OilGear EPC 300 Series User manual

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
1
EPC
300 Series (-3xx)
User Manual

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
2
Table of Contents
1 Introduction............................................................................................................................................ 4
2 Basic System Overview........................................................................................................................ 4
3 General Instructions .............................................................................................................................. 5
3.1 Password Protection........................................................................................................................5
3.2 PC Interface Groupings.................................................................................................................. 5
4 Module Configuration........................................................................................................................... 6
4.1 General Configuration .................................................................................................................... 6
4.1.1 Password Protection (000) ....................................................................................................6
4.1.2 Operating Modes (200) .........................................................................................................6
4.1.2.1 Dynamic Function Selection with Fault Monitor ..........................................................7
4.1.2.2 Dynamic Function Selection with Watchdog Monitor ..................................................7
4.1.2.3 Static Function Selection with Watchdog Daisy Chain ................................................7
4.1.2.4 Dynamic Function Selection with Limit Monitor ..........................................................8
4.1.2.5 Static Function Selection with Fault Monitor................................................................ 8
4.1.2.6 Static Function Selection with Watchdog Monitor ....................................................... 8
4.1.2.7 Static Function Selection with Watchdog Daisy Chain ................................................ 9
4.1.2.8 Static Function Selection with Limit Monitor .............................................................. 9
4.1.3 Program Block Configuration (21x).......................................................................................10
4.1.4 EPC Hardware and Software Information............................................................................11
4.1.5 USB Communication .............................................................................................................12
4.1.6 Update Rate...........................................................................................................................12
4.2 Program Configuration ....................................................................................................................12
4.2.1 Overview ...............................................................................................................................12
4.2.2 PIControl Algorithms ............................................................................................................12
4.2.3 Pressure Control Programs (40x, 41x) ..................................................................................13
4.2.4 Flow with Pressure Limit Programs - Generation 2 (42x, 43x).............................................15
4.2.5 Load Sense Control Programs (44x, 45x)..............................................................................18
4.2.6 Simple Flow Control Programs (46x, 47x).............................................................................21
4.2.7 Pressure Control with Flow Preset Programs - Generation 2 (48x, 49x)..............................22
4.2.8 Advanced Control with Feed-Forward Programs - (50x, 51x)..............................................26
4.3 Pump Controller Configuration .......................................................................................................30
4.3.1 Overview ...............................................................................................................................30
4.3.2Configuration ........................................................................................................................30
4.3.2.1 Function Zero Stroke Command ..................................................................................31
4.3.2.2 Stroke Controller ..........................................................................................................31
4.3.2.3 HP Limiter ...................................................................................................................32
4.3.2.4 Output Polarity .............................................................................................................32
4.3.2.5 Output Current Limit ....................................................................................................33
4.3.2.6 Dither ...........................................................................................................................33

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
3
4.3.3 Configuration Example ..........................................................................................................34
4.4 Analog IO Configuration .................................................................................................................35
4.4.1 General Purpose Analog Input Configuration ........................................................................35
4.4.2 LVDT Fine-Adjustable Analog Input Configuration..............................................................38
4.4.3 Programmable Analog Outputs .............................................................................................39
4.4.4 Servo Valve Driver with Stroke Feedback ............................................................................40
4.4.4.1 Servo Attenuation and Offset ......................................................................................40
4.4.4.2 Stroke Feedback Device ..............................................................................................41
4.4.4.3 Adjustment Mode .........................................................................................................41
4.4.5 LVDT Adjustment Algorithm ................................................................................................43
4.4.5.1. Determining LVDT Configuration Range ...................................................................43
4.4.5.2 Adjustment Algorithm ..................................................................................................44
4.5 Advanced Configuration..................................................................................................................46
4.5.1 Horsepower Limit Factor Calculation....................................................................................46
4.5.1.1 Experimental HP Limit Factor .....................................................................................47
4.5.1.2 Theoretical HP Limit Factor ........................................................................................48
4.5.2 Ramp Configuration ...............................................................................................................50
5 Module Diagnostics ............................................................................................................................. 53
5.1 Diagnostic Representation of Numbers ..........................................................................................53
5.1.1 DAC Counts ..........................................................................................................................53
5.1.2 Voltage and Percentages .......................................................................................................53
5.2 Basic Diagnostics on Front Panel ...................................................................................................53
5.2.1 Run / Fault LED ....................................................................................................................54
5.2.2 Valve Current LED................................................................................................................54
5.2.3 Feedback LED ......................................................................................................................54
5.2.4Testpoint.................................................................................................................................54
5.3 Basic Diagnostics with PC Interface ..............................................................................................55
5.4 Programmable Outputs Diagnostic .................................................................................................56
5.5 Advanced Diagnostics.....................................................................................................................56
5.5.1 Module Faults ........................................................................................................................56
5.5.2 System Messages ..................................................................................................................57
6 Technical Data....................................................................................................................................... 58
6.1 Module Pinout .................................................................................................................................58
6.3 Specifications ..................................................................................................................................59
6.4 IO Summary ....................................................................................................................................59
6.5 Cable Recommendations and Terminal Information .......................................................................59
7 Technical Support ................................................................................................................................. 60
8 Ordering Information........................................................................................................................... 61

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
1Introduction
The EPC is a fully programmable microcontroller-operated controller and
amplifier for servo controlled hydraulic pumps and valves. The unit can be
configured for several types of control applications including:
•FlowControl
•Pressure Control or Load Control
•FlowControl withPressure Limit(PQ-Control)
•Horsepower Control (Pump Stroke and Pressure)
•Pressure Control with Flow Preset
•Advanced Control with Feed-Forward.
2 Basic System Overview
The EPC allows one (1) single control axis with a power amplifier to drive VS-, VV- and VM-controlled
pumps and valves. The basic pump controller configuration allows for closed loop response with both
stroke position and pressure feedback. In addition, two (2) independent function programs can be
dynamically selected with adigital input signal. The unit provides a digital outputfor simple diagnostics or a
watchdogsignal.
Three(3)general-purposeanaloginputsare provided forcommandandpressurefeedbacksignalsincluding
±10 VDC, 0-to-20 mA, or 4-to-20 mA (see Section 6.4 Note 3 for current mode resistor). Additionally, one
(1) analog input is provided as a dedicated fine-adjustable LVDT stroke feedback device. The module allows
for(2) two low-power programmable output signals.
The device is configured by first assigning one of twelve (12) built-in function programs to each of the two
(2) program blocks. Typically, the output of the function programs is then passed to the Pump Controller,
which providesthe valve command.
Figure 2: System Overview
Figure 1: EPC
Module
4
Analog
Outputs
Analog
Inputs
Stroke Feedback
Pressure Feedback
Pump
Controller
Block
Selection
Digital
Output
Diagnostics
Program Block 2
(Program 0..12)
Program Block 1
(Program 0..12)
Digital
Input

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
5
If the full features of the module are used, up to three (3) independent closed loop PI (Proportional with
Integral) control algorithms are utilized. Most function programs provide a closed loop control algorithm for
pressure or stroke, while the Pump Controller can be configured for both stroke and power feedback.
The module is programmable through the PC Interface software. Various Forms in the software will be
discussed throughout the manual. Programming items are located in these Forms.
3 General Instructions
3.1 Password Protection
The EPC allows for edit protection of all programmable parameters. Please refer to Section 4.1.1 for a
thorough discussion of Password Protection.
3.2 PC Interface Groupings
The PC interface provides a programming and monitoring interface. A toolbar menu loosely groups
functions into Forms in the following manner:
File File, Print, and Communication Commands
General Password and Communication Setup,
Program Selection and Mode Selection
(program items 000 and 2xx)
Program Program Configuration (program items 4xx and 5xx)
Pump Controller Pump Controller Configuration
(Program items 8xx)
Diagnostics General Purpose Input Configuration,
Analog IO Configuration Fine-Adjustable Input Configuration (LVDT),
Diagnostics, Servo Driver Configuration,
Programmable Output Selections
(Program items 84x, 85x, 86x, 88x, and 93x)
Diagnostics Ramp Configuration and Advanced HP Limit Setup
Advanced Configuration (program items 87x and 810)
Language Select English, German or Italian
Help User Help
Items are programmable either through Numeric Input boxes or Drop-Down List boxes.

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
4ModuleConfiguration
4.1GeneralConfiguration
General Configuration parameters include Password, Mode, and Communication Setup Parameters.
4.1.1Password Protection (000)
ProgramItem Range Description
000 0 to 255 Password Table 1: Password Protection
The EPC has a simple lockout password that can be used to protect the program configuration from
accidental changes. The password is entered through program item 000 in the General Configuration
Form.
If the password is set to 249, the user will be able to modify any editable entry. Any other password
will place the device in read-only mode. The user will not be able to modify any entry in this mode.
4.1.2 Operating Modes (200)
ProgramItem Range Description
200 0 to 7 Operating Mode:
0: DynamicFunctionSelectionwithFaultMonitor
1: Dynamic FunctionSelection with Watchdog Monitor
2: Static Function Selection with Watchdog Daisy Chain
3: DynamicFunction SelectionwithLimitMonitor
4: Static Function Selectionwith Fault Monitor
5: Static Function Selection with Watchdog Monitor
6: Static Function Selection with Watchdog Daisy Chain
7: Static FunctionSelectionwithLimit Monitor
Table2:OperatingModes
The EPC has eight (8) operating modes. For Dynamic Modes, the EPC will dynamically select
the active function program based on the state of the digital input and the Program Block
settings. For Static Modes, the EPC has only function block 1 active and the digital input may
be used for an alternative purpose defined by that particular mode described in the following
sections.
The digital output is always controlled by the mode specification.
Note: Firmware versions prior to 1.10 only support Modes 0, 1 and 2.
6

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
7
4.1.2.1DynamicFunctionSelectionwithFaultMonitor
This operating mode is selected by setting program item 200 to 0 by choosing Mode 0:
Dynamic Function Selection with Fault Monitor fromthe General Configuration Form.
In this operating mode, the digital input selects which program block is active. If the digital
input is low (<5 VDC), Program Block 1 is made active and the program defined in program
item 210 is used. If the digital input is high (> 5VDC), Program Block 2 is made active and the
program defined in program item 211 is used. Refer to Section 4.1.3 for discussion of Program
Block Configuration (21x).
The digital output provides standard condition status. If no faults are present, the digital output
will be high (VSupply); If faults are present, the digital output will be low (0 VDC). Refer to
Section 5.5 for information on module fault and message conditions.
4.1.2.2DynamicFunctionSelectionwith WatchdogMonitor
This operating mode is selected by setting program item 200 to 1 by choosing Mode 1: Dynamic
Function Selection with Watchdog Monitor from the General Configuration Form of the PC
Interface.
In this operating mode, the digital input selects which program block is active. If the digital
input is low (<5 VDC), Program Block 1 is made active and the program defined in program
item 210 is used. If the digital input is high (> 5VDC), Program Block 2 is made active and the
program defined in program item 211 is used. Refer to Section 4.1.3 for discussion of Program
Block Configuration (21x).
The digital output provides a watchdog signal of approximately 100 Hz.
4.1.2.3StaticFunctionSelectionwithWatchdogDaisyChain
This operating mode is selected by setting program item 200 to 2 by choosing Mode 2: Static
Function Selection with Watchdog Daisy Chain from the General Configuration Form.
In this operating mode, Program Block 1 is always active and the program defined in program
item 210 is used. Program Block 2 is always inactive and program item 211 has no function.
Refer to Section 4.1.3 for discussion of Program Block Configuration (21x).
The digital input is passed through the module into the digital output. In this way, one single
watchdog timer can be used for a number of EPC modules. One EPC module would need to be
configured for Mode 1: Dynamic Function Selection with Watchdog Monitor; the remaining
EPCs would be configured for Mode 2. Any module failure would break the daisy chain.

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
8
4.1.2.4DynamicFunctionSelectionwith LimitMonitor
This operating mode is selected by setting program item 200 to 3 by choosing Mode 3:
Dynamic FunctionSelection with Limit Monitor from the General Configuration Form.
In this operating mode, the digital input selects which program block is active. If the digital
input is low (<5 VDC), Program Block 1 is made active and the program defined in program
item 210 is used. If the digital input is high (> 5VDC), Program Block 2 is made active and the
program defined in program item 211 is used. Refer to Section 4.1.3 for discussion of Program
Block Configuration (21x).
The digital output provides a signal as to whether the stroke command is being limited due to an
over-Power or over-Pressure condition. The over-Power condition is specified from the
Horsepower Limiter. The only supported over-Pressure condition is specified by the Flow with
Pressure Limit Control algorithm (Generation 2).
If either limiting condition is taking place, the digital output will be low (0 VDC). If no limiting
situation is taking place, the digital output will be high (Vsupply). If the Horsepower limiter is
disabled and a program other than a Flow with Pressure Limit Control program (Generation 2) is
active, the digital output will behigh.
4.1.2.5 StaticFunctionSelectionwithFaultMonitor
This operating mode is selected by setting program item 200 to 4 by choosing Mode 4: Static
Function Selection with Fault Monitor from the General Configuration Form of the PC
Interface.
In this operating mode, Program Block 1 is always active and the program defined in menu
210 is used. Program Block 2 is always inactive and menu item 211 has no function.
The digital output provides standard condition status. If no faults are present, the digital output
will be high (VSupply); If faults are present, the digital output will be low (0 VDC).
4.1.2.6StaticFunctionSelectionwithWatchdogMonitor
This operating mode is selected by setting menu item 200 to 5, or by choosing Mode 5: Static
Function Selection with Watchdog Monitor from the General Configuration form of the PC
Interface.
In this operating mode, Program Block 1 is always active and the program defined in menu
210 is used. Program Block 2 is always inactive and menu item 211 has no function.
The digital output provides a watchdog signal of approximately 100 Hz.

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
9
4.1.2.7StaticFunctionSelectionwithWatchdogDaisyChain
This operating mode is selected by setting menu item 200 to 6 by choosing Mode 6: Static
Function Selection with Watchdog Daisy Chain from the General Configuration form of the
PC Interface.
In this operating mode, Program Block 1 is always active and the program defined in menu
210 is used. Program Block 2 is always inactive and menu item 211 has no function.
The digital input is passed through the module into the digital output. In this way, one single
watchdog timer can be used for a number of EPC modules. One EPC module would need to be
configured for Mode 1 (Dynamic Function Selection with Watchdog Monitor) while the
remaining EPCs would be configured for Mode 2. Any module failure would break the daisy
chain.
4.1.2.8StaticFunctionSelection withLimitMonitor
This operating mode is selected by setting menu item 200 to 7, by choosing Mode 7: Static
Function Selection with Limit Monitor from the General Configuration form of the PC
Interface.
In this operating mode, Program Block 1 is always active and the program defined in menu
210 is used. Program Block 2 is always inactive and menu item 211 has no function.
The digital output provides a signal as to whether the stroke command is being limited due to an
over-Power or over-Pressure condition. The over-Power condition is specified from the
Horsepower Limiter. The only supported over-Pressure condition is specified by the Flow with
Pressure Limit Control algorithm (Generation 2).
If either limiting condition is taking place, the digital output will be low (0 VDC). If no limiting
situation is taking place, the digital output will be high (VSupply). If the Horsepower limiter is
disabled and a program other than a Flow with Pressure Limit Control program (Generation 2) is
active, the digital output will behigh.

EPC
SERVO AMPLIFIER MODULE
Part Number L723888-3xx
ELECTRONIC
Telephone: [phone] Oilgear
Fax: [phone] International Dr Issued May 31, 2018
Web Site: www.oilgear.com Traverse City, MI USA 49686 Bulletin836260F
10
4.1.3ProgramBlockConfiguration(21x)
Program Item Range Description
210 0 to 12 Program Selection for Program Block 1
0: No Program used for Block 1
(refer to Section 4.3.2.1)
1-12: Program 1 to 12 used for Block 1
211 0 to 12 Program Selection for Program Block 2
0: No Program used for Block 2
(refer to Section 4.3.2.1)
1 to12: Program 1 to 12 used for Block 2
Table3:ProgramBlockConfiguration
The program block configuration parameters are used in conjunction with the module operating
modes to assign pre-defined programs to the two (2) program blocks.
Dynamic Operating Modes: These modes are referred to as “dynamic” because the digital input
selects which Program Block is active. If the digital input is low (<5 VDC), Program Block 1 is
made active and the program defined in menu 210 is used. If the digital input is high (> 5VDC),
Program Block 2 is made active and the program defined in menu 211 is used (see Example).
Static Operating Modes: These modes are referred to as “static” because Program Block 1 is
always active and menu 210 defines the active function program. Menu 211 has no function in
operating mode 2. The static operating modes also free the digital input to be used for a function
other than program selection.