© UWIEKERS Electronics for KDG1-3/5 proportional directional valves Basic characteristics Power supply. pavoc (Current rating. For KDG1-2 valves. 188 ForkDGt-5 valves, 23a Power consumption: ForkDG?-a valves, 5vA ForKDG1-5 valves, SIU S8va Control range ‘ot tovoc Contents Introduction. Electronics .-- Specification. ........ Installation dimension... Installation and safety data. ‘Adjustment procedure Ordering procedure Pag 1. Introduction inordertoachieve optimum performance of the Vickers KOG1 proportional directional valves an amplifier system with ramp functions was developedior each size of valve. ‘Available accessories include a 220V ACSO/24V DC power supply unit ‘smoothing capacitor and pcb. card hoider. For dotalls of ne related proportional directional valves see ‘Directional controls leaflet 628, 2. Electronics © General Forconiroliing a KDG! proportional directional valve one of the following ‘amplifiers is required, KOG1-34-AR‘614887-10 forasize3 valve, or KOGI-5A-AR-614888-10 fora sizes valve. “The ampiieris the basiccomponent needed to drive the control solenoiss (having a common postion senson from a 24V OC supply. The ampifier printed circuitboard pc.) is of Eurocard format, 100 x 160 x approx 40mm, andis fitted with a plug connector (shrouded pins) o DIN 41612 (F32). ‘The capacitor required serves to smooth the supply voltage forthe electronics and toeliminate any interference pulses rom the output stage.Itis not mounted on the ‘pcb. for reasons of space and must be installed separately as close as possibie to the pcb (<05 m), © Controtsystem ‘The proportional ampiier needs an input signalotOto + 10V(RI 10k 21) Theppostion ‘ontrolsystemsives proportionality between {he inputsignalvoltage andthespool postion feedoack The ampifer has aPID action \which eliminates he sightest discrepancy between input signal and spoo! position feedback (nysteresis <1%). ‘Thepcb hasbeen designed specticallyfor ‘operation with drecionakcontrl proportional valves o ensure the best possible dynamic performance. The output Stagevanbs enabk. :c:inhibited independently ofthe input signal. A lightemiting diode (green) glows when ‘enabling is operative. I the input and/or feedback signals is Interupted the solenoids are de- ‘energised and the valve is centered by the ‘springs (al safe) If this happens there is no riskof accidental movement when next ‘enabling. ‘The proportional amplifier has tive identical (summing) input signal points, ‘The set point for control signals sat terminal b14, The contol signal 10V OC ‘can be derived from various sources eg Potentiometers, D/A converters. The input Fesistance Ri= 10 ki. ‘© Ramp-tunetion generator ‘The pcb. contains ramp-function ‘generator which faciitates separate adjustment of acceleration and deceleration ofthe hydraulic motion ‘The acceleration rampfunction controls the time for the valve spool to reach the signalled opening position (in either direction rom neutra) and the {deceleration ramp-function controls the Closing motion also in both directions (On/off switching ofthe ramp function is by anexternal floating contact wi quasrant recognition accoeration ‘wana Technical information GB-V-1030 July 1985Potentiometer supply from p.c.b. + 1OVDC to b/232/0V DC, (yx, SOA) ~F6VDCto232/0v0e (eux 50MA) Enabling/inhibiting ‘To“enable’, supply + 6VDC. (440V max) to218 or inkz16 to 232. ‘Agreen LED, near the handle, glows when ‘enabling is operative (Fl+ 100k). Hysteresis, <1% Response at 100% driving KDG1-3 valve spool ‘<40 ms from 10 10 90% travel KOG1-5 valve spool ‘<55 ms from 10 10 90% travel Max. frequency @ 348, Hz approx Max. cable longth between amplifier and valve 8) 60m with 100 pF/mcable, screened type. for position sensor. b) Solenoid cable Upto 20m. +0775 mm? section Uptoaom. 150 mm? section Upto6om. 250mm? section Special features Short circuit proot outputs: = output stage to solenoids ~ signal to travel sonsor = potentiometer supply Ramp-function adi. ranges 005 10.50 sec. aporox. fork0G1-3 arnpitier 0100 100 sec. approx fork0G1-5 ampitior Both adjustable with timmer potentiometer. ‘OrvOt switching by floating contacts 620, and b22 (acceleration/decoleration adjustable separately). Valve connectors ‘As in‘Directional controls leaflet V-629, ‘Must not have indicator ights, Powersupply ForkKDG1-3A-AR amplifier... 24VDC/35 VA ForkDG1-SA-ARamplir..- 24VOG/55VA ‘The pacts for proportional valves with 12V1DC control solenoids can be ed from various sources fitered DC or battery supply 20-40V {rated voltage 24V DC} eg. 615238 ower supply unit described on this page. = unfitered 24V Da Iya f0F KDGI-3ACAR ampifior...... 1,58 Ine for KOGI-5A-AR amplfiet..-.-. 2.38 ‘Supplied from a single-phase full wave rectifier 24V DC (21-28V DO) or froma three-phase fulwave rectlier 24V00 (21-28V 00, Note Positive toterminalb16/18 negative (OVitoterminal b2/o4. Note: Aicitinduced vtaae peaks of more than sovonUp Important: Insal 10000 uF capacitor Vickers no. 615234) separately but coseto ‘heaps Gee stanton andi cata 615236 power supply unit 220V 50Hz-t024V0C/4A complete with 1615234 capacitor, 10000 uF (C2) ‘Sembdblayuse(OaA) | | Bt potesurge use 4) 1 X 2 7

0,5mirom the ampitfer pcb then {8 10000.nF capacitor eg. Vickors part 616234 must be separately fitted ciose tothe ampitier pcb.Cable length <0.5 m Cross-section >1 mm? Insuch circumstances any integral smoothing capacitor, such as thatin the Vickers power supply unit, should not be connected. ) Screcning of he input signal cable is idvisabe if there are extensive electrical installations in the vicinity and there's the possibilty of induced voltages ‘The position sensor and solenoids must be correctly wired tothe. Connections shown on the circu diagram on the second page. Incorrect ‘connections will cause malfunction. 4) Thecable tothe spool position sensor of the valve must be screened and must not exceed 60 min length (for cable of, 4100 p/m, {9} Do not instal the printed-circuit board in the immediate vicinity ofthe power relay because induced voltage peaks ‘can cause disturbancesin the integrated circuits. ty fas. result of incorrect extemal wing the integral autoesot fuse is ripped ‘out then the power supply unit must be ‘switched off momentanly and then ‘Switched back on in order to restore the ampitiertoits working state. D Before removing a printed-circut-board from its card-holder make sure that the ‘power supply has been switched off ° 6. Adjustment procedure Initial check Check the wiring against the circuit diagram, ensure that the 24V 0 supply is within the permitted tolerance (also.at the {Capacitor Unin™ 20V, Upaa = 40V) and that the output stage has been enabled at 216 (10, 40V mas), ie. the LED is on. Balancing r0 vay Lo eats Zero adjustment ‘Supply OVto the U, input signal point The ‘mechanism controlled by the proportional valve must not move. Next, set the input to + 1Vand-1Vin turn. The valve willbe movedby the amount of the overlap travel plus.a small opening travel The movement ‘ofthe control mechanism must be ‘symmetrical in both directions of ‘operation. Adjustments can be made with the zero potentiometer. Sonsitvty adjustment ‘The rated flow (Q,) can be adjusted within the band 25 ~ 100% separately for bath rections of operation. The adjustments ‘made by means of potentiometers Q, and ,, Use Q,(+10V) for adjustment of positions EA, B-T and, (-10V) for -B, AT. Clockwise rotation= increase flow, ‘Anti-clockwise rotation = decrease flow. ‘Adjusting the ramp-tunction generator Tocca 894 Tone) ‘The électroni¢ quadrant recognition circuitry enables like ramp functions (acceleration or deceleration) for both VICKERS . Proportional directional valves and electronics ee Lat Mounting surface... ASSO a401/GETOP RASH sizes 3 and 5 plus drain por a Hydraulic fuidsstitation ‘Temperature mis. Based on ISO 4401/CETOP R35H sizes 3 and 5 Series KDG1-3A, 10 (Size 3) KDGY-5A; 10 [Size 8} directional valves Basic characteristics Contents Page ~ Rated tlow(ap= 8 ban 1. General description 1 KOGt-aa 100120 min 2: Funeilonal symbols and applications. 2 KOG1-6A '20.400°80l/min 3. Model codes. 2 Max operating pressure ‘31Sbar 4. Operating dala Powersupply....24V deviapcb amplifier @ Max operating prossure 3 1o12Vdesolenoids © Electrical data proportional valves... 3 ‘Typical hysteresis 1% © Performance dala m3) 5 6 6 Accassotis... -Pressurehydrostat modules Mounting subpiaes = Proponional control ampiars ~ Capacitor, edge connector, card holder and power supply accessories 1. General description Proportional directional control valves can beused whore one or more ct the following Fequiremants exist: ‘© Remote control of machine actuator speeds and direction of movement ‘© Speed and directional contratin accordance with machine operating ‘oycles or programs (© Motorirvmetor-out throtte vestcton) ‘control by the proportional val itselt © Pressure compensated flow control for the PloAandP to Bmeterinunctions forthe Ato T meter out function with he ‘aid of an appropriate hydrostat modula. © Smooth adjustable control of machine ‘actuator acceleration and/or ‘deceleration © Suitability for industal or mobile appications, «4 Requrealor some apeeations © Electronic contro system ‘5, Instaltaion dimensions. 10 6 Mass, approx mas 7. instalation daia hydraulic units... 13 8 Otdoring procedure.........e0sc0000 13 nett Infinitely variable control of machine cual! speeds instead of mul stop ‘control ‘© “Spot speedsheldconstant independent ‘of oad, with the aid ofa hyarostat module © Elimination of ransient shocks occurring Insome step-speed systems ‘© Simplor hydraulic systems. © ‘installed cost savings by eliminating separate flow controls and thelr selector valve ‘© Reducednumber ofpipaconnectionsand potential eak points © Reduced size and weight of hydraulic systems Design and construction ‘Tha proportional control drectionalvalveis. position controlled, ie the input signal to ampifieris continuously compared with tn Actual value from the valve spo! position ‘Sensor and any deviations which occur are ‘eliminated by contol action This also ‘overcomes any stallcand dynamic lorces acting on the spook. ‘Typleal proportional valve, KOG1-5A-254) example Thetravelolthe valve spooltromcentretoa required positions proportional tothe input Signal The wavelis measured by an induct pasion sensorandfed backto the lectronic foliar Any diference between the inot ‘Signal voltage) and feedback signal (voltage proportional to travel is calculated and Cowrected: thus the valve isinan elect position control circu, itis unaffected by disturbance forces, responds to the input signals rapidly and precisely and possesses very ow hysteresis ‘ihe low rataiscdoterminedby tha cross section of aperture and pressure diference ‘ross the spool Fluctuations in pressure tiference wllcause changes in flow rate but they can be offset by pressure compensation ‘obtained by adding the appropriate pressure Ihydrostat module under the valve Technical Information GB-V-629 April 1983 es aastchnereeeie