OEM Controls Superflex 4 User Manual
Table of Contents
INTRODUCTION.........................................................................................................................................2
WARNING....................................................................................................................................................2
GENERAL DESCRIPTION........................................................................................................................3
UPERFLEX
S
IGISENSOR
D
PTIMIZER
O
UNCTIONS
F
ONTROLLER
4 C
............................................................................................................................. 3
..................................................................................................................................................... 4
....................................................................................................................................................... 5
...................................................................................................................................................... 5
INSTALLATION................................................................................................................... ....................... 6
OUNTING THE
M
YPICAL WIRING
T
ONTROLLER
SF4 C
.................................................................................................................. 6
............................................................................................................................................. 6
Joystick Controllers.................................................................................................................................... 7
Valves.......................................................................................................................................................... 8
Superflex 4 Controller.................................................................................................................................8
Power.......................................................................................................................................................... 9
Optimizer .................................................................................................................................................... 9
IRING (APPENDIX
W
5) ..................................................................................................................................... 9
OPERATION..............................................................................................................................................10
ENERAL
G
UNCTIONS FOR THIS APPLICATION (APPENDIX
F
PTIMIZER
O
....................................................................................................................................................... 10
1).......................................................................................... 10
..................................................................................................................................................... 10
Adjustments ............................................................................................................................................... 11
Diagnostic Menus..................................................................................................................................... 12
Customized Display (Appendix 2)............................................................................................................. 13
DJUSTMENTS AND CALIBRATION
A
................................................................................................................. 13
Active Adjustments.................................................................................................................................... 13
Bench / Static Adjustments........................................................................................................................ 16
Factory Default Values (Appendix 3)....................................................................................................... 16
TROUBLESHOOTING............................................................................................................................. 17
S ON SUPERFLEX
LED’
PTIMIZER DIAGNOSTICS
O
IGISENSOR
D
ONNECTORS
C
................................................................................................................................................... 19
................................................................................................................................................. 19
................................................................................................................................... 17
............................................................................................................................... 18
OPTIMIZER MENU FUNCTION DIAGRAM....................................................................................... 20
APPENDIX.................................................................................................................................................. 21
PPLICATION SPECIFIC FUNCTIONS
1. A
USTOMIZED OPTIMIZER DISPLAY
2. C
ACTORY DEFAULTS AND ADJUSTMENT LIMITS
3. F
NPUTS AND OUTPUTS CONNECTION TABLE
4. I
IRING DRAWING
5. W
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............................................................................................................ 21
............................................................................................................. 21
........................................................................................ 21
.............................................................................................. 21
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December 30, 1996
Introduction
The quality and versatility of your joystick control system can make a critical difference in the performance
of your machinery. That is why OEM Controls Inc. products are the controllers of choice for mobile
equipment manufacturers.
OEM, the largest manufacturer of controls for electrohydraulic valves, offers the industry’s most advanced
line of high-quality products. Their compact design, rugged performance, and expanded application
versatility can help improve the performance and capabilities of your equipment. Sophisticated electronic
control methods help create a responsive interface between the equipment and its operators.
For over 28 years, OEM has developed winning products by solving specific application challenges and
anticipating the ongoing needs of the industries we serve. We are prepared to help you meet your
performance requirements.
OEM configures each product to individual customer specifications, utilizing field-proven components, a
long list of options, and industry-leading engineering expertise. We can provide completely customengineered systems to most precisely match your configuration, control, and performance criteria, from
basic on/off functions to multi-axis joystick control.
Compatible with most electrohydraulic valves, OEM controllers feature heavy-duty construction in a
compact design. Metal internal structures and industrial-grade electronics are used to ensure long-term
reliability.
Warning
WARNING: IT IS THE PURCHASER'S RESPONSIBILITY TO DETERMINE T HE
SUITABILITY OF ANY OEM CONTROLS PRODUCT FOR AN INTENDED
APPLICATION, AND TO INSURE THAT IT IS INSTALLED AND GUARDED IN
ACCORDANCE WITH ALL FEDERAL, STATE, LOCAL AND PRIVATE SAFETY
AND HEALTH REGULATIONS, CODES AND STANDARDS.
Due to the unlimited variety of machines, vehicles and equipment on which our controls are used, and the
numerous standards which are frequently the subject of varying interpretation, it is impossible for OEM
Controls personnel to provide expert advice regarding the suitability of a given controller for a specific
application. The flexibility of our products allows us to offer thousands of custom configurations. We can
advise you of the various features that are available and you can examine models to see what meets your
needs. We believe our customers' engineering departments should be the qualified experts in their own
product field. If the product will be used in a safety critical application, the customer must undertake
appropriate testing to prevent injury to the ultimate user.
SHOULD YOU HAVE ANY QUESTIONS, OR IF ANY OF THIS WARNING IS UNCLEAR, PLEASE
CONTACT OEM CONTROLS, INC., 10 CONTROLS DRIVE, SHELTON, CT 06484 (203) 929-8431.
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December 30, 1996
General Description
The Superflex 4 System consists of joysticks and a stand alone controller that electrically drives
electrohydraulic valves. Typical applications include operating crane booms, fire truck ladders, track
driven machines and other hydraulic equipment with electrohydraulic valves and pumps.
Superflex 4 Controller
The Superflex 4 Controller is a rugged, micropro cessor controll ed device that can directly operat e four bidirectional electrohydraulic valves. The Superflex 4 receives inputs from Digisensors, switches, and other
transducers, and converts these signals into proportional PWM outputs to drive the valves. Each output
signal may be independently fine-tuned and calibrated by using the hand held Optimizer .
Figure 1
Figure 1 shows a Superflex 4 Controller. The Superflex 4 has three 12 pin connectors for inputs, outputs,
and power / Optimizer connections. (Revision B and later Superflexes also have two 4 pin connectors).
The connec tors are designa ted “BT1” to “BT5” throughout this manual. Three red LEDS p rovide the user
with status and diagnostic information. A user friendly label identifies the connectors and provides simple
troubleshooting information.
The Superflex 4 Controller is a versatile and flexible control device. It may be factory programmed by
OEM Controls Inc. to include many different options. A few examples of its flexibility include -
!"
The Superflex 4 is supplied with factory default settings for the electrohydraulic valves used. However, the
customer may select other default values and adjustment limits. This factory programmed data allows the
Superflex 4 to be installed and ready to use as delivered from the factory. Please contact OEM Controls
Inc. for details on customizing the Superflex 4 Controller for your particular application.
Single or dual coil valves with PWM frequencies from 33 to 1000 Hz.
"
Single or dual axis joysticks. Arotrack drive (convert dual axis to left and right track drive).
"
Discrete digital inputs for High / Low ranges, start up interlocks, ramp disable shutdown, etc.
"
Auxiliary outputs (2) for dump valves, alarms, multiplexed output selection, etc.
"
Various “belly” curves to modify the joystick controller’s characteristics.
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December 30, 1996
Digisensor
The Digisensor (Figure 2) is a small, rugged device that c onverts joystick handl e movement into an
electrical signal. The Digisensor requires only two wires, and can transmit its signal to a Superflex
controller up to 500 feet away. Figure 18 (on page 19) shows the various features of the Digisensor.
A potentiometer embedded in the Digisensor measures
the joystick controller’s movement (usually with a gear).
The potentiometer is also used for mounting the
Digisensor. Two red LEDS indicate the Digisensor
position (whenever power is applied). The “Direction
A” LED turns on when the potentiometer shaft is turned
counter-clockwise, and the “Direction B” LED turns on
when rotated clockwise. When the Digisensor’s shaft is
Figure 2
Two wires connect the Digisensor to the system. The red wire connects to the +12 or +24 volt power, and
the black wire connects to one of the Superflex inputs. Figure 3 shows typical wiring for a single axis
joystick controller. In this example, a microswitch turns on the Digisensor when the joystick handle is
moved from its center or “off” position.
centered (turned halfway between its ends) both LEDS
will be on. The section titled “Troubleshooting Digisensor” has additional details.
Figure 3
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Optimizer
The OPT4 Optimizer is a hand held user interface with a keypad and an alphanumeric display. It is used as
a calibration and diagnostic tool, to display various system values, and to make adjustments to the Superflex
4 Controller.
Figure 4 shows the Optimizer and its connecting
cable. The Optimizer cable length should be
limited to 120 feet.
Figure 4
Functions
A typical system application uses four single axis, bi-directional joysticks as inputs and controls four bidirectional channels. Each channel has two proportional PWM (pulse width modulated) output signals, and
each signal has independently adjustable threshold, maximum output and ramp time adjustments. The AUX
output turns on whenever any of the joysticks are operated. Four digital inputs can be used to select high or
low range (dual speed option) for the 4 channels. Diagnostic indicator LEDS show the Superflex system’s
status and can be used for easy checkout. An Optimizer may be connected for calibration and
troubleshooting.
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Installation
Mounting the SF4 Controller
Figure 5
The Superflex Controller is an electronic circuit board assembly mounted on an aluminum plate. The
device can be mounted in standard enclosures or in another protected area. Mounting dimensions are
shown in figure 4. Allow at least 9 by 7 inches to mount the Superflex 4, and provide at least 3 inches of
clearance above it for the wire connectors and cable routing. (The Superflex 4 is approximately 1 inch in
height).
Since the Superflex 4 Control System is installed at the site of the machine’s final assembly there are many
installation variations. Follow these guidelines when installing or replacing the Controller -
"
Place the Superflex 4 in a metal enclosure, protected from rain and other fluids.
"
Be sure there are weep holes or one way drains at the bottom of the enclosure.
"
Use a minimum of 18 AWG wiring, especially on the power and output connections.
"
Install the wiring per SAE Specification J-1121.
"
Use 3 amp flyback diodes on all relay coils and non-proportional solenoid valves to prevent
EMI. Refer to the wiring drawing in appendix 5.
"
CAUTION
connectors from the Superflex 4 before welding to prevent damage to the system or to its wiring.
- Provide external current paths when welding on the machine. Disconnect all of the
Typical Wiring
Inputs and outputs are controlled by the particular application’s software program that is built into the
Superflex 4. The function of various terminals are dependent on the application. The following sections
provide general guidelines for wiring the system.
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