W.E.S.T. Elektronik POS-124-A-PDP, POS-124-I-PDP Technical Documentation Manual
W.E.ST.
Technical Documentation
POS-124-A-PDP
POS-124-I-PDP
Two axes positioning and synchronisation control module with
integrated profibus interface and SSI sensor interface
Elektronik GmbH
W.E.ST.
1 General Information ............................................................................................................................................. 4
1.1 Order number .............................................................................................................................................. 4
1.2 Scope of supply ........................................................................................................................................... 4
1.3 Accessories ................................................................................................................................................. 4
1.4 Symbols used .............................................................................................................................................. 5
1.5 Using this documentation ............................................................................................................................ 5
1.6 Legal notice ................................................................................................................................................. 5
1.7 Safety instructions ....................................................................................................................................... 6
2 Characteristics ..................................................................................................................................................... 7
2.1 Device description ....................................................................................................................................... 8
3 Use and application ............................................................................................................................................. 9
3.1 Installation instructions ................................................................................................................................ 9
3.2 Typical system structure ............................................................................................................................ 10
3.3 Method of operation ................................................................................................................................... 10
3.4 Commissioning .......................................................................................................................................... 12
4 Technical description ......................................................................................................................................... 13
4.1 Input and output signals ............................................................................................................................. 13
4.2 LED definitions ........................................................................................................................................... 14
4.3 Circuit diagram ........................................................................................................................................... 15
4.4 Typical cabling ........................................................................................................................................... 16
4.5 Connection examples ................................................................................................................................ 16
4.6 Technical data ........................................................................................................................................... 17
5 Parameters ........................................................................................................................................................ 18
5.1 Parameter overview ................................................................................................................................... 18
5.2 Parameter description ................................................................................................................................ 20
5.2.1
LG (Changing the language for the help texts) ................................................................................. 20
5.2.2
PDPADR (Profibus adress) ............................................................................................................... 20
5.2.3
MODE (Switching between parameter groups) ................................................................................. 20
5.2.4
SENS (Module monitoring) ............................................................................................................... 21
5.2.5
STROKE1 /STROKE2 (Full stroke) ................................................................................................... 21
5.2.6
VRAMP1 /VRAMP2 (Ramp time for external speed demand) .......................................................... 21
5.2.7
VMODE1 / VMODE2 (Switching over the control mode)................................................................... 22
5.2.8
VMAX1 / VMAX2 (Maximum speed in NC Mode) ............................................................................. 22
5.2.9
POL1 / POL2 (Output polarity) .......................................................................................................... 23
5.2.10 EOUT1 / EOUT2 (Output signal in case of error) .............................................................................. 23
5.2.11 INPX (Sensor type define) ................................................................................................................ 24
5.2.12 SSI:OFFSET (Sensor offset) ............................................................................................................. 24
5.2.13 SSI:POL (Direction of the sensor signal) ........................................................................................... 24
5.2.14 SSI:RES (Signal resolution) .............................................................................................................. 25
5.2.15 SSI:BITS (Number of bits) ................................................................................................................. 25
5.2.16 SSI:CODE (Signal coding) ................................................................................................................ 25
5.2.17 AIN (Analogue input scaling) ............................................................................................................. 26
5.2.18 A1 / A2 (Acceleration time) ............................................................................................................... 27
5.2.19 D1 / D2 (Deceleration / braking distance) ......................................................................................... 27
5.2.20 V01 / V02 (Loop gain setting) ............................................................................................................. 28
5.2.21 CTRL1 / CTRL2 (Deceleration function characteristic) ..................................................................... 29
5.2.22 GL: P (gain of the synchronization in SDD mode) ............................................................................. 30
5.2.23 GL: V0 (gain of the synchronization in NC mode) ............................................................................. 30
5.2.24 GL:T1 (Time constant of the synchronisation control) ....................................................................... 30
5.2.25 GL:E (Window for the synchronization error) .................................................................................... 30
Elektronik GmbH
CONTENTS
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5.2.26 HAND1 / HAND2 (Manual speed) ..................................................................................................... 31
5.2.27 MIN / MIN2 (Overlap compensation) ................................................................................................. 32
5.2.28 MAX1 / MAX2 (Limitation) ................................................................................................................. 32
5.2.29 TRIGGER (Response threshold for the MIN parameter) ................................................................... 32
5.2.30 OFFSET1 / OFFSET2 (Zero correction) ............................................................................................ 33
5.2.31 INPOS:S1 / INPOS:S2 (In position window) ...................................................................................... 33
5.2.32 INPOS:D1 / INPOS:D2 (following error window) ............................................................................... 33
5.2.33 PROCESS DATA (Monitoring) .......................................................................................................... 34
6 Appendix ............................................................................................................................................................ 35
6.1 Failure monitoring ...................................................................................................................................... 35
6.2 Troubleshooting ......................................................................................................................................... 35
6.3 Description of the command structure ........................................................................................................ 37
7 Profibus DP interface ......................................................................................................................................... 38
7.1 Profibus functions....................................................................................................................................... 38
7.2 Installation .................................................................................................................................................. 38
7.3 GSD Configuration File .............................................................................................................................. 38
7.4 Description Profibus DP interface .............................................................................................................. 39
7.5 Commands via PROFIBUS ........................................................................................................................ 40
7.5.1
Command map .................................................................................................................................. 40
7.5.2
Definition of the control bits: .............................................................................................................. 41
7.6 DATA send to PROFIBUS ......................................................................................................................... 42
7.6.1
Feedback map ................................................................................................................................... 42
7.6.2
Definition of the status bits: ............................................................................................................... 43
8 Notes.................................................................................................................................................................. 44
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1 General Information
1.1 Order number
POS-124-A-PDP-11211 triple stage module with digital SSI-interface with analogue ±10 V
differential output, housing width 67,5 mm
POS-124-I-PDP-1121 triple stage module with digital SSI-interface with analogue 4… 20 mA
output, housing width 67,5 mm
Alternative products:
POS-124-A-PDP-S1-1121 double stage module without digital SSI-interface with analogue ±10 V
differential output, 45 mm housing width
POS-124-I-PDP-S1-1121 double stage module without digital SSI-interface with analogue
4… 20 mA output, 45 mm housing width
1.2 Scope of supply
The scope of supply includes the module including the terminal blocks which are a 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
RS232-SO - Programming cable with RS232 interface
USB-SO - Programming cable with USB interface
WPC-300 - Start-Up-Tool (download: www.w-e-st.de/produkte/software)
PDP-Plug - Profibus connector with switchable terminating resistors
1
The number of the version consists of the hardware-version (first two digits) and the software-version (second 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.
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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.
1.6 Legal notice
W.E.St.
Gewerbering 31
D-41372 Niederkrüchten
Tel.: +49 (0)2163 577355-0
Fax.: +49 (0)2163 577355 -11
Homepage: www.w-e-st.de or www.west-electronics.com
EMAIL: info@w-e-st.de
Date: 13.02.2013
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 copyright.
Elektronik GmbH
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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, con-
tamination 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.
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2 Characteristics
This electronic module has been developed for controlling hydraulic positioning drives.
Both axes are controlled complete autonomous via the Profibus. Optionally an interconnection to a two
axes synchronised system is intended.
The differential outputs are covered for activation of constant valves with integrated or external
electronics (differential input). Intended is this module for the connection of analogue way sensors 0...10V
or 4...20mA (scalable) or digital SSI sensor interfaces.
The internal control signals operating states and error conditions via Profibus to the higher-level control.
The operation is signaled by a switch output.
Typical applications: Positioning control or synchronization control with hydraulic axes.
Features
• Two independent positioning axes
• Can be combined for synchronization controls
• Command position parameter, actual value response, on loop control byte and status byte via
fieldbus Profibus DP
• Principle of stroke-dependent deceleration for the shortest positioning time or NC profile gen-
erator for constant speed
• Analogue or digital (SSI) actual value registration for both axes
• Superimposed synchronization controller as PT1 actuator
• Usable with zero lapped control valves
• Fault diagnosis and extended function checking
• Simplified parameterization with WPC-300 software version 3.2
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2.1 Device description
Elektronik GmbH
99,0000 mm
D-outputs
Ready
24 V
0 V
Enable
D-inputs
Made in Germany
ID:
V:
W.E. ST.
D-41372 Niederkrüchten
Homepage: http://www.w-e-st.de
1
9
2
10
3
11
4
12
5
13
6
14
15
7
16
8
Add.:Date:
Elektronik
Analogue
GND
GND
Pos. 1
Pos. 2
A
B
Differential
output
Typenschild und Anschlussbelegung
Type plate and terminal pin assignment
LEDs
RS232
Interface
1 2 3 4
5 6 7 8
W.E.ST.
Ready
Status
18 19 2017
22 23 2421
Online
Profibus
9pol SUBD
67,5000 mm
114,0000 mm
34 35 3633
38 39 4037
121,0000 mm
Klemmblöcke (steckbar)
Terminals (removable)
PROFIBUS Buchse
PROFIBUS connector
9 10 11 12
14 15 1613
26 27 2825
30 31 3229
42 43 4441
46 47 4845
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Elektronik GmbH
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 a requirement
that no strong electro-magnetic interference sources are installed nearby when using our control
and regulation modules.
• Typical installation location: 24V 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 space close to the PLC (24 V area) is most suitable. All
digital and analogue inputs and outputs are fitted with filters and surge protection 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- connected
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 shielded.
• All other cables must be screened if there are powerful interference sources (frequen-
cy converters, power contactors) and cable lengths > 3m. 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.
• With 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). Particular care is required with cables of over 40 m in length – the manufacturer
should be consulted if necessary.
• A low-resistance connection between PE and the mounting rail should be provided. Transient in-
terference 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 connected to the same power
supply) must always be provided with appropriate overvoltage protection directly at the coil.
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3.2 Typical system structure
This minimal system consists of the following components:
(*1) proportional valve
(*2) hydraulic cylinder
(*3) position sensor
(*4) POS-124-PDP 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
based 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.
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).
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Positioning sequence:
The positioning is controlled via Profibus. After releasing (ENABLE input), the command
position is set to the actual position of the sensor and the axis stays in closed loop position control
mode. The READY output indicates that the system is generally ready for operation. When setting the
START-signal, the preset command value will be taken over. The axis immediately will drive to this new
command position and indicates reaching it by setting the InPos output.
The InPos output stays active as long as the axis is within the preset InPos window and the START input
is active. The driving velocity is forced by preset parameter, too.
The axis can be driven in manual mode (START is off) using the control bits HAND+ or HAND-. The
velocity is programmable. When the HAND signal is deactivated, the command position is set to the actu-
al position and the system stays in closed loop position control mode.
Setting the synchronous bit (GL) will synchronize both axes and the synchronization controller is overrid-
ing the position controller of axis 2. Axis 2 is now following axis 1 according to the master-slave-principle.
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 with our modules a
resolution of < 0.01% only needs to be considered with long positions. In addition, the linearity of the individual signal points (PLC, sensor and control module) must be considered. The worst-case scenario is
that a system-specific absolute fault occurs.
The repeat accuracy is, however, not affected by this.
V+
A:A D:A
D:B
V+
volumetric flow
MAX:A
control direction
driving out
control direction
driving in
MAX:B
P-A
and B-T
A:B
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3.4 Commissioning
Step Task
Elektronik GmbH
Installation
Switching on for the first
time
Setting up communication
Pre-parameterisation
Control signals
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 metal
protective housing (control cabinet or similar).
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 cabling. Switch the device off
immediately and check the cabling.
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.
Now set up the following parameters (with reference to the system design and circuit diagrams):
The STROKE, POSITION, SENSOR SETTING, POLARITY, ACCELERATION
and DECELERATION.
Pre-parameterisation is necessary to minimise the risk of uncontrolled movements.
Parameterise specific settings for the control element (MIN for following error
compensation and MAX for maximum velocity).
Reduce the speed limitation to a value which is uncritical for the application.
Check the control signal with a voltmeter. The control signals (PIN 15 to PIN16
and PIN19 to PIN20) lies in the range of ± 10V. In the current state it should be
0V. Alternatively, if current signals are used, approx. 0 mA should flow.
CAUTION! This signal depends on the EOUT setting.
Profibus communication
Switching on the hydraulics
Activating ENABLE
Activating START
Manual (HAND) operation
Optimise controller
Activate the profibus communication and check whether the right values and bits
are send to the module.
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).
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 is in the current position (with ENABLE the actual position is accepted
as the required position). Should the drive move to an end position the polarity is
probably wrong.
With the start signal the demand value on 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.
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.
Now optimise the controller parameters according to your application and your
requirements.
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4 Technical description
4.1 Input and output signals
Connection Supply
Elektronik GmbH
PIN 3, PIN 31
and PIN 35
PIN 4, PIN 32
and PIN 36
Power supply (see technical data)
0 V (GND) connection.
Caution, PIN 4 is connected internally to PIN 11 (and also possibly to PIN 12 depending on
the model). These connections serve as a reference potential for the analogue sensor or
demand value signals.
Connection Analogue signals
PIN 13
PIN 14
PIN 15 / 16
PIN 19 / 20
Analogue position actual value (X1), range 0… 100% corresponds to 0… 10V or 4… 20 mA
Analogue position actual value (X2), range 0… 100% corresponds to 0… 10V or 4… 20 mA
Analogue differential output for activation of the axis 1:
-100...100% corresponds to -10...10V.
Analogue differential output for activation of the axis 2:
-100...100% corresponds to -10...10V.
Connection SSI sensors
PIN 37-40
PIN 33, 34
PIN 41-44
PIN 47, 48
Interface 1 to the SSI sensor. RS422 interface and power supply
Interface 2 to the SSI sensor. RS422 interface and power supply
Connection Digital inputs and outputs
PIN 8
PIN 2
PIN 1
Enable input:
This digital input signal initializes the application. The signal will be approved in connection
with the software enable the corresponding axis.
Synchronous error output (only active in synchronous mode):
ON: Slave axis within the error window (GL:E)
OFF: Slave axis outside the error window (GL:E)
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.
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4.2 LED definitions
LEDs Description of the LED function
GREEN
YELLOW
GREEN
(right side)
Identical to the READY output.
OFF: no power supply or ENABLE is not activated
ON: System is ready for operation
Flashing: Error discovered (valve solenoid or 4… 20 mA).
The error of one axis results to a flashing LED.
Only active in synchronous mode:
OFF: Slave axis outside the error window
ON: Slave axis within the error window
Profibus connection.
OFF: No Profibus communication
ON: Profibus communication in prozess
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