W.E.S.T. Elektronik PAM-199-P Guide
Technical Documentation
PAM-199-P
Power amplifier for all typical proportional valves
Page 2 of 48 PAM-199-P 05.06.2020
CONTENTS
1General Information......................................................................................................................................................4
1.1 Order Number.......................................................................................................................................................4
1.2 Scope of supply....................................................................................................................................................4
1.3 Accessories..........................................................................................................................................................4
1.4 Symbols used.......................................................................................................................................................5
1.5 Legal notice..........................................................................................................................................................5
1.6 Safety instructions................................................................................................................................................6
2Characteristics.............................................................................................................................................................. 7
2.1 Device description................................................................................................................................................8
3Use and application...................................................................................................................................................... 9
3.1 Installation instruction...........................................................................................................................................9
3.2 Commissioning...................................................................................................................................................10
4Function modes and technical description.................................................................................................................. 11
4.1General Information............................................................................................................................................11
4.2 LED Indications ..................................................................................................................................................11
4.3 Control of directional valves (195)......................................................................................................................12
4.3.1 Typical system structures ..........................................................................................................................12
4.3.2 Method of operation...................................................................................................................................12
4.3.3 Input and output signals.............................................................................................................................13
4.3.4 Circuit diagram...........................................................................................................................................14
4.3.5 Typical wiring.............................................................................................................................................15
4.3.6 Parameter list.............................................................................................................................................16
4.4 Control of two throttle and / or pressure valves (196).........................................................................................17
4.4.1 Typical system structure............................................................................................................................17
4.4.2 Method of operation...................................................................................................................................17
4.4.3 Input and output signals.............................................................................................................................18
4.4.4 Circuit diagram...........................................................................................................................................19
4.4.5 Typical wiring.............................................................................................................................................20
4.4.6 Parameter list.............................................................................................................................................21
4.5 Control of proportional valves by preprogrammed values and ramp times (197)................................................22
4.5.1 Typical system structure............................................................................................................................22
4.5.2 Method of operation...................................................................................................................................22
4.5.3 Input and output signals.............................................................................................................................23
4.5.4 Circuit diagram...........................................................................................................................................24
4.5.5 Typical wiring.............................................................................................................................................25
4.5.6 Parameter list.............................................................................................................................................26
4.6 Input connection (examples)...............................................................................................................................27
4.7 Technical data....................................................................................................................................................28
5Parameter description ................................................................................................................................................ 29
5.1 FUNCTION (Function mode)..............................................................................................................................29
5.2 LG (Changing the language for the help texts)...................................................................................................29
5.3 MODE (Switching between parameter groups) ..................................................................................................30
5.4 SENS (Failure monitoring)..................................................................................................................................30
5.5 CCMODE (Activation of the characteristic linearization).....................................................................................31
5.6 SOLENOIDS (One or two solenoids)..................................................................................................................31
5.7 PIN:5 (Choice of the additional function of PIN 5) ..............................................................................................31
5.8 PIN:6 (Choice of the additional function of S1/PIN 6).........................................................................................32
5.9 USCALE (Output current scaling depending on PIN:6)......................................................................................32
5.10 ENABLE_B (Switching of the ENABLE Function)...............................................................................................32
5.11 LIM (Signal monitoring) ......................................................................................................................................33
Page 3 of 48 PAM-199-P 05.06.2020
5.12 POL (Output polarity)..........................................................................................................................................34
5.13 AINA (Current- / Voltage input)...........................................................................................................................34
5.14 AINB (Current- / Voltage input)...........................................................................................................................34
5.15 AIN (Analogue input scaling) ..............................................................................................................................35
5.16 AA (Ramp function/Acceleration time)................................................................................................................36
5.17 AB (Ramp function/Acceleration time)................................................................................................................36
5.18 AA (Ramp function) ............................................................................................................................................37
5.19 RMODE (Choosing ramp function).....................................................................................................................37
5.20 S (Presetting command values)..........................................................................................................................38
5.21 RA (Ramp function / Acceleration time)..............................................................................................................38
5.22 CCA (Characteristics linearization channel A)....................................................................................................39
5.23 CCB (Characteristics linearization channel B)....................................................................................................39
5.24 CC (Characteristics linearization) .......................................................................................................................40
5.25 MIN (Overlap compensation)..............................................................................................................................41
5.26 MAX (output scaling) ..........................................................................................................................................41
5.27 TRIGGER (threshold value of MIN function).......................................................................................................41
5.28 MIN (Overlap compensation)..............................................................................................................................42
5.29 MAX (Output scaling)..........................................................................................................................................42
5.30 TRIGGER (Threshold value of MIN function) .....................................................................................................42
5.31 CURRENT (Nominal output current)...................................................................................................................43
5.32 DFREQ (Dither frequency) .................................................................................................................................43
5.33 DAMPL (Ditheramplitude)...................................................................................................................................43
5.34 PWM (PWM frequency)......................................................................................................................................44
5.35 ACC (Auto adaptation of the closed loop current controller)...............................................................................44
5.36 PPWM (Solenoid current controller P gain) ........................................................................................................45
5.37 IPWM (Solenoid current controller I gain)...........................................................................................................45
5.38 PROCESS DATA (Monitoring)............................................................................................................................46
6Appendix.....................................................................................................................................................................47
6.1 Failure monitoring...............................................................................................................................................47
6.2 Troubleshooting..................................................................................................................................................47
7Notes..........................................................................................................................................................................48
Page 4 of 48 PAM-199-P 05.06.2020
1 General Information
1.1 Order Number
PAM-199-P - Power amplifier for proportional directional, pressure or throttle valves with analog
command signal input
Alternative / extended products
PAM-199-P-ETC -Power amplifier for proportional directional, pressure or throttle valves with
EtherCAT –interface
PAM-199-P-PFN -Power amplifier for proportional directional, pressure or throttle valves with
Profinet IO –interface
PAM-199-P-PDP -Power amplifier for proportional directional, pressure or throttle valves with
Profibus DP –interface
PAM-190-P - Power amplifier in plug housing with 0… 10 V or 4… 20 mA command signal input
PAM-190-P-IO - Power amplifier in plug housing with IO –Link interface
PAM-140-P - Mobile amplifier in IP65 housing with 0… 10 V or 4… 20 mA command signal input
PAM-193-P - Power amplifier with potentiometers and DIL switches for top hat rail mounting
1.2 Scope of supply
The scope of supply includes the module plus 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
WPC-300 - Start-Up-Tool (downloadable from our homepage –products/software)
Any standard cable with USB-A and USB-B connector can be used as the programming cable.
Page 5 of 48 PAM-199-P 05.06.2020
1.4 Symbols used
General information
Safety-related information
1.5 Legal notice
W.E.St.
Elektronik GmbH
Gewerbering 31
D-41372 Niederkrüchten
Tel.: +49 (0)2163 577355-0
Fax.: +49 (0)2163 577355 -11
Homepage: www.w-e-st.de
EMAIL: contact@w-e-st.de
Date: 05.06.2020
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.
Page 6 of 48 PAM-199-P 05.06.2020
1.6 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 protec-
tion) 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 as-
sembly. 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 in-
struction 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, contamina-
tion 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 7 of 48 PAM-199-P 05.06.2020
2 Characteristics
This module is used for the control of one directional valve with two solenoids or one/two independent pres-
sure or throttle valves with one solenoid each. Various adjustable parameters allow for an optimized adapta-
tion to the respective valve. The integrated power amplifier with a short cycle time of 0.125 ms for the current
loop is an inexpensive and space-saving solution.
FUNCTION MODES:
195 (comparable to PAM-195): the amplifier can be used to control one directional valve. The current is con-
trolled by a +/- 10 V (or 4… 20 mA with cable breakdown monitoring) input signal.
196 (comparable to PAM-196): the amplifier can be used to control one/two throttle or pressure valves. The
output current is controlled by 0...10 V (or 4… 20 mA with cable breakdown monitoring) input signal.
197 (comparable to PAM-197): the amplifier can be used to control proportional valves with one or two sole-
noids by three digital input signals to select up to eight pre-programmed command and ramp values.
The output current is closed loop controlled and therefore independent from the power supply and the solenoid
resistance. The output stage is monitored for cable breakdown, is short circuit proof and disables the power
stage in case of an error.
RAMP, MIN and MAX, the DITHER (frequency and amplitude) and the PWM frequency are programmable.
In addition, the valve characteristics can be linearized via 10 XY-points. For example: using pressure valves a
linear behavior between input signal and pressure can be reached.
Typical applications: Control of directional, throttle and pressure valves, which need a flexible adaptation of the
solenoid control. All typical proportional valves of the different manufactures (BOSCH, REXROTH, PARKER,
EATON ...) can be controlled.
Features
General power amplifier, one unit for all applications
GL-certification
Control of directional valves or two pressure or throttle valves
Controlled by analogue or digital inputs
Compact housing
Digital reproducible adjustments
Free scaling of the analogue inputs
Range monitoring of the input signal (e.g. joysticks)
Characteristics linearization via 10 XY-points per direction
Free parameterization of RAMPS, MIN und MAX, output current, DITHER (frequency, amplitude)
Nominal output current range: 0.5… 2.6 A
Simple and application orientated parameter settings via WPC-software
Failure monitoring and extended function check
Page 8 of 48 PAM-199-P 05.06.2020
2.1 Device description
V:
ID:
Add.:Date:
Made in Germany
W.E.ST.
Ready
1 2 3 4
5 6 7 8
910 11 12
14 15 1613
D-41372 Niederkrüchten
Homepage: http://www.w-e-st.de
W.E.ST.
Elektronik
13 14 15
910 11 12
16
A B
Klemmblöcke (steckbar)
Terminals (removable)
LEDs
USB
Interface
Typenschild undAnschlussbelegung
Type plate and terminal pin assignment
23,0000 mm99,0000 mm
114,0000 mm
Page 9 of 48 PAM-199-P 05.06.2020
3 Use and application
3.1 Installation instruction
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 open and closed loop con-
trol 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 wir-
ing 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 > 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 possi-
ble. 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 interfer-
ence 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 partic-
ular. Switched inductances (relays and valve coils connected to the same power supply) must always
be provided with appropriate overvoltage protection directly at the coil.
Page 10 of 48 PAM-199-P 05.06.2020
3.2 Commissioning
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 imme-
diately 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 nominal output CURRENT and the typical valve parameters such as DITHER
and MIN/MAX.
Pre-parameterization is necessary to minimize the risk of uncontrolled movements.
Control signal
Check the control signal with an amp meter. The control signal (the current of the
solenoid) is within the range of 0... 2.6A. In the actual status it should show approxi-
mately 0 A.
ATTENTION! You can monitor the current of the solenoids also in the WPC-300 pro-
gram.
Switching on the hydrau-
lics
The hydraulics can now be switched on. The module is not yet generating a signal.
Drives should be at a standstill or drift slightly (leave its position at a slow speed) if it
is a proportional valve.
Activating ENABLE
CAUTION! The drive can now leave its position and move to an end position with full
speed or the pressure can reach maximum. Take safety measures to prevent per-
sonal injury and damage.
Page 11 of 48 PAM-199-P 05.06.2020
4 Function modes and technical description
4.1 General Information
The PAM-199 is replacing the functionality of several power amplifiers. The functionality can be chosen by the
command FUNCTION (195, 196 or 197). After this selection the settings have to be saved before the module
may be loaded with a previously saved parameter set.
Due to safety reasons the switching takes places within protected conditions.
4.2 LED Indications
LEDs
Description of the LED function
GREEN + YELLOW
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 cor-
rected automatically! The module still works regularly. To acknowledge the error
the module has to be cycle powered.
YELLOW + YELLOW
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.
GREEN
Identical to the READY output.
OFF: No power supply or ENABLE is not activated
ON: System is ready for operation
Flashing: Error detected (e. g. valve solenoid or 4… 20 mA).
Not active when SENS = OFF.
YELLOW
LED in the middle position = Current, Channel A; the intensity is proportional to the
output current
LED in the right position = Current, Channel B; the intensity is proportional to the
output current
Page 12 of 48 PAM-199-P 05.06.2020
4.3 Control of directional valves (195)
4.3.1 Typical system structures
This minimal system consists of the following components:
(*1) proportional valve
(*2) hydraulic cylinder
(*3) power amplifier
(*4) interface to PLC with analogue and digital signals
4.3.2 Method of operation
This power amplifier is controlled by an analogue signal (from the PLC, from a joystick or a potentiometer). An
ENABLE signal (typically 24V) activates the module and the READY output indicates this, if no internal or ex-
ternal error was detected.
The integrated standard functions will be configured via different parameters.
In case of a fault, the power output stage will be deactivated and the fault will be indicated through a deac-
tivated READY output and a flashing READY LED. To leave the error state the ENABLE has to be reset.
The output current is closed loop controlled whereby a high accuracy and a good dynamic will be obtained. All
custom proportional valves (up to 2.6A) may be controlled with this power amplifier.
T
A B
P
POWERSTAGE
MINMAXRAMPINPUT
cx
b
a
y
PLC / SPS
*1
*2
*4 *3
Page 13 of 48 PAM-199-P 05.06.2020
4.3.3 Input and output signals
Connection
Supply
PIN 7
Power supply (see technical data)
PIN 8
0 V (GND) Power supply (ground).
Connection
Reference voltages output
PIN 12
Reference output voltage (8 V).
Connection
PWM output
PIN 3 / 4
Current controlled PWM outputs for solenoid A.
PIN 1 / 2
Current controlled PWM outputs for solenoid B.
Connection
Analogue input signals
PIN 9 / 10
Command signal (W), range -100…100 % corresponds with -10…10 V or 4…20 mA, scalable.
PIN 11
0 V reference for the signal inputs (potential from PIN 8).
Connection
Digital inputs and outputs
PIN 15
Enable Input:
General enabling of the application.
PIN 6
S1 input:
Function depends on parameter PIN:6 (USCALE/RAMP).
OFF: Output current depends on parameter USCALE; ramp function is deactivated.
ON: Output current is not scaled by USCALE, ramp function is activated.
PIN 5
READY output:
ON: Module is ready, no errors are detected
OFF: ENABLE is deactivated or an error is detected.
Page 14 of 48 PAM-199-P 05.06.2020
4.3.4 Circuit diagram
9
5
15
Ready
Enable
S1
PAM-199-P(FUNCTION 195)
6
12
11
7
8
DC
DC
GND
+Ub
Power
supply
Reference
voltage
10
Input
Scaling
Demand
Lineari-
zation
U
Valve
adaption
3
4
IA
to solenoidA
Power
stage
USB Typ B
Control program
PE via DIN rail
digital output
Digital input
Digital input
WA C
to solenoid B
IB
2
1
Ramp
function
Differential input
W
Page 16 of 48 PAM-199-P 05.06.2020
4.3.6 Parameter list
Command
Default
Unit
Description
FUNCTION
195
-
Defining functionality
LG
EN
-
Changing language help texts
MODE
STD
-
Parameter mode (standard or expert)
SENS
AUTO
-
Activation and deactivation of the monitoring functions
CCMODE
OFF
-
Activation and deactivation of the characteristic linearization
PIN:5
RDY
-
Switching function of PIN 5
PIN:6
USCALE
-
Switching function of PIN 6
USCALE
10000
0,01 %
Output current scaling depending on PIN:6
LIM
0
0,01%
Range of the input signal monitoring (e. g. detecting failures of joy-
sticks)
POL
+
-
Changing output polarity
AINA
V
-
Simple input switchover between current (4...20 mA) and voltage
(±10 V)
AIN:A
A: 1000
B: 1000
C: 0
X: V
-
Free scaling of the analogue input signal.
AA:1
AA:2
AA:3
AA:4
100
100
100
100
ms
ms
ms
ms
Four quadrant ramp times
CC:-10… +10
X Y
-
Linearization function
MIN:A
MIN:B
0
0
0,01%
0,01 %
Zero-point adjustment / Compensation of the deadband
MAX:A
MAX:B
10000
10000
0,01%
0,01 %
Scaling of the maximum output signal
TRIGGER
200
0,01%
Trigger point for activating the MIN value
CURRENT
1000
mA
Nominal output current
DAMPL
500
0,01%
Dither amplitude
DFREQ
121
Hz
Dither frequency
PWM
2604
Hz
PWM frequency.
ACC
ON
-
Automatic adjustment of PPWM and IPWM parameters
PPWM
IPWM
7
40
-
-
Control parameter for the current control loop
Page 17 of 48 PAM-199-P 05.06.2020
4.4 Control of two throttle and / or pressure valves (196)
4.4.1 Typical system structure
This minimal system consists of the following components:
(*1) proportional valves
(*2) power amplifier
(*3) interface to PLC with analogue and digital signals
4.4.2 Method of operation
This power amplifier is controlled by an analogue signal (from the PLC, from a joystick or a potentiometer).
ENABLE signals (typically 24V) activate the power stages and the READY output indicates this, if no internal
or external error was detected.
The integrated standard functions will be configured via different parameters.
In case of a fault, the power output stage will be deactivated and the fault will be indicated through a deac-
tivated READY output and a flashing READY LED. To leave the error state the ENABLE has to be reset.
The output current is closed loop controlled whereby a high accuracy and a good dynamic will be obtained. All
custom proportional valves (up to 2.6A) may be controlled with this power amplifier.
Page 18 of 48 PAM-199-P 05.06.2020
4.4.3 Input and output signals
Connection
Supply
PIN 7
Power supply (see technical data)
PIN 8
0 V (GND) Power supply (ground).
Connection
Reference voltages output
PIN 12
Reference output voltage (8 V)
Connection
PWM output
PIN 3 / 4
Current controlled PWM outputs for solenoid A
PIN 1 / 2
Current controlled PWM outputs for solenoid B
Connection
Analogue input signals
PIN 9 / 10
Command (input) signal A, 0…100 % corresponds with 0…10 V or 4…20 mA, scalable.
PIN 13 / 14
Command (input) signal B, 0…100 % corresponds with 0…10 V or 4…20 mA, scalable.
PIN 11
0 V reference for the signal inputs (potential from PIN 8).
Connection
Digital inputs and outputs
PIN 15
Enable Input Channel A/B or Channel A (dependent on ENABLE_B):
General enabling of the application (Channel A).
PIN 6
Enable Input Channel B (dependent on ENABLE_B):
General enabling of the application of Channel B.
PIN 5
READY output:
ON: No internal or external errors are detected.
OFF: Both power stages are deactivated or an error is detected.
Page 19 of 48 PAM-199-P 05.06.2020
4.4.4 Circuit diagram
2
Input
PE via DIN-RAIL
3
4
1
5
15
Ready
Enable (A)
Enable B
Digital output
USB type B
PAM-199-P(FUNCTION 196)
6
13
Valve adaption
Digital input
ua
Control program
Ramp
Function Linearization Power stage
ia
ib
to solenoidA
ca
cb ub
wa
wb
12
GND
+Ub
8
7
DC
DC
to solenoid B
Power
supply
Ramp
Function Linearization Valve adaption Power stage
Digital input
Reference
voltage
14
11
Demand
A
Demand
B
Scaling
Input
Scaling
9
10
Differential input
This manual suits for next models
7
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