdog Daisy Chain 9 4 1 2 8 Static Function Selection with Limit Monitor 9 4 1 3 Program Block Configuration 21x 10 4 1 4 EPC Hardware and
34. 90V signal decreases to 5 00V EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 35 4 4 Analog IO Configuration The EPC module provides four Analog Inputs two Analog Outputs and a Current Driver Analog Inputs 1 2 and 3 are referred to as General Purpose Analog Inputs and have a maximum input range of 10VDC to 10VDC Analog Input 4 is usually referred to as LVDT Input This input is intended for sinusoidal LVDT input Analog Outputs 1 and 2 are programmable with a range of 10VDC to 10VDC The Current Driver is either a Linear or PWM signal to drive a valve 4 4 1 General Purpose Analog Input Configuration Program Item Range Description 850 10V to 10V Analog Input 1 Offset 851 0 125 to 4 Analog Input 1 Gain 852 0 to 1 Analog Input 1 Polarity 853 0 to 1 Analog Input 1 Current Fault Enable 860 10V to 10V Analog Input 2 Offset 861 0 125 to 4 Analog Input 2 Gain 862 0 to 1 Analog Input 2 Polarity 863 0 to 1 Analog Input 2 Current Fault Enable 880 10V to 10V Analog Input 3 Offset 881 0 125 to 4 Analog Input 3 Gain 882 0 to 1 Analog Input 3 Polarity 883 0 to 1 Analog Input 3 Current Fault Enable Table 12 General Purpose Analog Input Configuration Program
35. Control Horsepower Control Pump Stroke and Pressure Pressure Control with Flow Preset Advanced Control with Feed Forward 2 Basic System Overview The EPC allows one 1 single control axis with a power amplifier to drive VS VV and VM controlled pumps and valves The basic pump controller configuration allows for closed loop response with both stroke position and pressure feedback In addition two 2 independent function programs can be dynamically selected with a digital input signal The unit provides a digital output for simple diagnostics or a watchdog signal Three 3 general purpose analog inputs are provided for command and pressure feedback signals including 10 VDC 0 to 20 mA or 4 to 20 mA see Section 6 4 Note 3 for current mode resister Additionally one 1 analog input is provided as a dedicated fine adjustable LVDT stroke feedback device The module allows for 2 two low power programmable output signals The device is configured by first assigning one of twelve 12 built in function programs to each of the two 2 program blocks Typically the output of the function programs is then passed to the Pump Controller which provides the valve command Figure 2 System Overview Figure 1 EPC Module 4 Analog Outputs Analog Inputs Stroke Feedback Pressure Feedback Pump Controller Block Selection Digital Output Diagnostics Program Block 2 Prog
36. T sine wave excitation signal 7 12VDC Supply 8 12VDC Supply 9 Servo Driver Output 10 Command to Pump Controller Output of Active Function Program 11 Ramp Table 15 Diagnostic Signals EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 40 4 4 4 Servo Valve Driver with Stroke Feedback The Servo Valve Driver Configuration allows for selecting the pump adjust mode monitoring the driver current and stroke feedback and scaling and offsetting the driver The scaling and offsetting parameters are only available for EPC modules running firmware Version 1 10 or later The Servo Driver information is located in the lower left corner of the Analog IO Configuration Form see Figure 17 Figure 17 Servo Valve Driver 4 4 4 1 Servo Attenuation and Offset The Servo Driver configuration settings are used together with the Output Polarity and Output Current Limit from the Pump Controller Configuration Form to configure the servo driver output The Configuration Settings are applied AFTER the Polarity setting and BEFORE the Current Limit Setting The Servo Driver Attenuation parameter menu item 965 attenuates the servo driver signal Valid entries are from 0 4 to 100 at approximately 0 4 increments The Attenuation
37. Typically for pumps Analog Input 4 LVDT is selected 4 4 4 3 Adjustment Mode The Pump Controller Adjust Mode is a special operation mode in which an Adjust Mode Toggle Command controls the servo driver rather than the Pump Controller or Active Function block The Adjust Mode works optimally with Main Pumps off and Pilot Pumps pressurized Adjust mode is set by pressing the Adjust mode Command button from the Analog IO Configuration Form Adjust mode is indicated by a System Message The Adjust Mode Toggle Command will alternately command neutral full positive and full negative current to the driver Initially the output toggle is at the neutral zero current position The Adjustment toggle command is monitored from the PC interface The Analog I O Configuration Form has a toggle command button The display and bar graph indicator will show the value of the toggle EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 42 The Adjust Mode Command Toggle is a special function available in Adjustment mode that will alternately command neutral full positive and full negative current to the driver If in Adjustment mode the following graphics are shown The graphic will appear as in Figure 18 when the toggle sets the servo valve dr
38. age with 0 equivalent to a 0VDC input signal and 100 equivalent to a 10VDC offset signal The offset value is added to the Pressure Command Source signal to make the Toggle Point between Pressure and Flow control Finally if the Q to P Control Switch Source is set to 7 Limit Attenuation the Preset is configured as a percentage and the Control Switch Toggle Point will be equal to the percentage of the Pressure Command signal Q to P Control Switch Source The Q to P Control Switch Source selects the source of the Flow to Pressure Toggle Point command Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 5 Ramp 1 6 Limit Offset or 7 Limit Attenuation Program Overview The Pressure with Flow Preset Control Program functions as either Flow Control or Pressure Control depending on whether the feedback pressure is greater or less than the Q to P Control Switch signal Under most circumstances the control begins as a Flow Control The algorithm will switch from a Flow Control to Pressure Control once the feedback pressure signal is greater than the Q to P Control Switch command Once in Pressure Control the Pressure command is compared to the feedback value to produce an error value The error is multiplied by the KP and KI constants to produce the Yp and Yi contributions of the program output In the pressure mode the Flow command acts as a limit to the pressure control loop
39. als 4 91V 4 05V 0 86V The Yi and Yp signals are produced from the PI controller and the program output is roughly equal to their sum 8 00V 0 66V 8 66V The Program Output is set to the Pump Controller program item 403 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 15 4 2 4 Flow with Pressure Limit Programs Generation 2 42x 43x Program Item Range Description 420 0 to 100 Program 3 Flow Command Preset 421 1 to 100 Program 3 Pressure Limit Preset 422 0 to 5 Program 3 Flow Command Source 423 0 to 5 Program 3 Pressure Limit Source 424 1 to 5 Program 3 Pressure Feedback Source 425 0 to 1 Program 3 Program Output Destination 426 0 to 100 Program 3 KP 427 0 to 100 Program 3 Full Scale Command 428 0 to 100 Program 3 Pressure Breakpoint Preset 429 0 to 7 Program 3 Pressure Breakpoint Source 430 0 to 100 Program 4 Flow Command Preset 431 1 to 100 Program 4 Pressure Limit Preset 432 0 to 5 Program 4 Flow Command Source 433 0 to 5 Program 4 Pressure Limit Source 434 1 to 5 Program 4 Pressure Feedback Source 435 0 to 1 Program 4 Program Output Destination 436 0 to 100 Program 4 KP 437 0 to 100 Program 4 Full Scale Command 438 0 to 10
40. am Output is roughly equal to their sum 5 00V 0 24V 5 24V The Program Output is set to the Pump Controller program item 447 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 21 4 2 6 Simple Flow Control Programs 46x 47x Program Item Range Description 460 0 to 100 Program 7 Flow Command Preset 461 0 to 5 Program 7 Flow Command Source 464 0 to 1 Program 7 Program Output Destination 470 0 to 100 Program 8 Flow Command Preset 471 0 to 5 Program 8 Flow Command Source 474 0 to 1 Program 8 Program Output Destination Table 7 Simple Flow Programs Configuration Function Programs 7 and 8 provide for Simple Flow Control Program 7 is configured in program items 460 through 464 from the Program 7 Form Program 8 is configured in program items 470 through 474 from the Program 8 Form Flow Command Preset The Flow Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Flow Command Source The Flow Command Source selects the source of the flow command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Ana
41. ax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 55 5 3 Basic Diagnostics with PC Interface The Basic Diagnostics are easily identifiable through the Analog IO Configuration Form Items include Digital Input Digital Output Analog Input 1 Analog Input 2 Analog Input 3 LVDT Analog Input 4 Programmable Outputs and Servo Driver Output See Figure 23 for details In addition diagnostic values are available throughout as needed Figure 23 Analog IO Configuration Form EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 56 5 4 Programmable Outputs Diagnostic There are 2 programmable outputs Analog Output 1 program item 930 is located on the front of the EPC typically used as a test point for debugging Analog Output 2 program item 933 is located on terminals J3 1 and J3 3 typically connected to an analog input of a PLC The test point can easily be monitored externally The signals for the programmable outputs are selected in the Analog IO Configuration Form Available Diagnostic signals are shown in Table 21 Selection Diagnostic 0 Output Disabled 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 Analog I
42. digital input is used as a watchdog input signal Therefore no dynamic function selection is possible In this mode Program Block 1 is always active and program item 210 defines the active function program Program item 211 has no function in operating mode 2 The program blocks are selected from the General Configuration Form 4 1 4 EPC Hardware and Software Information After an upload from the EPC to a PC several non editable parameters are shown in the General Configuration Form These items include the model serial number software version and hardware version See Figure 3 11 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 12 4 1 5 USB Communication The PC software interface must be configured properly to communicate to the EPC module The EPC should be connected via the USB B connecter on the front of the device and it carries an internal USB 232 converter but if necessary download the appropriate driver from http www ftdichip com drivers VCP htm The COM port number will be assigned when the driver installs check your device manager for that COM port and baud rate is listed on the General Configuration Form See Figure 3 4 1 6 Update Rate The PC interface will update on line information as quickly a
43. duced from the PI controller and the PI controller output command is roughly equal to their sum 2 50V 3 87V 6 37V The Command is offset and multiplied by the gain 1 00V 0 5V x 1 5 2 25V This Feed Forward Command is then summed with PI control output 2 25V 6 37V 4 12V Finally the Program Output is set to the Pump Controller program item 503 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 29 Figure 12 Advanced Control with Feed Forward Program in Open Loop Example Figure 12 shows Program 11 Form for Advanced Control with Feed Forward in Open Loop The Command is offset and multiplied by the gain 1 00V 0 5V x 1 5 2 25V This Feed Forward Command is then summed with the Open Loop output 2 25V 0 0V 2 25V Finally the Program Output is set to the Pump Controller program item 503 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 30 4 3 Pump Controller Configuration 4 3 1 Overview The Pump Controller provides the basic functionality of the module to provide closed loop stro
44. e www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 3 4 3 3 Configuration Example 34 4 4 Analog IO Configuration 35 4 4 1 General Purpose Analog Input Configuration 35 4 4 2 LVDT Fine Adjustable Analog Input Configuration 38 4 4 3 Programmable Analog Outputs 39 4 4 4 Servo Valve Driver with Stroke Feedback 40 4 4 4 1 Servo Attenuation and Offset 40 4 4 4 2 Stroke Feedback Device 41 4 4 4 3 Adjustment Mode 41 4 4 5 LVDT Adjustment Algorithm 43 4 4 5 1 Determining LVDT Configuration Range
45. e motor rating in horsepower DMAX is the maximum displacement of the Pump in in3 rev PXDCR is the maximum measured pressure in PSI i e the pressure corresponding to a 10VDC or 20mA reading N is the speed in rpm is the pump efficiency 48 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E Example 1 What HP factor would be used for a PVG075 powered by a 25 HP motor rotating at 1500 rpm The EPC uses a 5000 PSI pressure transducer to measure pressure From Oilgear Bulletin 47019 a PVG075 has a maximum displacement of 4 60 in3 rev and an overall efficiency of 80 at maximum pressure These values are used in the formula 4 0 107 4 0 107 25 4 60 5000 1500 0 80 23 Example 2 What HP factor would be used for a PVG100 powered by a 50 kW motor rotating at 1500 rpm The EPC uses a 400 Bar pressure transducer to measure pressure From Oilgear Bulletin 47019 a PVG100 has a maximum displacement of 98 3 ml rev and an overall efficiency of 85 at maximum pressure These values are used in the formula 6 0 107
46. ectional flow Servo valves are commanded with current a positive current command will move the valve in one direction while a negative current command will move the valve in the opposite direction A neutral zero current command will remove command to the valve the valve might stay in its current state or it may move in either direction For a uni directional pump only one port is available and the stroke can supply 0 to 100 of the rated flow The LVDT should be configured so that the maximum positive toggle command will produce the equivalent of a 10VDC command for the LVDT input The maximum negative toggle command should produce the equivalent of a 0 VDC command at the LVDT input The range of 0 to 10VDC corresponds to DAC values of 2048 to 4095 or a percentage of 0 to 100 refer to Section 5 1 for a discussion of the Diagnostic Representation of Numbers For a uni directional pump the midpoint command is 5VDC DAC value of 3072 or 50 stroke For a bi directional pump two ports are available and the stroke can supply 0 to 100 of rated flow in each direction Like the uni directional valve the LVDT should be configured so that the maximum positive toggle command will produce the equivalent of a 10VDC command for the LVDT input The maximum negative toggle command however should produce the equivalent of a 10VDC command for the LVDT input The range of 10VDC to 10VDC corresponds to DAC values of 0 to 4095 or a perce
47. entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller module and is passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination KP and KI KP and KI provide the proportional and integral constants respectively for the PI control algorithm Both terms are expressed as 0 to 100 of a maximum value The PI control loop can be made a P only control loop by setting the KI term to 0 Likewise the PI control loop can be made an I only control loop by setting the KP term to 0 Orifice Figure 6 Load Sense Circuit P P1 P2 EPC Pressure P1 Pressure P2 P P U U EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 20 Program Overview The Load Sense Control Program is one of the more complex control algorithms supplied with the EPC The goal of the load sense
48. er For certain applications it might be desirable to have the ability to switch between two function programs and the EPC provides that feature by allowing two program blocks selectable by the digital input In some circumstances a second program is not needed but some type of state is desired A prime example would be a stand by mode in which a fixed stroke would be commanded In this circumstance the user could place a pre defined program in block 1 and select program 0 for block 2 please refer to Section 4 1 3 regarding Program Block Configuration 21x The Function Zero Stroke Command is configured by program item 801 or from the Pump Controller Form It is expressed as a value from 0 to 100 where 0 equals full negative current 100 equals full positive current and 50 represents neutral or no current A Function Zero Stroke Command of 75 for instance would provide a 50 stroke command to the valve 4 3 2 2 Stroke Controller The Stroke Controller portion of the Pump Controller is configured by selecting a Stroke Feedback Source program item 800 and setting values for KP program item 804 and KI program item 805 for the Stroke PI Controller These values can be optimal adjusted from the Pump Controller Form Stroke Feedback Device The Stroke Feedback Device determines which signal the command to the Stroke Controller is compared to Valid entries are 0 Open Loop 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3
49. gnal of 0VDC For a bi directional pump a positive toggle command should produce an LVDT signal of 10VDC and a negative toggle command should produce an LVDT signal of 10VDC EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 45 Example 1 Balance an LVDT for a bi directional pump The example can be followed from the Example 1 sheet of the Excel template Toggling with the initial values produces a low reading of 92 50 and a high reading of 40 60 These readings should be offset to produce a low reading of 25 95 and a high reading of 25 95 This is calculated by finding the midpoint of the current readings 90 50 40 60 2 66 55 and comparing that to the desired midpoint a bi directional pump should have a midpoint at 0 Adding 65 55 to each value results in 90 50 65 55 25 92 and 40 60 66 55 25 95 This setting is reached when the Balance is set to 411 low and high readings of 25 90 and 26 20 respectively Notice that at this point approximate values are good enough The user then attempts to adjust the gain to near saturation At a Course gain 30 the low reading is 91 60 while the high reading is 9 20 The next gain 31 actually saturates the low reading to 100 so 30 is used The user then a
50. he Pump Controller 4 2 2 PI Control Algorithms Most programs use a PI Proportional with Integral control scheme Although an advanced tutorial on digital control systems is beyond the scope of this technical document some level of knowledge and experience is necessary to successfully implement the control programs The basis of a PI controller is that an output signal is produced due to a difference between a command and feedback term the difference is usually referred to as Error The output signal for a PI control is made of a proportional error signal combined with an integral error signal EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 13 4 2 3 Pressure Control Programs 40x 41x Program Item Range Description 400 1 to 100 Program 1 Pressure Command Preset 401 0 to 5 Program 1 Pressure Command Source 402 1 to 5 Program 1 Pressure Feedback Source 403 0 to 1 Program 1 Program Output Destination 404 0 to 100 Program 1 KP 405 0 to 100 Program 1 KI 410 1 to 100 Program 2 Pressure Command Preset 411 0 to 5 Program 2 Pressure Command Source 412 1 to 5 Program 2 Pressure Feedback Source 413 0 to 1 Program 2 Program Output Destination 414 0 to 100 Program 2 KP 415 0
51. imately 100 Hz 4 1 2 3 Static Function Selection with Watchdog Daisy Chain This operating mode is selected by setting program item 200 to 2 by choosing Mode 2 Static Function Selection with Watchdog Daisy Chain from the General Configuration Form In this operating mode Program Block 1 is always active and the program defined in program item 210 is used Program Block 2 is always inactive and program item 211 has no function Refer to Section 4 1 3 for discussion of Program Block Configuration 21x The digital input is passed through the module into the digital output In this way one single watchdog timer can be used for a number of EPC modules One EPC module would need to be configured for Mode 1 Dynamic Function Selection with Watchdog Monitor the remaining EPCs would be configured for Mode 2 Any module failure would break the daisy chain EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 8 4 1 2 4 Dynamic Function Selection with Limit Monitor This operating mode is selected by setting program item 200 to 3 by choosing Mode 3 Dynamic Function Selection with Limit Monitor from the General Configuration Form In this operating mode the digital input selects which program block is active If the digital input is low
52. in 836260E 32 4 3 2 3 HP Limiter The HP Limiter can be configured to limit the command to the stroke controller refer to Section 4 3 2 2 This portion of the Pump Controller is configured by selecting a Stroke Feedback Source program item 800 Pressure Feedback Device program item 811 and setting values for KP program item 813 and KI program item 814 for the HP Limiter PI Controller Additionally a HP Limit Factor program item 810 must be entered please refer to Section 4 6 2 regarding the HP Limit Factor Calculation These values can be optimal adjusted from the Pump Controller Form Stroke Feedback Source The Stroke Feedback Source determines which stroke signal is used in the HP calculation this is the same stroke feedback used in the Stroke Controller refer to Section 4 3 2 2 Valid entries are 0 Open Loop 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If Open Loop is chosen the stroke controller is inactive but the HP Limiter can be active as long as a Pressure Feedback Source is configured In this case the module uses the pump controller command as the stroke feedback Pressure Feedback Source The Pressure Feedback Source determines which pressure signal is used in the HP calculation Valid entries are 0 No HP Limit 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If No HP Limit is chosen the
53. it minus the Pressure Breakpoint Preset 7 00V 1 00V 6 00V Note there is a slight conversion error in this example The Pressure Limit Preset is 70 but at the Pressure Limit Source it is 6 99V instead of 7 00V The error signal is produced by comparing the Pressure Breakpoint Source to the Feedback signal 6 00V 6 95V 0 95V The error is multiplied by the KP constant to produce the Yp limit 0 95V x 10 26 9 75V A KP value of 64 equals a 10 26 KP constant The Pressure Limit command is summed with the Full Scale command to set the limit for the Flow command 10 0V 9 75V 0 25V Finally the Program Output is set to the Pump Controller program item 425 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 18 4 2 5 Load Sense Control Programs 44x 45x Program Item Range Description 440 1 to 100 Program 5 Pressure Point 2 Preset 441 1 to 100 Program 5 Delta Pressure Preset 442 1 to 100 Program 5 Pressure Limit Preset 443 0 to 5 Program 5 Pressure Point 2 Source 444 0 to 5 Program 5 Delta Pressure Source 445 0 to 5 Program 5 Pressure Limit Source 446 1 to 5 Program 5 Pressure Point 1 Source 447 0 to 1 Program 5 Program Output Destination 448 0 to 100 Program 5 KP 449 0 to
54. iver at neutral current valve approximately centered at 0ma Figure 18 Neutral Current The graphic will appear as in Figure 19 when the toggle sets the servo valve driver at maximum positive current Figure 19 Positive Current Finally graphic will appear as in Figure 20 when the toggle sets the servo valve driver at maximum negative current Figure 20 Negative Current EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 43 4 4 5 LVDT Adjustment Algorithm Both the HP Limiter and Stroke Controller portions of the Pump Controller module rely on the LVDT being configured correctly Typically there are three 4 configuration parameters for each LVDT Refer to Section 4 4 2 for a complete overview Polarity Offset Course Gain Fine Gain The general sequence of operations for LVDT scaling is to Set LVDT polarity to normal Place the EPC in Adjust mode Alternately Adjust the LVDT Offset and Gains until configured Return EPC to normal operation mode 4 4 5 1 Determining LVDT Configuration Range The LVDT input should be scaled to match the range of stroke command The range of stroke command is a factor of whether the pump is designed for uni or bi dir
55. ke feedback control for the servo valve In addition to stroke feedback the Pump Controller module can be configured for horsepower limitation Under usual circumstances the pre defined programs are used as outer loop control while the Pump Controller provides inner loop control The output of the pre defined programs is very nearly always passed through to the Pump Controller module refer to Section 4 2 1 for an overview of the pre defined Program modules 4 3 2 Configuration Program Item Range Description 800 0 to 5 Pump Controller and HP Limiter Stroke Feedback Source 801 0 to 100 Pump Controller Function Zero Stroke Command 802 0 to 1 Pump Controller Output Polarity 803 15 to 100 Pump Controller Output Current Limit 804 0 to 100 Pump Controller KP 805 0 to 100 Pump Controller KI 810 0 to 100 HP Limiter Reference 811 0 to 5 HP Limiter Pressure Feedback Source 812 HP Limiter Spare 813 0 to 100 HP Limiter KP 814 0 to 100 HP Limiter 875 0 to 255 Dither Table 10 Pump Controller Configuration EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 31 4 3 2 1 Function Zero Stroke Command Normally the Active Program Block provides the command to the Pump Controll
56. kee WI USA 53219 Bulletin 836260E 10 4 1 3 Program Block Configuration 21x Program Item Range Description 210 0 to 12 Program Selection for Program Block 1 0 No Program used for Block 1 refer to Section 4 3 2 1 1 12 Program 1 to 12 used for Block 1 211 0 to 12 Program Selection for Program Block 2 0 No Program used for Block 2 refer to Section 4 3 2 1 1 to 12 Program 1 to 12 used for Block 2 Table 3 Program Block Configuration The program block configuration parameters are used in conjunction with the module operating modes to assign pre defined programs to the two 2 program blocks Dynamic Operating Modes These modes are referred to as dynamic because the digital input selects which Program Block is active If the digital input is low lt 5 VDC Program Block 1 is made active and the program defined in menu 210 is used If the digital input is high gt 5VDC Program Block 2 is made active and the program defined in menu 211 is used see Example Static Operating Modes These modes are referred to as static because Program Block 1 is always active and menu 210 defines the active function program Menu 211 has no function in operating mode 2 The static operating modes also free the digital input to be used for a function other than program selection EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414
57. lletin 836260E 6 Technical Data 6 1 Module Pinout Output 2 back Oscillator Figure 24 Module Pinout 58 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 6 3 Specifications Supply Voltage 24VDC 18VDC to 36VDC Supply Current Run 100mA Maximum Driver Current Supply Current Start Up 1200mA Maximum Driver Output 1000 mA PWM Closed Loop Update Rate 1600 Hz Size 23mm wide 91mm height 88mm length 0 87in wide 3 56in height 3 44in length 4 53in length with connector Ambient Temperature 0 C to 70 C Mounting DIN EN 50022 35 6 4 IO Summary Digital Input 1 Digital High 5VDC to 36VDC Digital Output 1 Vsupply short circuit protected Analog Inputs General Purpose 3 Voltage Potential mode 10VDC Current mode 0 to 20mA or 4 to 20mA see Note 3 LVDT Inputs 1 approximately 0 to 20VDC Test Point Output 1 10VDC see Note 1 Programmable Outputs 2 10VDC see Notes 1 2 Notes 1 Output signal programmable refer to Section 5 3 2 Includes testpoint 3 A 500 resister is required across the analog input to convert the current into voltage See Figure 20 for a typical connection for current mode on Analog Inp
58. log Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Flow Command Preset is used as the flow command Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller module and passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination Program Overview The Simple Flow Control Program is by far the least complex control algorithm In fact in does little more than transfer an analog or fixed input directly to the Pump Controller Figure 8 Simple Flow Program Example Figure 8 shows the Program 7 Form for Flow Control The Flow Command Source is Analog Input 1 program item 461 1 The Flow Command Preset is set to 10 program item 460 10 although the preset is not used in this example The Program Output is set to the Pump Controller program item 464 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 22 4 2 7 Pressure Control with Flow Preset Programs
59. log Inputs Example EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 38 4 4 2 LVDT Fine Adjustable Analog Input Configuration Program Item Range Description 840 0 to 63 LVDT Course Gain 841 0 to 63 LVDT Fine Gain 843 0 to 1023 LVDT Offset 845 0 to 1 LVDT Polarity Table 14 LVDT Input Configuration Program items 840 through 845 are used to configure the LVDT The LVDT Input is configured from the Analog IO Configuration Form select menu Diagnostics and then Configuration See Figure 15 The adjust program item allows the module to be placed in Pump Controller Adjust Mode This is a special operating mode designed for adjustment of the LVDT inputs Please refer to Section 4 4 5 for a thorough discussion of this adjustment mode Course and Fine Gains Since greater resolution is needed to scale and offset the input of the sinusoidal LVDT input signals the gain and offset are not done directly in the microcontroller but performed through electrical circuitry The Course and Fine Gain increases over the range from 0 to 63 The LVDT should be configured using the algorithm discussed in Section 4 6 1 Offset The LVDT offset like the course and fine gains manipulates hardware circuitry An offset setting ra
60. low Command 9 00V is simply passed through to the Program Output Finally the Program Output is set to the Pump Controller program item 425 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 26 4 2 8 Advanced Control with Feed Forward Programs 50x 51x Program Item Range Description 500 1 to 100 Program 11 Command Preset 501 0 to 5 Program 11 Command Source 502 1 to 5 Program 11 Feedback Source 503 0 to 1 Program 11 Program Output Destination 504 10 to 10 Program 11 Command Offset 505 0 06 to 2 Program 11 Command Gain 506 0 to 100 Program 11 KP 507 0 to 100 Program 11 KI 510 1 to 100 Program 12 Command Preset 511 0 to 5 Program 12 Command Source 512 1 to 5 Program 12 Feedback Source 513 0 to 1 Program 12 Program Output Destination 514 10 to 10 Program 12 Command Offset 515 0 06 to 2 Program 12 Command Gain 516 0 to 100 Program 12 KP 517 0 to 100 Program 12 KI Table 9 Advanced Control with Feed Forward Programs Function Programs 11 and 12 provide for Advanced Control with Feed Forward Program 11 is configured in program items 500 through 507 in the Program 11 Form Program 12 is configured in program items 510 through 517 in the Program 1
61. more information Small Engineered System Units are fully engineered and tested application system components including customized wiring diagrams and installation drawings The number of EPC modules determines the base price of the Small Engineered System In addition to wiring and installation drawings Oilgear provides Configured Modules to simplify replacement parts All accessory items should be ordered as separate line items please see the Accessories Section for more information 61 61
62. n 836260E 27 Command Offset The Command Offset is used to apply a voltage offset to the Command Signal of the program The voltage offset can be in the range of 10VDC to 10VDC in 0 1VDC increments although the resulting signal cannot extend beyond the maximum input range of 10VDC to 10VDC The resulting signal multiplied the Command Gain determines the Open Loop or Feed Forward signal for the program Command Gain The Command Gain is used to apply a voltage gain to the Command Signal after the Command Offset Voltage is applied The voltage gain can be in the range of 0 0625 attenuation to x2 gain in 0 0625 increments although the resulting signal cannot extend beyond the maximum input range of 10VDC to 10VDC The resulting signal determines the Open Loop or Feed Forward signal for the program KP KP provides the proportional gain setting to PI control loop of the program KP is configured as a percentage with 0 to no proportional gain and 100 equivalent to maximum proportional gain KI KI provides the integral gain setting to PI control loop of the program KI is configured as a percentage with 0 to no integral gain and 100 equivalent to maximum integral gain Open Loop The program is in Open Loop only when the Mode Selection 200 is in the Static Mode and the digital input is low Closed Loop The program is in Closed Loop when the Mode Selection 200 is in the Static Mode with the digital input high or in the
63. nalog Input 4 or 5 Ramp 1 Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller module and is passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination KP KP provides the proportional gain setting to control the pressure limit slope KP is configured as a percentage with 0 to no integral gain and 100 equivalent to maximum proportional gain KI KI provides the integral gain setting to PI control loop of the program KI is configured as a percentage with 0 to no proportional gain and 100 equivalent to maximum integral gain Q to P Control Switch Preset The Q to P Control Switch Preset allows for direct numeric input The preset has a slightly different characteristics depending on the value of Q to P Control Switch Source entry If the Q to P Control Switch Source is set to 0 Preset Value the preset is configured as a percentage with 0 equivalent to a 0VDC input signal and 100 equivalent to a 10VDC signal This value is used as the toggle point between Pressure and Flow control If the Q to P Control Switch Source is set to 6 Limit Offset the Preset is configured as a percent
64. namic Function Selection with Fault Monitor from the General Configuration Form In this operating mode the digital input selects which program block is active If the digital input is low lt 5 VDC Program Block 1 is made active and the program defined in program item 210 is used If the digital input is high gt 5VDC Program Block 2 is made active and the program defined in program item 211 is used Refer to Section 4 1 3 for discussion of Program Block Configuration 21x The digital output provides standard condition status If no faults are present the digital output will be high VSupply If faults are present the digital output will be low 0 VDC Refer to Section 5 5 for information on module fault and message conditions 4 1 2 2 Dynamic Function Selection with Watchdog Monitor This operating mode is selected by setting program item 200 to 1 by choosing Mode 1 Dynamic Function Selection with Watchdog Monitor from the General Configuration Form of the PC Interface In this operating mode the digital input selects which program block is active If the digital input is low lt 5 VDC Program Block 1 is made active and the program defined in program item 210 is used If the digital input is high gt 5VDC Program Block 2 is made active and the program defined in program item 211 is used Refer to Section 4 1 3 for discussion of Program Block Configuration 21x The digital output provides a watchdog signal of approx
65. nfigured for Mode 1 Dynamic Function Selection with Watchdog Monitor while the remaining EPCs would be configured for Mode 2 Any module failure would break the daisy chain 4 1 2 8 Static Function Selection with Limit Monitor This operating mode is selected by setting menu item 200 to 7 by choosing Mode 7 Static Function Selection with Limit Monitor from the General Configuration form of the PC Interface In this operating mode Program Block 1 is always active and the program defined in menu 210 is used Program Block 2 is always inactive and menu item 211 has no function The digital output provides a signal as to whether the stroke command is being limited due to an over Power or over Pressure condition The over Power condition is specified from the Horsepower Limiter The only supported over Pressure condition is specified by the Flow with Pressure Limit Control algorithm Generation 2 If either limiting condition is taking place the digital output will be low 0 VDC If no limiting situation is taking place the digital output will be high VSupply If the Horsepower limiter is disabled and a program other than a Flow with Pressure Limit Control program Generation 2 is active the digital output will be high EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwau
66. nges from 0 to 1023 to offset the LVDT from 10V to 10V A 512 setting has a 0V offset Please refer to Section 4 6 1 for a discussion of the LVDT Adjustment Algorithm Polarity The Polarity setting is set to either 0 Normal or 1 Inverted Inverting the input in this way would be equivalent to reversing wire leads to the module In fact a better long term solution to using the invert setting would be to reverse the wire leads to the module Figure 15 LVDT Input EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 39 4 4 3 Programmable Analog Outputs There are 2 programmable analog outputs see Figure 16 Analog Output 1 program item 930 is located on the front of the EPC typically used as a test point for debugging Analog Output 2 program item 933 is located on terminals 7 and 8 typically connected to an analog input of a PLC Figure 16 Analog Outputs The test point can easily be monitored externally The signals for the programmable outputs are selected in the Analog IO Configuration Form Available Diagnostic signals are shown in Table 15 Selection Diagnostic 0 Output Disabled 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 Analog Input 4 LVDT 5 Current Feedback Signal 6 LVD
67. nput 4 LVDT 5 Current Feedback Signal 6 LVDT sine wave excitation signal 7 12VDC Supply 8 12VDC Supply 9 Servo Driver Output 10 Command to Pump Controller Output of Active Function Program 11 Ramp Table 21 Diagnostic Signals 5 5 Advanced Diagnostics Advanced Diagnostics are viewable in the upper right hand corner of all Forms listed as High Priority Faults and System Messages See Figure 23 5 5 1 Module Faults Module Faults are high priority faults that show EPC failure There are up to 8 eight module faults Any fault will cause the PC interface to register a module fault The eight faults are represented by a fault bit number from 0 to 7 A fault condition will be represented by the high priority box turning red In addition a triangle with an exclamation sign inside it indicates the specific fault EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 57 Fault Bit Fault Condition 0 Spare Fault Condition 1 Spare Fault Condition 2 Spare Fault Condition 3 Spare Fault Condition 4 LVDT Excitation Signal Fault 5 12VDC Supply Fault 6 12VDC Supply Fault 7 Non Volatile Memory EEPROM Fault Table 22 Fault Condition Codes 5 5 2 System Messages System Message
68. nt to 10VDC while 4095 DAC counts is equivalent to 10VDC 2048 DAC counts represents the midpoint of 10VDC and 10VDC or 0VDC 5 1 2 Voltage and Percentages The PC interface allows a great range of diagnostic options For most diagnostic Forms the user can select to view input and output values as voltages or percentages This feature is particularly helpful in LVDT adjustment A comparison summary of the different number representation follows Volts 10V 5V 0V 5V 10V Percentage 100 50 0 50 100 DAC decimal 0000 1024 2048 3072 4095 5 2 Basic Diagnostics on Front Panel On the front of the EPC are 3 bi color LEDS These indicate Run Fault conditions Valve Current and Feedback In addition there is a testpoint labelled Analog Output 1 See Figure 22 for the location of the LEDS and Testpoint Figure 22 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 5 2 1 Run Fault LED The bi color LED provides diagnostics information about the Run Fault conditions The Run Fault LED has several modes See Table 22 for detail information on high priority faults and Table 23 for system messages Mode Description Steady Green EPC has power 24V supply Flashing Green EPC is comm
69. ntage of 100 to 100 refer to Section 5 1 for a discussion of the Diagnostic Representation of Numbers For a bi directional pump the midpoint command is 0VDC DAC value of 2048 or 0 stroke EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 44 4 4 5 2 Adjustment Algorithm The following algorithm may be used to optimally configure the unit The PC Interface includes a Microsoft Excel template EPCConfig xlt that can be used to optimize the setup The Excel template is also available through e mail by request to USSales oilgear com 1 Place the module in Adjustment mode refer to Section 4 6 1 1 2 Use an Initial setting of Offset 512 Course Gain 0 and Fine Gain 0 3 Toggle the Pump Command and note the LVDT readings at the maximum positive and negative toggle commands refer to Section 4 4 4 3 regarding toggle command 4 Determine the midpoint of these two LVDT readings and compare with the desired midpoint reading see previous Section 5 Adjust the LVDT offset so that the two LVDT readings have the desired midpoint reading 6 Adjust the LVDT course gain upwards from the initial setting such that the positive and negative toggle commands produce LVDT signals as large as possible without eithe
70. odule and is passed directly to the servo driver Under most circumstances the Pump Controller should be chosen as the output destination KP and KI KP and KI provide the proportional and integral constants respectively for the PI control algorithm Both terms are expressed as 0 to 100 of a maximum value The PI control loop can be made a P only control loop by setting the KI term to 0 Likewise the PI control loop can be made an I only control loop by setting the KP term to 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 14 Program Overview The Pressure Control Program is a straightforward PI control algorithm Comparing the command to the feedback value produces an error value The error is multiplied by the KP and KI constants to produce the Yp and Yi contributions to the program output Figure 4 Pressure Control Program Example Figure 4 shows the Program 1 Form for Pressure Control The Pressure Command Source is Analog Input 1 program item 401 1 and the Pressure Feedback Source is Analog Input 2 program item 402 2 The Pressure Command Preset has a value of 50 program item 400 50 although it is not used for this particular example The error signal is produced by comparing the command to the feedback sign
71. orsepower region Figure 21 The user then sets the Pump Controller module with the proper settings for stroke and pressure feedback see Section 4 3 2 3 The horsepower limit factor can be determined in two ways experimentally or theoretically Figure 21 PQ HP Limit Curve 46 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 47 4 5 1 1 Experimental HP Limit Factor For the Experimental HP Limit Factor the user builds up pressure and increases stroke until the motor supplies the maximum rated current This procedure requires a program that allows for direct stroke command so a good function program to use would be the Simple Flow Program refer to Section 4 2 6 To determine the HP Limit Factor the user must first configure the EPC for stroke feedback Section 4 4 2 and connect a pressure transducer to an available analog input An additional analog input can be used for stroke command The user then sets the HP factor to an initial setting of 100 and rigs the hydraulic circuit to build maximum pressure Once this achieved the user uses a current transducer and multimeter to measure motor current Stroke to the pump is slowly increased and the multimeter is monitored until the current to the motor is at
72. output will be high VSupply If faults are present the digital output will be low 0 VDC 4 1 2 6 Static Function Selection with Watchdog Monitor This operating mode is selected by setting menu item 200 to 5 or by choosing Mode 5 Static Function Selection with Watchdog Monitor from the General Configuration form of the PC Interface In this operating mode Program Block 1 is always active and the program defined in menu 210 is used Program Block 2 is always inactive and menu item 211 has no function The digital output provides a watchdog signal of approximately 100 Hz EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 9 4 1 2 7 Static Function Selection with Watchdog Daisy Chain This operating mode is selected by setting menu item 200 to 6 by choosing Mode 6 Static Function Selection with Watchdog Daisy Chain from the General Configuration form of the PC Interface In this operating mode Program Block 1 is always active and the program defined in menu 210 is used Program Block 2 is always inactive and menu item 211 has no function The digital input is passed through the module into the digital output In this way one single watchdog timer can be used for a number of EPC modules One EPC module would need to be co
73. quivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Pressure Command Preset The Pressure Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Flow Command Source The Flow Command Source selects the source of the flow command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Flow Command Preset is used as the Flow command Pressure Command Source The Pressure Command Source selects the source of the pressure command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Pressure Command Preset is used as the Pressure command EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 23 Pressure Feedback Source The Pressure Feedback Source selects the source of the pressure feedback for the program Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 A
74. r toggle command producing an LVDT signal out of the LVDT configuration range 7 Repeat steps 3 through 6 until a one digit course gain change is unable to produce LVDT signals within the configuration range For a uni directional pump a positive toggle command should produce an LVDT signal slightly less than 10VDC and a negative toggle command should produce an LVDT signal slightly greater than 0VDC For a bi directional pump a positive toggle command should produce an LVDT signal slightly less than 10VDC and a negative toggle command should produce an LVDT signal slightly greater than 10VDC 8 Once the Course gain is found adjust the fine gain upward from the initial setup Do not adjust the course gain and fine gain concurrently since the two do not function together in a straightforward linear fashion 9 Determine the midpoint of these two LVDT readings and compare with the desired midpoint reading see previous Section 10 Adjust the LVDT offset so that the two LVDT readings have the desired midpoint reading 11 Adjust the LVDT fine gain downward from the initial setting until one of the two pump toggle commands is just under the pump range 12 Repeat steps 9 through 11 until a one digit fine gain change produces LVDT signals spanning the entire configuration range For a uni directional pump a positive toggle command should produce an LVDT signal of 10VDC and a negative toggle command should produce an LVDT si
75. ram 0 12 Program Block 1 Program 0 12 Digital Input EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 5 If the full features of the module are used up to three 3 independent closed loop PI Proportional with Integral control algorithms are utilized Most function programs provide a closed loop control algorithm for pressure or stroke while the Pump Controller can be configured for both stroke and power feedback The module is programmable through the PC Interface software Various Forms in the software will be discussed throughout the manual Programming items are located in these Forms 3 General Instructions 3 1 Password Protection The EPC allows for edit protection of all programmable parameters Please refer to Section 4 1 1 for a thorough discussion of Password Protection 3 2 PC Interface Groupings The PC interface provides a programming and monitoring interface A toolbar menu loosely groups functions into Forms in the following manner File File Print and Communication Commands General Password and Communication Setup Program Selection and Mode Selection program items 000 and 2xx Program Program Configuration program items 4xx and 5xx Pump Controller Pump Controller Configuration
76. ration Acceleration is defined as increasing stroke while Deceleration is defined as decreasing stroke Ramping from 5V to 10V is acceleration while ramping from 10V to 5V is deceleration Ramping from 5V to 10V is also acceleration since 10V provides greater stroke than 5V Conversely ramping from 10V to 5V is deceleration Since the EPC is a digital controller the ramp is actually a staircase like signal The Rate describes the time length of each step and is expressed in whole number multiples of the closed loop update rate The Step describes the potential step at each interval and is expressed as DAC counts The closed loop response is 1600 Hz The Ramp Rate can be expressed in Volts second with the equation 0 004884 The larger the ramp rate or step is the more course the ramp stair casing will be The time length of each step can be computed from the Rate setting Time Length seconds Potential Step Volts Step 0 004884 50 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site
77. s display system messages about the EPC There are up to 8 eight module system messages Any message will cause the PC interface to register a module system message The eight faults are represented by a fault bit number from 0 to 7 A fault condition will be represented by the system message box turning red In addition a triangle with an exclamation sign inside it indicates the specific fault Fault Bit Fault Condition 0 Line Break Warning Analog Input 1 1 Line Break Warning Analog Input 2 2 Digital Output Error 3 Line Break Warning Analog Input 3 4 Spare Run Time Message 5 Driver Current Fault 6 Module Closed Loop Warning 7 Module LVDT Adjustment Mode Table 23 System Messages Generally a module message does not describe a module failure but communicates that the EPC is probably configured incorrectly or a temporary fault condition exists For instance the module can be configured to display a system message when the General Purpose Analog Input is less than 3mA refer to Section 4 4 1 This condition would result in a run time fault being generated The most probably cause of the Digital Output Error is to incorrectly connect the output as a digital input EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bu
78. s possible Often times this can be improved by limiting the number of Windows applications Typically the EPC update rate will be maximized in the 2 to 3 Hz range See Figure 3 4 2 Program Configuration 4 2 1 Overview The EPC offers 12 pre defined programs The programs range from simple flow control to advanced functionality Six different types of programs exist and the module provides two distinct copies of each program Programs 1 and 2 provide Pressure Control programs Programs 3 and 4 provide Flow with Pressure Limit Control programs Programs 5 and 6 provide Load Sense Control programs Programs 7 and 8 provide Simple Flow Control programs Programs 9 and 10 provide Pressure Control with Flow Preset programs Finally Programs 11 and 12 provide Advanced Control with Feed Forward Programs 3 4 9 and 10 have been modified since the manual 3 revisions ago Bulletin 83260A to improve performance This software enhancement is called Generation 2 It requires EPC software versions 1 07 or later and PC Interface software version 1 55 0014 or later See Appendix A for Generation 1 information Programs 11 and 12 require EPC software versions 1 10 or later and PC Interface software version 1 20 or later Under usual circumstances the pre defined programs are used as outer loop control The output of the pre defined programs is normally passed through to the Pump Controller module refer to Section 4 3 1 for an overview of t
79. t 1 to control a bi directional pump command range of 10VDC First the user would enable the current fault for Analog Input 1 program item 853 1 and place a 500 ohm resistor across the analog 1 input terminals This will create a 2VDC to 10VDC voltage at the terminals and generate a fault if the voltage drops below 1 5VDC 3 mA Second the user would set the Analog Input Offset to generate a 6VDC offset program item 850 6 0 This creates a 4VDC to 4VDC voltage from the original 2VDC to 10VDC voltage Next the user would set the gain to 2 5 program item 852 2 5 This creates a 10VDC to 10VDC voltage from the offset voltage of 4VDC to 4VDC Finally the user would set the input polarity to normal program item 852 0 so the input is not inverted See Figure 14 Example 2 A user wants a 0V to 5VDC signal at Analog Input 2 to control a unidirectional pump command range of 0 to 10VDC First the user would disable the current fault for Analog Input 2 program item 863 0 Second the user would configure the input for 0VDC voltage offset program item 860 0 since the input voltage needs no offset for this particular example Next the user would set the gain to 2 program item 861 2 to create a 0 to 10VDC voltage from the offset voltage of 0 to 5VDC Finally the user would set the input polarity to normal program item 862 0 so the input is not inverted See Figure 14 Figure 14 Ana
80. tch 4 00V the program is in Pressure Control The Pressure command is limited by the Flow command Since the Pressure command 4 86V is less than the Flow command 9 00V it is not limited Finally the Program Output is set to the Pump Controller program item 425 0 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 25 Figure 10 Pressure Control with Flow Preset Program in Flow Mode Example Figure 10 shows Program 9 Form for Pressure Control with Flow Preset in the Flow Mode The Flow Command Source is Analog Input 1 program item 482 1 The Flow Command Preset is set to 10 program item 480 10 although the Flow Command Preset is not used in this example The Q to P Control Switch Source is Limit Offset program item 489 6 The Q to P Control Switch Preset is set to 10 program item 488 10 therefore the Q to P Toggle Point is 5 00V 1 00V 4 00V The error signal is produced by comparing the Pressure Command Source to the Feedback signal 5 00V 3 40V 1 60V The Yi and Yp signals are produced from the PI controller and the Pressure Command is roughly equal to their sum 0 00V 6 33V 6 33V Since the Pressure Feedback 3 40V is less than the Q to P Control Switch 4 00V the program is in Flow Control The F
81. to 100 Program 2 KI Table 4 Pressure Control Programs Configuration Function Programs 1 and 2 provide for basic Pressure Control Program 1 is configured in program items 400 through 405 or from the Program 1 Form Program 2 is configured in program items 410 through 415 from the Program 2 Form Pressure Command Preset The Pressure Command Preset allows for direct numeric input for the control program The preset is configured as a percentage with 0 being equivalent to a 0VDC input signal and 100 being equivalent to a 10VDC signal Pressure Command Source The Pressure Command Source selects the source of the pressure command for the program Valid entries are 0 Preset Value 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 If the Preset Value is chosen the Pressure Command Preset is used as the program command Pressure Feedback Source The Pressure Feedback Source selects the source of the pressure feedback for the program Valid entries are 1 Analog Input 1 2 Analog Input 2 3 Analog Input 3 4 LVDT 1 Analog Input 4 or 5 Ramp 1 Program Output Destination The Program Output Destination selects the output of the program Valid entries are 0 Pump Controller or 1 Direct If the Pump Controller is chosen the output of the Program will be the input to the Pump Controller module If Direct is chosen the output of the Program will by pass the Pump Controller m
82. ttempts to offset the readings to low 41 20 and high 41 20 The user finds this at Offset 334 In a similar fashion the user continues alternately selecting offset and course gain values At step 6 a change in course gain saturates the low reading so the user has successfully found the optimal setting for course gain The user continues as before but this time uses the fine gain to set the near saturation gains At step seven the user finds that a fine gain change from 5 to 6 saturates both readings LVDT configuration is complete Example 2 Balance an LVDT for a unit directional pump The only difference between this and the previous example would be that the midpoint would be 50 rather than 0 The user is invited to view the Example 2 sheet of the Excel template for this example EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 4 5 Advanced Configuration The Advanced Diagnostics Form contains the setups for Horsepower Limiting and Ramping functions 4 5 1 Horsepower Limit Factor Calculation The horsepower limit factor can be used to limit the power consumed by the hydraulic pump To limit horsepower the user first enters a value for the HP factor this factor produces a PQ pressure flow curve that defines a certain h
83. unicating with a PC Steady Red High priority faults Flashing Red System messages and during power on for approximately 2 seconds Table 18 Run Fault LED 5 2 2 Valve Current LED The bi color LED provides diagnostic information about the Valve Current The color of Valve Current LED indicates the direction of the current to the valve The intensity of the Valve Current LED indicates the amount of current to the valve Color Direction Intensity Current Green Positive Low Low Green Positive High High Amber Negative Low Low Amber Negative High High Table 19 Valve Current LED 5 2 3 Feedback LED The bi color LED provides diagnostic information about the Feedback The color of the Feedback LED indicates the direction of the Feedback The intensity of the Feedback LED indicates the amount of Feedback Color Direction Intensity Feedback Green Positive Low Low Green Positive High High Amber Negative Low Low Amber Negative High High Table 20 Feedback LED 5 2 4 Test Points Two test points are accessible from the front of the EPC The first is directly below the USB port which is a copy of the signal driving analog output 2 The second which is toward the bottom is a copy of the signal that drives analog output 1 They accept 0 080 test probes 54 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear F
84. ut 2 6 5 Cable Recommendations and Terminal Information Cable recommendations and terminal information are as follows equivalent cable may be substituted EPC Connection Cable Type Gauge Belden P N Length max Linear Torque Motor 2 Conductor Shielded 22 AWG 8761 250 Feet Linear LVDT 4 Conductor Shielded 24 AWG 9729 250 Feet PWM Valve 2 Conductor Shielded 18 AWG 8760 250 Feet PWM LVDT 4 Conductor Shielded 24 AWG 9729 250 Feet Table 24 Cable Recommendations Terminal Number Hole Diameter Gauge All Terminals 1 1 mm 16 26 AWG Table 25 Terminal Information 59 EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 60 7 Technical Support For US customer support contact The Oilgear Company The Oilgear Company 2300 So 51st Street PO Box 343924 Milwaukee WI USA 53234 3924 Shipping Address Zip Code is 53219 2340 Voice Support 414 327 1700 Fax Support 414 327 0532 E Mail Support USSales oilgear com Website www oilgear com For European Technical Support contact the Electronics Division of Oilgear GmbH Oilgear Im Gotthelf 8 D 65795 Hattersheim Industriegebiet Eddersheim Germany Voice Support 49 6145 377 0 Fax Support 49 6145 30770
85. value produces an error value The error is multiplied by the KP constant to produce the Yp limit signal which is summed with the full scale command The summation of the full scale command and the YP limit signal in turn sets a limit to the Flow command If the Breakpoint Pressure Limit command is greater than the Feedback signal the Flow command will only be limited by the full scale command If using EPC software version 1 06 or earlier see Appendix A for Generation 1 control EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 17 Figure 5 Flow with Pressure Limit Program Example Figure 5 shows Program 3 Form for Flow with Pressure Limit The Flow Command Source is Analog Input 1 program item 422 1 The Flow Command Preset is set to 10 program item 420 10 although the Flow Command Preset is not used in this example The Pressure Limit Source command is the Preset Value program item 423 0 therefore the pressure limit command is set at a 70 level program item 421 70 The Pressure Feedback Source is Analog Input 2 program item 424 2 The Pressure Breakpoint Source is Limit Offset program item 429 6 The Pressure Breakpoint Preset is set to 10 program item 428 10 The Pressure Breakpoint value is the Pressure Lim
86. would expect a step of 1 and a rate of 4 to be close to the ramp rate yet provide a smaller staircase Accordingly a step of 1 and a rate of 4 create a 1 95 Volt second ramp this time with a 5 mV step every 0 6 milliseconds PC Interface The PC interface contains a worksheet for ramp values Advanced Diagnostics Form The user selects a desired ramp rate and one of five resolution factors The worksheet calculation function will display the results of the most optimal settings EPC SERVO AMPLIFIER MODULE Part Number L723888 3xx ELECTRONIC Telephone 414 327 1700 Oilgear Fax 414 327 0532 2300 S 51st Street Issued April 28 2015 Web Site www oilgear com Milwaukee WI USA 53219 Bulletin 836260E 53 5 Module Diagnostics The EPC has diagnostics available through both the front of the EPC LEDs and testpoint and the PC interface However due to the extensive features of the controller the PC interface is the recommended diagnostic tool 5 1 Diagnostic Representation of Numbers Throughout this manual reference has been made to DAC counts percentages and voltages DAC count representation is the basis for all other diagnostic representation since all internal numbers are represented within the controller as DAC Digital to Analog Converter counts 5 1 1 DAC Counts Most Diagnostic numbers are stored as a 12 Bit number from 0 to 4095 For an input or output variable 0 DAC counts is equivale

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