W.E.S.T. Elektronik Technical Documentation Manual
Specifications and Main Features
Frequently Asked Questions
User Manual
Technical Documentation
POS-123-U
POS-123-P
POS-123-U-SSI
Universal positioning module, alternatively with power output stage or SSI interface
CONTENTS
1 General Information ................................................................................................................................................. 4
1.1 Order number ................................................................................................................................................. 4
1.2 Scope of supply .............................................................................................................................................. 4
1.4 Symbols used ................................................................................................................................................. 5
1.5 Using this documentation ............................................................................................................................... 5
3 Use and application ............................................................................................................................................... 10
4.1 Input and output signals ............................................................................................................................... 15
4.2 LED definitions ............................................................................................................................................. 16
4.6 Technical data .............................................................................................................................................. 19
5.2.5 HAND (Manual speed) .......................................................................................................................... 23
5.2.6 INPOS (In position range) ..................................................................................................................... 24
5.3 Signal adaptation .......................................................................................................................................... 24
5.3.2 SIGNAL (Type of input)......................................................................................................................... 24
5.3.3 N_RANGE:X (Nominal range of the sensor) ......................................................................................... 25
5.5.1 VMODE (Methode of positioning) ......................................................................................................... 28
5.5.1 ACCEL (Acceleration in NC mode) ....................................................................................................... 28
5.5.2 VMAX (Maximum speed in NC mode) .................................................................................................. 28
5.6 Control parameter ......................................................................................................................................... 29
5.6.1 A (Acceleration (ramp) time) ................................ ................................................................ ................. 29
5.6.2 D (Deceleration / braking distance) ....................................................................................................... 29
5.6.3 V0 (Loop gain setting) ........................................................................................................................... 30
5.6.4 V0:RES (Scaling of the loop gain) ........................................................................................................ 30
5.6.5 PT1 (Timing of the controller) ............................................................................................................... 31
5.7.5 SIGNAL:U (Type and polarity of the output signal) .............................................................................. 33
5.8 Special commands ....................................................................................................................................... 34
5.8.1 Drift compensation / high accurate positioning ..................................................................................... 34
5.9 Process data ................................................................................................................................................. 37
6.3 Description of the command structure .......................................................................................................... 40
7 ADDITIONAL INFORMATION: Power output stage ............................................................................................. 41
7.1 General function ........................................................................................................................................... 41
7.6 Technical data .............................................................................................................................................. 44
7.7 Parameter overview of the power station ...................................................................................................... 45
7.8 Parameter description of the power stage .................................................................................................... 45
7.8.1 SIGNAL:M (Type of the monitor output signal) .................................................................................... 45
7.8.2 SIGNAL:U (Polarity of the output signal) .............................................................................................. 45
7.8.3 CURRENT (Rated output current) ....................................................................................................... 46
8.1 General function ........................................................................................................................................... 49
8.6 Technical data .............................................................................................................................................. 53
8.7 Special versions ............................................................................................................................................ 54
8.8 Parameter overview of the SSI interface ...................................................................................................... 54
8.9 Parameter description of the SSI interface ................................................................................................... 55
POS-123-U1-20302 - with programmable output (±10 V differential output or 4… 20 mA) and analogue
sensor interface
POS-123-P-2030 - with integrated power output stage up to 2,6 A (see additional information)
POS-123-U-SSI-2030 - with programmable output (±10 V differential output or 4… 20 mA), SSI sensor
interface and 0… 10 V output as a diagnosis signal for the SSI sensor
(see additional information)
Extended versions
PPC-125-U-PDP - with extended position and pressure control, SSI or analogue sensor interface and
Profibus interface
UHC-126-U-ETC - with extended position and pressure control, SSI or analogue sensor interface and
Ethernet interface (Ethercat, Profinet, …)
1.2 Scope of supply
The scope of supply includes the module plus the terminal blocks which are part of the housing.
The Profibus plug, interface cables and further parts which may be required should be ordered separately.
This documentation can be downloaded as a PDF file from www.w-e-st.de.
1.3 Accessories
WPC-300 - Start-Up-Tool (downloadable from our homepage – products/software)
Compared with older versions (ordering code A for voltages output and I for current output) the code U (universal) is
used for programmable outputs.
The number of the version consists of the hardware version (first two digits) and the software version (last two digits).
Because of the development of the products these numbers can vary. They are not strictly necessary for the order. We will
always deliver the newest version.
Page 4 of 58 POS-123-*-2030 23.08.2019
1.4 Symbols used
General information
Safety-related information
1.5 Using this documentation
Structure of the documentation:
The standard product is descibed up to chapter 6. The extensions like POWER STAGE or SSI-INTERFACE
are described in the chapters ADDITIONAL INFORMATION.
Home page: www.w-e-st.de or www.west-electronics.com
EMAIL: info@w-e-st.de
Date: 23.08.2019
The data and characteristics described herein serve only to describe the product. The user is required to
evaluate this data and to check suitability for the particular application. General suitability cannot be inferred
from this document. We reserve the right to make technical modifications due to further development of the
product described in this manual. The technical information and dimensions are non-binding. No claims may
be made based on them.
This document is protected by copyright.
Elektronik GmbH
Page 5 of 58 POS-123-*-2030 23.08.2019
1.7 Safety instructions
Please read this document and the safety instructions carefully. This document will help to define the product
area of application and to put it into operation. Additional documents (WPC-300 for the start-up software) and
knowledge of the application should be taken into account or be available.
General regulations and laws (depending on the country: e. g. accident prevention and environmental
protection) must be complied with.
These modules are designed for hydraulic applications in open or closed-loop control circuits.
Uncontrolled movements can be caused by device defects (in the hydraulic module or the
components), application errors and electrical faults. Work on the drive or the electronics must
only be carried out whilst the equipment is switched off and not under pressure.
This handbook describes the functions and the electrical connections for this electronic
assembly. All technical documents which pertain to the system must be complied with when
commissioning.
This device may only be connected and put into operation by trained specialist staff. The
instruction manual must be read with care. The installation instructions and the commissioning
instructions must be followed. Guarantee and liability claims are invalid if the instructions are
not complied with and/or in case of incorrect installation or inappropriate use.
CAUTION!
All electronic modules are manufactured to a high quality. Malfunctions due to the failure of
components cannot, however, be excluded. Despite extensive testing the same also applies
for the software. If these devices are deployed in safety-relevant applications, suitable external
measures must be taken to guarantee the necessary safety. The same applies for faults which
affect safety. No liability can be assumed for possible damage.
Further instructions
The module may only be operated in compliance with the national EMC regulations. It is
the user’s responsibility to adhere to these regulations.
The device is only intended for use in the commercial sector.
When not in use the module must be protected from the effects of the weather,
contamination and mechanical damage.
The module may not be used in an explosive environment.
To ensure adequate cooling the ventilation slots must not be covered.
The device must be disposed of in accordance with national statutory provisions.
Page 6 of 58 POS-123-*-2030 23.08.2019
2 Characteristics
This electronic module has been developed for controlling hydraulic positioning drives. Proportional valves
with integrated or external electronics can be controlled with the differential output.
The internal profile generation is optimized for stroke-dependent deceleration or the NC control mode. The
controller and the controller settings are adapted to typical requirements and thus permit rapid and uncritical
optimization of the control behavior. The optimized control function offers a high degree of precision together
with high stability for hydraulic drives. The movement cycle is controlled via the external position and speed
inputs.
The high resolution of the analogue signals ensures good positioning behavior.
Alternatively, the P version is available with an integrated power output stage (see additional information:
POWER OUTPUT STAGE). The advantage of the integrated power output stage is founded in the integrated
control behavior without additional dead times. This allows higher dynamics and higher stability respectively.
The SSI extension is available for use with digital sensors (see additional information: SSI INTERFACE).
Sensors with a resolution of one µm can be used for very high position accuracy.
Setting up this module is simple and easy to handle with our WPC-300 start-up software.
Typical applications: general positioning drives, fast transport drives, handling systems, speed-controlled axes
and also tracer control.
Features
Analogue position and speed inputs
Analogue feedback sensors
Simple and intuitive scaling of the sensor
Optional: start-up assistant for fast and simple adjusting of the control parameter
Motion command values in mm resp. mm/s
Internal profile definition by acceleration, velocity and deceleration
Principle of stroke-dependent deceleration for fast and robust positioning
NC profile generator for constant speed
Expanded closed loop control technology
Highest positioning accuracy by using the drift compensation
Usable with overlapped proportional valves and with zero lapped control valves
Fault diagnosis and extended function checking
Simplified parameterization with WPC-300 software
Optionally:
o Integrated power output stage (P version)
o SSI Sensor interface
Page 7 of 58 POS-123-*-2030 23.08.2019
2.1 Compatibility
As a result of further developments some smaller changes have to be taken in consideration.
Functionality:
1. Downward compatible to the older modules.
2. 100 % wiring compatible.
3. Baud rate: The default baud rate has changed from 9600 baud to 57600 baud. This is adaptable in
WPC-300: OPTIONS/SETTINGS/INTERFACE.
FIXBAUDRATE = 57600 and/or AUTO BAUDRATE DETECTION = 57600
4. Technical enhancements:
a. Programmable analogue output: only one version (U instead A and I) is necessary
b. Improved profile generator
c. Independent adjustment between SDD and NC mode
d. PT1 filter to stabilize the control behavior
e. Drift compensation and/or high accurate positioning
f. Start-up support
Parameterization:
1. Standardizing of parameter names
2. Simplified and intuitive parameterization of the analogue inputs and sensors
3. Compatibility mode of the input scaling (AINMODE), if necessary
4. Adaptation of the output signal (current or voltages) and the polarity with the command SIGNAL:U
(the POL commando is removed)
Typenschild und Anschlussbelegung
Type plate and terminal pin assignment
23,0000 mm99,0000 mm
114,0000 mm
2.2 Device description
Standard module – for the P-Version look at point 7.2
Page 9 of 58 POS-123-*-2030 23.08.2019
3 Use and application
3.1 Installation instructions
This module is designed for installation in a shielded EMC housing (control cabinet). All cables which
lead outside must be screened; complete screening is required. It is also necessary to avoid strong
electro-magnetic interference sources being installed nearby when using our open and closed loop
control modules.
Typical installation location: 24 V control signal area (close to PLC)
The devices must be arranged in the control cabinet so that the power section and the signal section
are separate from each other.
Experience shows that the installation place close to the PLC (24 V area) is most suitable. All digital
and analogue inputs and outputs are fitted with filters and surge absorbers in the device.
The module should be installed and wired in accordance with the documentation bearing in mind EMC
principles. If other consumers are operated with the same power supply, a star-shaped ground wiring
scheme is recommended. The following points must be observed when wiring:
The signal cables must be laid separately from power cables.
Analogue signal cables must be screened.
All other cables must be screened if there are powerful interference sources (frequency
converters, power contactors) and cable lengths > 3 m. Inexpensive SMD ferrites can be
used with high-frequency radiation.
The screening should be connected to PE (PE terminal) as close to the module as
possible. The local requirements for screening must be taken into account in all cases. The
screening should be connected to at both ends. Equipotential bonding must be provided
where there are differences between the connected electrical components.
If having longer lengths of cable (> 10 m), the diameters and screening measures should
be checked by specialists (e. g. for possible interference, noise sources and voltage drop).
Special care is required if using cables of over 40 m in length, and if necessary the
manufacturer should be consulted if necessary.
A low-resistance connection between PE and the mounting rail should be provided. Transient
interference is transmitted from the module directly to the mounting rail and from there to the local
earth.
Power should be supplied by a regulated power supply unit (typically a PELV system complying with
IEC364-4-4, secure low voltage). The low internal resistance of regulated power supplies gives better
interference voltage dissipation, which improves the signal quality of high-resolution sensors in
particular. Switched inductances (relays and valve coils) which are connected to the same power
supply must always be provided with appropriate overvoltage protection directly at the coil.
Page 10 of 58 POS-123-*-2030 23.08.2019
MINMAX
INPUT w
cx
b
a
y
INPUTx
cx
b
a
y
CONTROL
Application interface
y
*1
*2
*4
*3
*5
Speed
Position
3.2 Typical system structure
This minimal system consists of the following components:
(*1) Proportional valve (or control valve): the valve type determines the precision. It is expedient to use
control valves with integrated electronics.
(*2) Hydraulic cylinder
(*3) Integrated analogue or SSI position sensor (alternatively also with external position sensor)
(*4) POS-123-* control module
(*5) Interface to PLC with analogue and digital signals
3.3 Method of operation
This control module supports simple point-to-point positioning with hydraulic drives. The system works on the
principle of stroke-dependent deceleration, i. e. the control gain (deceleration stroke) is set via parameters D:A
and D:B. Alternatively the loop gain will be used in NC mode. In this mode the velocity is controlled and the
profile ist defined by the velocity and the acceleration.
The deceleration characteristics can be set linearly (LIN) or approximately quadratically (SQRT1) via the
CTRL parameter. For normal proportional valves SQRT1 is the input setting.
For control valves with a linear flow curve it depends on the application. If LIN is selected for these valves, a
significantly shorter deceleration distance can often be set (D:A and D:B).
Positioning sequence:
The positioning procedure is controlled by the switching inputs. After the ENABLE signal is applied, the
required position equal to the actual position is set in the module and the drive remains stationary under
control at the current position. The general readiness for operation is now reported via the READY output. The
START signal activates the analogue demand value input (PIN 13) which is accepted as the new required
position. The drive moves directly to the new required position and reports the reached position via the InPos
output. The InPos output remains active as long as the position is maintained and as long as the START
signal remains applied.
Page 11 of 58 POS-123-*-2030 23.08.2019
V+
V+
A:AD:A
A:B
D:B
MAX:A
MAX:B
driving out
volumetric flow
P-A
and B-T
control direction
control direction
driving in
In manual mode (START disabled) the drive can be moved by means of HAND+ or HAND-. The drive moves
under open-loop control at the programmed manual speeds.
When the HAND (+ or -) signal is switched off, the current actual position is accepted as the required position
and the drive comes to a controlled stop.
The HAND mode can be used – in case of a sensor failure – to drive the axis manually.
Influences on positioning accuracy:
The positioning accuracy is determined by the hydraulic and mechanical conditions. The right choice of valve
is therefore a decisive factor. In addition, two mutually contradictory requirements (short position time and high
accuracy) must be taken into account when designing the system.
The electronic limitations lie mainly in the resolution of the analogue signals, although a resolution of
< 0,01 % only needs to be considered for our modules with long positions. In addition, the linearity of the
individual signal points (PLC, sensor and control module) must be taken into account.
It is generally recomended to calculate the static and dynamic behavior of the hydraulic axis. For supporting
this, following technical basic data are required:
- minimum natural frequency of the cylinder,
- maximum theoretical speed for extending and retracting,
- valve characteristics (natural frequency, overlapped or zero lapped, hysteresis and the flow gain (flow and
pressure drop),
- system pressure, maximum pump flow,
- and a description of the general system requirements.
Page 12 of 58 POS-123-*-2030 23.08.2019
Step
Task
Installation
Install the device in accordance with the circuit diagram. Ensure it is wired
correctly and that the signals are well shielded. The device must be installed in a
protective housing (control cabinet or similar).
Switching on for the first
time
Ensure that no unwanted movement is possible in the drive (e. g. switch off the
hydraulics). Connect an ammeter and check the current consumed by the device.
If it is higher than specified, there is an error in the wiring. Switch the device off
immediately and check the wiring.
Setting up communication
Once the power input is correct, the PC (notebook) should be connected to the
serial interface. Please see the WPC-300 program documentation for how to set
up communication.
Further commissioning and diagnosis are supported by the operating software.
Pre-parameterization
Now set up the following parameters (with reference to the system design and
circuit diagrams):
The SYS_RANGE, SENSOR SETTING, POLARITY, ACCELERATION and
DECELERATION.
Pre-parameterization is necessary to minimize the risk of uncontrolled
movements.
Parameterize specific settings for the control element (MIN for deadzone
compensation and MAX for maximum velocity).
Reduce the speed limitation (VELO command) to a value which is uncritical for
the application.
Control signal
Check the control signal with a voltmeter. The control signal (PIN 15 to PIN16) lies
in the range of ± 10 V. In the current state it should be 0 V. Alternatively, if current
signals are used, approx. 0 mA should flow.
Switching on the
hydraulics
The hydraulics can now be switched on. Since the module is not yet generating a
signal, the drive should be at a standstill or drift slightly (leave its position at a
slow speed).
Activating ENABLE
CAUTION! The drive can now leave its position and move to an end position at
full speed. Take safety measures to prevent personal injury and damage.
The drive stays in the current position (with ENABLE the actual position is
accepted as the required position). If the drive moves to an end position, the
polarity is probably wrong.
Speed demand
The speed can be limited by means of the VELO parameter or the external speed
demand (VS = EXT).
Manual (HAND) operation
If START is disabled, the axis can be moved manually with HAND+ or HAND-.
After disabling the HAND signal, the axis stops in a controlled manner at the
current position.
CAUTION! Please check the manual operation in conjunction with the EOUT
command. If the EOUT is active do not use the manual operation.
Activating START
With the start signal the demand value of the analogue demand value input is
accepted and the axis moves to the predefined target position.
If START is disabled, the axis stops in the preset deceleration distance D:S.
Optimize controller
Now optimize the control parameters according to your application and your
requirements.
3.4 Commissioning
Page 13 of 58 POS-123-*-2030 23.08.2019
3
3.5 The Start-Up assistant
The function of the start-up assistant is available on request3.
„Start-up-assistant for positioning drives”.
This assistant is available in special versions of the positioning controllers only.
Page 14 of 58 POS-123-*-2030 23.08.2019
Connection
Supply
PIN 3
Power supply (see technical data)
PIN 4
0 V (GND) connection.
Connection
Analogue signals
PIN 9 / 10
External speed demand (V), range 0… 10 V or 4… 20 mA (scalable)
PIN 13
Position demand value (W), range 0… 10 V or 4… 20 mA (scalable)
PIN 14
Analogue position actual value (X), range 0… 10 V or 4… 20 mA (scalable)
PIN 11 / PIN 12
0 V (GND) connection for analogue signals
PIN 15 / 16
Valve control signal.
Type of signal and polarity can be selected by the parameter SIGNAL:U.
Connection
Digital inputs and outputs
PIN 8
Enable input:
This digital input signal initializes the application and error messages are deleted. The
controller and the READY signal are activated. The output signal to the control element is
enabled.
The actual position is accepted as the command position and the drive remains stationary
under control at this position.
If the input is disabled, the output (control signal) is switched off(disabled). Take care of the
EOUT-command!
PIN 7
START (RUN) input:
The position controller is active and the external analogue demand position is accepted as
the demand value. If the input is disabled during the movement, the system is stopped
within the set emergency stopping distance (D:S).
PIN 6
HAND + input:
Manual operation (START = OFF): the drive moves at the programmed speed in the
programmed direction. After deactivation, the actual current position is accepted as the
demand position. The START (RUN) input has priority over the HAND+ input.
If the sensor signal is missing (external ENABLE signal = ON), the drive can be operated in
manual mode.
PIN 5
HAND - input:
Manual operation (START = OFF); the drive moves with the programmed speed in the
programmed direction. After deactivation, the actual current position is accepted as the
required position. The START (RUN) input has priority over the HAND- input.
If the sensor signal is missing (external ENABLE signal = ON), the drive can be operated in
manual mode.
PIN 1
READY output:
ON: The module is enabled; there are no discernable errors.
OFF: Enable (PIN 8) is disabled or an error (sensor or internal error) has been detected.
PIN 2
STATUS output:
ON: INPOS message. The axisis within the INPOS window.
OFF: INPOS message. The axis is outside the INPOS window.
4 Technical description
4.1 Input and output signals
Page 15 of 58 POS-123-*-2030 23.08.2019
LEDs
Description of the LED function
GREEN
Identical to the READY output.
OFF: No power supply or ENABLE is not activated
ON: System is ready for peration
Flashing: Error discovered
Only active when SENS = ON
YELLOW A
Identical to the STATUS output.
OFF: The axis is outside the INPOS window.
ON: The axis is within the INPOS window.
GREEN +
YELLOW A+B
1. Chasing light (over all LEDs): The bootloader is active. No normal functions are
possible.
2. All LEDs flash shortly every 6 s: An internal data error was detected and corrected
automatically! The module still works regularly. To acknowledge the error the module
has to be cycle powered.
YELLOW A +
YELLOW B
Both yellow LEDs flash oppositely every 1 s: The nonvolatile stored parameters are inconsistent! To acknowledge the error, the data have to be saved with the SAVE command
or the corresponding button in the WPC. If the function of the module has changed via the
FUNCTION parameter, all parameters are deleted purposely and set to default values. In
this case the LEDs indicate no error, but a desired state. To acknowledge please save.
4.2 LED definitions
Page 16 of 58 POS-123-*-2030 23.08.2019
I-version: 4... 20 mA
PIN 15 = +, PIN 12 = GND
Commands:
SIGNAL:W
Input Selektor
PE via DIN-RAIL
15
16
12
1
2
Output: A
Output: B
8
5
Ready
InPos
Enable
Start
24 V output
24 V output
USB-B
Differential
Input
POS-123-U
7
13
14
0 V
0..10V
0 V
11
11
Feedback
Position
4..20mA
Output Adaptation
Hand -
24 V input
24 V input
24 V input
wa
x
u
Internal Power
3
4
0 V
10
9
Speed
Commands:
SIGNAL:V
VELO
VRAMP
0..10V
0 V
Command
speed
11
Control program
v
24 V input
6
Hand +
Profil Generator
Commands:
- VMAX
- SYS_RANGE
VMODE = NC
Input Selektor
Commando:
SIGNAL:X
0..10V
4..20mA
0 V
Command
position
0 V
Control Function
Commands:
- A:A and A:B
- D:A and D:B
- V0:A and V0:B
Commands:
- MIN:A and :B
- MAX:A and :B
- TRIGGER
- OFFSET
- SIGNAL:U
VMODE = SDD
Output
limitation
DC
DC
24 V
0 V
PELV
-
e
w
VMODE = SDD
Speed
Commands:
- LG
- MODE (Expert or Standard)
- EOUT (Error Mode)
- INPOS (InPos output)
Commands:
- VMODE
- SENS
- HAND A/B
- D:S
RS232 C
57600 Baud
1 Stopbit
no parity
c
4..20mA
4.3 Circuit diagram
Page 17 of 58 POS-123-*-2030 23.08.2019
+In PIN 13 or 14
PIN 12 (GND)
SPS / PLC 0... 10 V speed input signal
+In PIN 10
-In PIN 9
GND PIN 11
SPS / PLC 0... 10 V command and feedback signal
+In PIN 13 or PIN 14
In PIN 12 (GND)
PLC or sensor with 4... 20 mA (two wire connection)
z. B. 24 V
+In PIN 13 or 14
PIN 12 (GND)
PLC or sensor with 4... 20 mA (three wire connection)
z. B. 24 V
Valve (6 + PE plug) with OBE electronics
A : 24 V supply
B : 0 V supply
C : GND or enable
D : + differential input
E : - differential input
F : diagnostics
PE -
PIN 15
PIN 16
PIN 12
Module
8765
16151413
1211109
Screen
Power amplifier interface /
proportional valve
+/- 10V (differential input)
4... 12... 20mA PIN 15 to PIN 12
Analogue Input
0... 10V / 4... 20mA
Power Supply
PLC (digital IOs)
24V
0V
Ready
Error / InPos
Analogue feedback
0... 10V / 4... 20mA
4321
0V
0V
0..10V
0..10V / 4... 20mA
PE terminal
PE terminal
Hand-
Hand+
Start
Enable
Analogue velocity
0... 10V / 4... 20 mA
4.4 Typical wiring
4.5 Connection examples
Page 18 of 58 POS-123-*-2030 23.08.2019
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