Danfoss MCW100C User manual

1
MCW100C, MCW100E
Time Proportional Rotary Position Controller
DESCRIPTION
The MCW100C,E Time Proportional Rotary Position Controller provides
automatic grade or steering control of paving, trenching and curbing ma-
chines. The Controller uses a wand follower to sense the grade level or
steering command from a stringline or flat surface.
Two modules are housed in the case of the Controller. The grade sensing
module electromagnetically measures the machine's deviation from a grade
reference. The amplifier module receives the signal from the sensor module
and produces a voltage output to drive solenoid valves which, on a typical
paving machine, operate lift cylinders. Within the amplifier's proportional
band,thepercentoftimetheoutputisonisproportionaltothegradeerror.The
MCW100C,E may be used together with the MCW101 Time Proportional
Level Controller to control both parameters simultaneously.
FEATURES
• May be mounted on either side of machine
• Adjustable tracking force
• Dual UP/DOWN lamps show deviation from setpoint in
RUN and STANDBY modes
• Adjustable deadband varies sensitivity
• Run/Standby switch permits operator to switch to
manual control
• Flexible joint on follower prevents breakage
• Rugged aluminum housing
• 12 Vdc or 24 Vdc supply voltage
• Reverse polarity and short circuit protected
• Moisture and corrosion resistant
• Withstands vibration and shock
©Copyright 2001, Danfoss (US) Company.
All rights reserved. Contents subject to change.
ORDERING INFORMATION
ACCESSORIES
1. STEERING FOLLOWER
Straight tubular follower, 16 inches long overall with
breakaway joint. For steering only. Part number
KG07002.
2. RIGHT ANGLE GRADE FOLLOWER
Withbreakaway joint.Forgradeapplications only.Fol-
lows a stringline. Also used with skate assembly, or
skate and ski assembly for following hard reference
surface. Part number KG04003.
3. RIGHT ANGLE GRADE FOLLOWER LESS SENSING
ARM
For grade applications utilizing the skate and/or skate
and ski assemblies. Same as Part number KG04003,
above,butwithoutthesensingarmandbreakawayjoint.
Part number K09274.
4. SKATE ASSEMBLY
For grade applications. Use with right angle grade fol-
lower (PartnumberK09274) onhardreference surface
Part number KG06001.
5. SKI ASSEMBLY
For grade applications. Used with right angle grade
follower (Part number K09274), and skate assembly
(PartnumberKG06001)onhardreferencesurface.Part
number KG02001.
6. CABLE ASSEMBLY
KW01015 two-foot coiled cable that extends to ten feet
(3 meters). Has right angle connector on one end
and straight connector on the other end to make
connections between the MCW100C,E and Bendix
TypeNo.MS3102A18-1Pplug.(Partnumber K03989).
SERVICE PARTS
1. AMPLIFIER MODULE
Removable modular amplifier can be exchanged with
other voltage compatible grade controllers:
Part Number K02910 (12 volt, MCW100C)
K02911 (24 volt, MCW100C)
K10654 (12 volt, MCW100E)
K10655 (24 volt, MCW100E)
2. K00702 Lens
3. K00706 Lamp (12 volt models)
K00707 Lamp (24 volt models)
4. K00665 RUN/STANDBY Switch
BLN-95-9013-1Issued: March 1995

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ORDERING INFORMATION ( continued)
1842
TECHNICAL DATA
REVERSE POLARITY PROTECTION
200 Vdc, maximum
SHORT CIRCUIT PROTECTION
Full, with 0.5 Ωmaximum resistance
TIME PROPORTIONAL OUTPUT FREQUENCY
f = 3 Hz ±1 Hz
MINIMUM PULSE WIDTH
t = 37 ms ±12 ms
OPERATING VOLTAGE
12 Volt Model: 11 to 15 Vdc
24 Volt Model: 22 to 30 Vdc
SUPPLY CURRENT
0.6A,maximum,notincludingoutputcurrenttothevalve
MAXIMUM VOLTAGE DROP (3 A load current)
3.5 Vdc
CURRENT OUTPUT
3 A, maximum
BLOCK DIAGRAM MCW100C - Ground Side Switching
f
V
-+
+
Microsyn Sensitivity
potentiometer
V
t
3 Hz
V
t
V
t
V
t
440 Hz
V
t
Voltage regulator
Battery
-
+
F
BLOCK DIAGRAM MCW100E - High Side Switching
1812
f
V
-+
+
Microsyn Sensitivity
potentiometer
V
t
3 Hz
V
t
V
t
V
t
440 Hz
V
t
Voltage regulator
Battery
-
+
F
CONTROLLER SUPPLY VOLTAGE TYPE OF OUTPUT
MCW100C1007 12 Vdc Ground side switching
MCW100C1015 24 Vdc Ground side switching
MCW100E1005 12 Vdc High side switching
MCW100E1013 24 Vdc High side switching
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THEORY OF OPERATION
The secondary voltages are demodulated in the amplifier to
power a bridge network. A 3 Hz triangular wave is summed
with the error signal, defined by the difference between the
voltages, to effect the time proportioning. (See Figure 2.)
The sum is compared to a reference voltage by two Schmitt
triggers, which drive the solenoids. As the slope sensor
rotates, the triangular wave moves up or down with respect
to zero error signal. When the triangle crosses the upper or
lower trigger level the output signal is turned on. When a
Remote Setpoint is used, the difference between the volt-
ages is kept proportional to the commanded slope. The
separation between the reference voltages (the deadband)
is adjustable through a trim potentiometer in the front panel.
At minimumsensitivity(maximum deadband),a0.4%slope
error signal will fire the triggers. At maximum sensitivity
(minimumdeadband),bothtriggerswill firealternatelyatthe
peaksofthetriangularwaves,evenwhenthesystemislevel.
The sensitivity adjustment controls the difference between
the upper and lower trigger from overlap to 0.5% slope.
The MCW100C,E Time Proportional Grade Controller con-
sists of a grade-sensing transducer and an amplifier. The
sensor and amplifier are housed in a single aluminum chan-
nel and can be removed easily for repair or replacement.
They are connected with a MS-connector.
Steering and grade information is sent to the Controller
through either a right angle or straight tube follower. Right
angle followers are used to sense grade and are either
tubular (for stringlines) or skate and ski (for firm reference
surfaces). Straight followers are used to sense a steering
path and are tubular. As the reference is raised or lowered -
leftorrightforsteering-thetransducershaftisrotatedsothat
the follower maintains contact.
Thetransducertransformsthisshaftrotationintoanelectrical
signal through the rotor/stator interaction. (See Figure 1.)
A 440 Hz square wave from the amplifier is applied to the
primariesofcoilsAand B. The statorpositionwithrespectto
the rotor determines the voltages from the coil secondaries.
Figure 1. 1814
1815
Figure 2.
0error
t
0
output signal to the solenoid valve
min. sensitivity
t
upper trigger level
0
no output signal to the solenoid valve
max. sensitivity
max. sensitivity
min. sensitivity lower trigger level
adjust
sensitivity
upper trigger level
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CONNECTION DIAGRAM MCW100C - Ground Side Switching
CONNECTION DIAGRAM MCW100E - High Side Switching
DIMENSIONS
MS-CONNECTOR, 10-PIN
DOWN
UP
F
5A
B
C
D
E
F
G
H
I
J
A
BATTERY
-+
JOG
DOWN
UP
MS-CONNECTOR, 10-PIN
DOWN UP
F
5A
B
C
D
E
F
G
H
I
J
A
BATTERY
-
+
JOG
DOWNUP
1816
1817
1818
Dimensions in Millimeters (Inches)
S
E
N
S
I
T
I
V
I
T
Y
S
T
A
N
D
B
Y
O
N
39,1
(1.54) 114
(4.5)
136,7
(5.44)
46
28
117,1
(4.61)
188
(7.4)
158,8
(6.25)
86,6
(3.4)
39,4
(1.55)
63,5
(2.5)
31,8
(1.25)
190,5
(7.5)
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INSTALLATION - LOCATION
The MCW100C,E can be mounted on either side of the
machine, oriented according to the location of the reference
surface or stringline. It may be used with a right angle grade
follower, Part number KG04003, or straight tubular follower,
Part number KG07002.
TherightanglefollowermaybeattachedtotheMCW100C,E
hub horizontally, at a 45°angle downward, or at a 45°
upward.(SeeFigure3.)Theflatonthehubshouldbeparallel
to the grade reference.
The follower may be attached at a 45°angle downward.
(See Figure 4.)
The follower may be attached at a 45°angle upward. (See
Figure 5.) and the follower should be positioned toward the
operator panel.
Whenthestraighttubularfollowerisusedforsteeringcontrol
(see Figure 6), the MCW100C,E hub should be directly
above the stringline.
Note: When the right angle follower is
used, the transducer shaft must be mounted perpendicular
tothedirectionoftravel.Whenthestraighttubularfolloweris
used,thetransducershaftmustbeparallelwiththedirection
of travel.
Figure 5.
Figure 3.
Figure 4.
1825
1826 1828
1827
BLN-95-9013
Figure 6.

6
Attach the appropriate follower to the hub. Note the guide
hole location, and direction of travel. Guide holes in the
mounting bracket for the steering follower, Part number
KG07002,arelocated asshown(see Figure7).The follower
may be attached to either hub. The right angle follower, Part
number KG04003, is used for grade applications.
Afterthefollower hasbeen installed,adjust thespring onthe
hub so the follower exerts a very light pressure on the
stringlineor referencesurface. Notethat theflat ofthe hubis
paralleltothetopofthecasewhentheMCW100C,Eisatnull
position.
INSTALLATION - MOUNTING
Askateassembly(PartnumberKG06001)andskiassembly
(Part number KG02001) may be used with the right angle
follower (Part number KG04003) when a firm reference
surface is used. (See Figures 8 and 9.)
STEERING
LEFT HUB STEERING RIGHT HUB
GRADE
RIGHT
HUB LEFT HUB
BREAKAWAY JOINT
1
1
1THE RIGHT HUB IS DEFINED AS THE ONE WITH
THE SPRING BIAS ADJUSTMENT THUMBSCREW
952B
Figure 7.
Figure 8.
Figure 9. 951A
1829
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WIRING
All wiring connections are made through an MS connector
locatedonthe backof theunit.Althoughtwo connectorsare
provided, only the larger, 10-pin connector is used. (See
Figure 1, page 3 of this document.) A two-foot coiled cable
that extends to ten feet is available with plugs for easy
removal, A straight plug is provided on one end, and a right
angle plug on the other. Order Part number KW01015. Use
Part number MS3102A18-1P (K03989) connector on the
control panel for cable connection.
ADJUSTMENT
TheGradeControllerwillprovideextended,trouble-free
operation and should not need servicing under normal
operating conditions. If preliminary investigation of a
system malfunction indicates trouble in the
MCW100C,E the following facts should be kept in mind
to help determine the problem.
1. The lights will indicate deviations in grade whenever
power is applied to the MCW100C,E, regardless of the
Run/Standby switch position.
2. Inthe Run position, amplifier output is connected to the
solenoid. In the Standby position, it is not.
3. If the deadband potentiometer is turned fully clockwise
(maximumdeadband), a large deviationwill be needed
to command an output to the solenoid.
4. Preliminary checks should include examination of the
cablesandleadsfordamagedorbrokenwire. Examine
areas where shorting may occur. Check the power
supplytobesureitis greaterthan11Vdc(22Vdc on24
volt models).
5. Shouldabulbneedreplacement,unscrewthelensfrom
thepanel.Thebulbsnapsoutofitssocket,butbecause
clearances are tight it may be impossible to remove by
hand.Ifapieceof5/16"rubbertubingisavailable,itcan
bepushed down over thebulb and pulled back toeffect
removal.Thereplacementsare'DQIRVVPartQXPEHU
K00706 for 12 volt models and K00707 for 249ROW
models. The part can also be purchased through
othervendors asa number161 (129olt)or number656
(24 9olt) bulb.
1. Place the RUN/STANDBY switch on STANDBY.
2. Turn the deadband potentiometer fully counterclock-
wise to minimum deadband.
3. Applyelectricalpower tothe system.Hydraulicpoweris
not necessary at this time.
4. With the equipment at the correct grade position, adjust
thepositionoftheMCW100CuntiltheUP/DOWNgrade
lightsare blinkingfor the sameamount oftime. Lock the
controller in place.
5. Movethefollowerupand downabout1/4"whileobserv-
ing the lights and increase the deadband setting (turn
clockwise) until both lights are off for about 1/16" of
movement. Usually this is about 1/4 turn clockwise.
6. TurnONthehydraulicpowerandplaceRUN/STANDBY
switch on RUN.
7. Introduce a grade error into the system by either using
the machine JOG switch or by pushing down on the
follower.
8. Observe the response of the machine. If it oscillates
whenreturning to null, the deadband istoosmall.Turn
the potentiometer clockwise. If the machine slowly
approaches null but stops short, the deadband is too
large. Turn the potentiometer counterclockwise.
9. Replace the screw to cover the deadband adjustment.
TROUBLE CHECK
1. With the RUN/STANDBY switch in the STANDBY posi-
tion, operate the machine JOG switch in both directions
while noting operation of the solenoid. (The JOG switch
is wired separately.) If the solenoid operates in the
wrong direction, reverse the leads on the valve and
recheck.Ifthesolenoidfailstooperate,checkforvoltage
attheJOGswitchterminalsatthecenter-offpositionand
atthesolenoidterminalswhentheswitchisactivated.If
propervoltageexists,replace thesolenoid.If thereisno
voltage, check the wiring.
2. Check the lights when the Grade Controller is in the
STANDBY mode. Use the JOG switch to vary machine
position and note the indication. One light and then the
other should glow as the conditions are reversed.
3. Disconnect the power and output cable connector from
theMCW100C,E.Checkvoltageatthesocketendofthe
cable for at least 11 Vdc between sockets A and B. If
voltage does not exist across A and B, the cable or the
voltage supply is faulty.
4. Check the output voltage from C to ground and D to
ground.
5. If another Grade Controller is available, set it on the
same surface as the other and plug the MS connectors
into the replacement unit. Check system operation. If
the problem disappears, the Controller is defective.
Substitute the replacement controller in its place.
TROUBLESHOOTING
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CUSTOMER SERVICE
NORTH AMERICA
ORDER FROM
Danfoss (US) Company
Customer Service Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
Phone: [phone]
Fax: [phone]
DEVICE REPAIR
For devices in need of repair or evaluation, include a
description of the problem and what work you believe
needs to be done, along with your name, address and
telephone number.
RETURN TO
Danfoss (US) Company
Return Goods Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
EUROPE
ORDER FROM
Danfoss (Neumünster) GmbH & Co.
Order Entry Department
Krokamp 35
Postfach 2460
D-24531 Neumünster
Germany
Phone: [phone]
Fax: [phone]
BLN-95-9013