Continental Hydraulics CEM-AC-E0-A User manual

Continental Hydraulics Installation Manual
Page 1 of 8 CEM-AC-A CHI 1013472 April 2012
CEM-AC-E0-A
CEM-AC-E1-A
Description:
This power amplifier mounts directly to a single solenoid proportional valve coil with a DIN style
connector, and will drive up to 2.5A. It is suitable to control current to either a proportional flow or
pressure valve coil.
A wide range of analog signals are accepted. There are two product choices for input, one
accepts voltage commands, the other accepts current commands. These inputs are easily scaled
to match system requirements. Two independent ramps are available for acceleration and
deceleration control.
Min and Max output current are adjustable. Output characteristics can be independently
customized. The module is disabled if the coil outputs are shorted or open. If command current is
outside of the proper range, the module is also disabled. PWM and Dither are user adjustable.
This module is easily adapted to a variety of system requirements. All variables are user adjusted
with easy to use software on your Microsoft Windows laptop. Control variables are stored in non-
volatile memory internal to the module. All variables can be read by the laptop, and reproduced
exactly on other modules.
Technical Data:
Solenoid Output
A
A1.2 2.5
PWM Frequency 60 to 2650
60 to 400
0 to 30
0.17
Dither Frequency
Dither Amplitute
Sample Time
Hz
Hz
%
mS
Software Selectable
Housing
Housing Attaches to DIN 43650 coil
Polyamide PA
Combustability Class
Protection Class
Material
-20 to +60
UL94
CWorking Temperature
Humidity
Storage Temperature
Emission
C
% 95 (non condensing)
-20 to +70
IP 65 (with gasket)
V1
Immunity
Electro Magnetic Compatibility EN 61000-6-2
EN 61000-6-3
Vibration Resistance EIC 60068-2-6
vDC 0 to +10 (voltage version)
Impendance ohm 90k
mA 4 to 20 (current version)
390
Current
Impendance
Resolution
Sample Time mS
%<0.1
1.0
Voltage
ohm
Power Supply
vDC 12 to 30 (including ripple)
<100mA + solenoid
3 (medium action)
mA
AExternal Fuse
Consumption
Analog Input
Electrical Connection
Power and Signal
Communication
Ground via DIN coil pin
LIN bus
M12 5 pin male key style A

Continental Hydraulics Installation Manual
Page 2 of 8 CEM-AC-A CHI 1013472 April 2012
Functional Diagram:
1
3
Input
Scaling
Control Program
DC
DC
+12 to 24v
(Brown)
0v (Gnd)
(Blue)
Sol A
Output
Command input
(White)
2
4
5
Ramp Output
Control
+
-
0 to +10v
or
4 to 20 mA
Communication
(Gray) Ground via DIN
plug
Command Return
(Black)
CEM-AC-E0 (voltage input)
CEM-AC-E1 (current input)
uc
w
Wiring Example:
3
1
2
5
4
(communications)
12-30vDC
Ground
0 to 10v
Ground
programming
E0 - Voltage input
E1 - Current input
Power
Signal
3
1
2
5
4
(communications)
Power
Signal
12-30vDC
Ground
4-20 mA
return
programming
Dimensions:
3.1"
1.3"
1.5"
DIN 43650 Form A
M12 5pin male
43
12
5
Face view of
connector
on module

Continental Hydraulics Installation Manual
Page 3 of 8 CEM-AC-A CHI 1013472 April 2012
Steps to install and configure a new application:
1. Mount the module on the valve solenoid.
2. Connect the M12 cordset with power supply and command wires
3. Attach VEA-PB5 programming box tool
4. Connect programming tool to computer with VEA-USB programming cable
5. Adjust current range to match valve
6. Adjust PWM/Dither to optimize valve performance
7. Adjust analog input to scale command input
8. Adjust ramping (if desired)
9. Adjust internal monitor functions (if desired)
Module Mounting:
This module is to be mounted on a proportional valve solenoid with a DIN 43650 connector. It
has an environmental protection rating of IP65. Additional external protection may be necessary
on machinery subjected to extreme wash down conditions.
Do not mount near other items that emit high power electrical interference, such as motor
controllers and high power contactors.
Power Supply:
This amplifier module is designed to operate on DC power from a regulated power supply ranging
from 12 to 30 volts. Match valve solenoid voltage rating to power supply, typically 12 or 24 volts.
A 3 amp medium action fuse is recommended in the “+” power supply line.
Wiring to Amplifier:
The CEM-AC products have an industry standard M12 5pin male electrical connector. Mating
connectors or complete cordsets are available from many sources.
Voltage drop must be considered when selecting connecting cable.
CHI offers the VEA-3P5C, a 5 meter long 22 gauge 5 conductor shielded cable cordset. The
voltage drop in this cable should be acceptable with 24v solenoid applications. Allowable voltage
drop may limit the cable length in an application where the solenoid requires the full 2.5A.
Adjust MODE to STD or EXP:
The module wakes up in the default mode of STD. Several parameters may be adjusted while in
STD mode.
EXP mode allows more complex parameter adjustments to the module.
MODE parameter valid options are STD and EXP.

Continental Hydraulics Installation Manual
Page 4 of 8 CEM-AC-A CHI 1013472 April 2012
Adjust module current output to match valve requirements:
Proportional valve manufactures will generally list the following specifications:
Maximum current
Minimum current (cracking current)
Recommended dither for optimum performance
This module must first be adjusted to match the valve solenoid requirements.
The first step is to select the appropriate current range. There are two choices:
CURRENT = 0 solenoid current up to 1.2A
CURRENT = 1 solenoid current up to 2.5A
Maximum current is set with software as a percentage of this range. Max is usually
adjusted to the solenoid rating.
Minimum current is adjusted via software for the purpose of deadband elimination.
Min A =
% of Range
Max A =
% of Range
Current Range + 100%
Trigger = % of Command
+ 100%
0% Command
This module has a software adjustable “dead zone” near zero, termed TRIGGER. With a
command in this near zero area, neither solenoid will be energized. Trigger is intended to keep
small noise signals on the analog command from causing either solenoid to be energized.
PWM and Dither are set via software.
Output Current:
1. Select Module output range to meet valve requirements:
Example: D03 direction valve with 24v solenoid – Max = 0.86A
CURRENT = 0; output up to 1.2 A
CURRENT = 1; output up to 2.5A
1a Set Value of software parameter CURRENT = “0”.
2. Adjust Maximum solenoid current for the solenoid:
Example: 0.86A/1.2A = 71.67%
2a Set software parameter MAX:A to value of 7167.
(note: Software parameter has units of 0.01%)
3. Adjust Minimum solenoid current for the solenoid:
Example: Valve will start to flow at about 0.180A.
0.180A/1.2A=15.00%
3a Set software parameter MIN A to value of 1500.
(note: Software parameter has units of 0.01%)
Note: Minimum values (cracking current) will need to be adjusted for each and every
valve, as each valve has a unique flow gain characteristic.

Continental Hydraulics Installation Manual
Page 5 of 8 CEM-AC-A CHI 1013472 April 2012
Command input with Voltage:
The CEM-AC-E0 can accept voltage signals for commanding valve performance.
An analog command source voltage may be either “differential” or “ground referenced”.
2
4
+24v 1
3
Power Supply
Gnd Line
AC
DC
Analog Command Source
"Differential Voltage"
(PLC, Digitial Motion
Controller, etc.)
+
-
CEM-AC-
E0
2
3
4
+24v 1
3
Power Supply
Gnd Line
AC
DC
Analog Command Source
"Ground Referenced Voltage"
(PLC, Digitial Motion
Controller, etc.)
Gnd
+
CEM-AC-
E0
-
All ground based reference voltages must have a connection to Pin 3.
2
3
4
+24v 1
3
Power Supply
Gnd Line
AC
DC
Gnd
CEM-AC-
E0
+10v potentiometer
( 5k ohm typical)
Gnd
External
Voltage
Reference
Command input with current:
The CEM-AC-E1 can accept current signals for commanding valve performance.
The CEM-AC-E1 has a 390 ohm resistor inserted across terminals 2 and 4. This resistor
converts the current to a voltage. This voltage is measured by the differential amplifier to become
the module command.
Input current range is 0 to +/- 20 mA, and is typically used at 4 to 20mA. This current is
converted to voltage, and software scale and offset parameters are applied to meet system
requirements.
2
4
+24v 1
3
Power Supply
Gnd Line
AC
DC
CEM-AC-
E1
4 to 20mA
Transmitter
A
Line AC
DC
Loop Monitor
(optional)
Power Supply

Continental Hydraulics Installation Manual
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All analog input signal cables must be shielded!
Good analog system design requires that all analog signals in an electrically noisy environment
be shielded. Long wires act like antenna’s that pick up analog noise. The wire connecting the
analog command source to command this module must be shielded! An unshielded cable can
allow electrical noise to be added to the desired command signal, and can make the system
response erratic.
Good design principals require a noise sensitive wire be wrapped in a noise blocking shielded
cable. That shield must be grounded at only one end, usually the end that sends the signal.
Short signal wires in electrically quiet environments may not need to be shielded.
Swapping polarity with the POL parameter:
The input command polarity may be swapped with the POL command. Valid parameter values
are “+” and “-“. (Default = +).
Setting POL to “-“ will change the 0% to 100% valve operation to 100% to 0%.
Adjustment of SENS internal monitoring function:
SENS parameter has two options: ON (default) and OFF
The CEM-AC-E0 is able to monitor the solenoid electrical connection. If the module senses a
short circuit or open circuit on the output to the valve solenoids, the module is disabled.
The CEM-AC-E1 adds the ability to monitor the analog input current range to the solenoid
monitoring listed above. If SENS is “ON”, and the command current falls outside of the 4 to
20mA range, the module is disabled.
Adjustment of LIM internal monitoring function:
LIM is an optional analog input voltage monitor. LIM can be used to monitor a possible cable
break or open circuit from command input sources.
LIM can be set from 0 to 20% of total input range.
Example: The module has been configured for a joystick with total input range of
0 to 10v. Setting LIM to 500 (5.00%) will allow module operation with input command
between 0.5v and 9.5v. A command below 0.5v, or over 9.5v will cause the module to
disable.
5
010
0.5 9.5
Module active
Module disabled
Output
100%
0%
Command input

Continental Hydraulics Installation Manual
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Scaling of analog input:
The CEM-AC-E0 module has a native analog voltage input range of 0 to +10v. This input can be
scaled and offset with software to allow a wide variety of input voltages. A few examples are:
0 to +10v, 0 to +5v, 1 to 5v, 0.5 to 4.5v
The CEM-AC-E1 module has a native analog current input range of 0 to 20mA. This input can be
scaled and offset with software to allow a wide variety of input currents. A few examples are:
0 to 20mA, 4 to 20mA, 0 to 10 mA
The AIN:W is the Parameter used to adjust the analog input.
Analog voltages or currents are scaled with the following linear equation:
Output = A/B * (Input – C)
“Output” of this scaling equation must always be equal to the module native input range, 0 to +/-
10v. “Input” can be any voltage within this 20v range.
A/B allows for a decimal scaling factor. These two numbers are chosen to provide a “gain” to the
input signal. A and B are positive or negative whole numbers up to 10000. (Default; A = 1000, B
= 1000)
C is an offset, measured as a percentage of range. C has the units of 0.01%, and has the
allowable range of –10000 to 10000. (Default; C = 0)
Scaling voltage inputs:
Example: Typical AIN:W parameter settings for popular command voltages:
Command A B C description valve centered
0 to +10v 1000 1000 0 100% scale, 0% offset 0v
0 to +10v 1 1 0 100% scale, 0% offset 0v
0 to +5v 10 5 0 200% scale, 0% offset 0v
+1 to +9v 10 8 1000 125% scale, 10% offset 1.0v
+0.5 to +4.5v 10 4 500 250% scale, 5% offset 0.5v
0 to 8v 10 8 0 125% scale, 0% offset 0v
Scaling current inputs:
Example: Typical AIN:W parameter settings for popular command currents:
Command A B C description valve centered
4 to 20mA 20 16 2000 125% scale, 20% offset 4mA
4 to 20mA 1250 1000 2000 125% scale, 20% offset 4mA
0 to 20mA 20 20 0 100% scale, 0% offset 0mA
0 to 10mA 20 10 0 200% scale, 0% offset 0mA

Continental Hydraulics Installation Manual
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PWM and Dither:
PWM and Dither are parameters that are recommended by the valve manufacturer. For
Continental Hydraulics recommendations for PWM and Dither, look for the latest updated
reference chart at: www.continentalhydraulics.com
Ramping:
Command input signals may be ramped.
There are two independently adjustable ramps, R:UP for ramp up, and R:DOWN for ramp down.
Max A
Ramp up (R:UP)
Ramp down (R:DOWN)
Command signal = 0 to 100% to 0
T0 T1 T2 T3
All ramp rates are set via software. All ramps are specified in milliseconds, and are actually “time
to ramp for a 0 to 100% signal change.” For example, a value of 2000 will give a ramp time of 2
seconds for a 0 to 100% step command. The ramp time will be 1 second for a step command of
0 to 50%.
100% Command "Off"
0123 6
50%
0% 4 5 7
Command "On"
Time (seconds)
Command Ramped Valve Response
(R:DOWN = 4000)
(R:UP = 2000)
LED function:
Yellow Steady on System OK
Blinking SENS is turned on, and 4 to 20mA current input is out of range
Blinking LIM is turned on, and input voltage is out of range
Blinking Connection to solenoid is open or shorted
Parameter monitoring using software:
The following parameters may be monitored in real time using Windows configuration software:
Parameter Description Unit
W Command after scaling 0.01%
C Command after ramping 0.01%
U Output to power stage 0.01%
IA Solenoid Current mA