Iqan-xs Uk Instructionbook

IQAN-XS Instruction book Publ no HY33-8331-IB/UK Edition August, 2009

Contents

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3

Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IQAN-XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mounting the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 IQAN-XS addressing/terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Voltage inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

7

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 IQAN-XS Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Error codes, messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Dimensioning of the IQAN-XS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Instruction book, IQAN-XS

1

Safety symbols 1

1

Introduction

Introduction

These instructions are to be used as a reference tool for the vehicle manufacturer’s design, production, and service personnel. The user of these instructions should have basic knowledge in the handling of electronic equipment.

Safety symbols Sections regarding safety, marked with a symbol in the left margin, must be read and understood by everyone using the system, carrying out service work or making changes to hardware and software. The different safety levels used in this manual are defined below. W ARNING

Sections marked with a warning symbol in the left margin, indicate that a hazardous situation exists. If precautions are not taken, this could result in death, serious injury or major property damage. C AUTION

Sections marked with a caution symbol in the left margin, indicate that a potentially hazardous situation exists. If precautions are not taken, this could result in minor injury or property damage. N OTICE

Sections marked with a notice symbol in the left margin, indicate there is important information about the product. Ignoring this could result in damage to the product. Contact the manufacturer if there is anything you are not sure about or if you have any questions regarding the IQAN product and its handling or maintenance. The term "manufacturer" refers to Parker Hannifin Corporation.

Instruction book, IQAN- XS

3

General safety regulations 2

2

Precautions

Precautions

General safety regulations Work on the hydraulics control electronics may only be carried out by trained personnel who are well-acquainted with the control system, the machine and its safety regulations. These are general safety guidelines only and other safety procedures may apply to individual situations. W ARNING

Mounting, modification, repair and maintenance must be carried out in accordance with the manufacturer's regulations. The manufacturer has no responsibility for any accidents caused by incorrectly mounted or incorrectly maintained equipment. The manufacturer does not assume any responsibility for the system being incorrectly applied, or the system being programmed in a manner that jeopardizes safety. W ARNING

Damaged product may not be used. If the control system shows error functions or if electronic modules, cabling or connectors are damaged, the system shall not be used. W ARNING

Electronic control systems in an inappropriate installation and in combination with strong electromagnetic interference fields can, in extreme cases, cause an unintentional change of speed of the output function. N OTICE

As much as possible of the welding work on the chassis should be done before the installation of the system. If welding has to be done afterwards, the electrical connections on the system must be disconnected from other equipment. The negative cable must always be disconnected from the battery before disconnecting the positive cable. The ground wire of the welder shall be positioned as close as possible to the place of the welding. The cables on the welding unit shall never be placed near the electrical wires of the control system. Construction regulations C AUTION

The vehicle must be equipped with an emergency stop which disconnects the supply voltage to the control system's electrical units. The emergency stop must be easily accessible to the operator. The machine must be built if possible, so that the supply voltage to the control system's electrical units is disconnected when the operator leaves the operator’s station. Safety during installation C AUTION

Incorrectly positioned or mounted cabling can be influenced by radio signals which can interfere with the functions of the system.

Instruction book, IQAN- XS

4

General safety regulations 2

Precautions

Safety during start-up W ARNING

The machine's engine must not be started before the control system is mounted and its electrical functions have been verified. Ensure that no one is in front, behind or nearby the machine when first starting up the machine. Follow the instructions for function control in the Start-up section. Safety during maintenance and fault diagnosis C AUTION

Ensure that the following requirements are fulfilled before any work is carried out on the hydraulic’s control electronics. • The machine cannot start moving. • Functions are positioned safely. • The machine is turned off. • The hydraulic system is relieved from any pressure. • Supply voltage to the control electronics is disconnected.

Instruction book, IQAN- XS

5

IQAN-XS 3

3

Product description

Product description

IQAN-XS The IQAN-XS is one out of several expansion modules designed for controlling hydraulic systems in vehicles and machinery.

The IQAN-XS module.

I/O overview +BAT

ADDR-H

-BAT

ADDR-L

+VRE F

CAN-H

-VREF

CAN-L

XS VIN

DOUT

DIN

Inputs

The IQAN-XS module has ten (10) voltage inputs VIN-A thru VIN-J for connecting of 0-5 Vdc signals. The module has sixteen (16) digital inputs. (10) Voltage inputs VIN-A, VIN-B, VIN-C....VIN-J (16) Digital inputs DIN-A, DIN-B ... DIN-P Outputs

The IQAN-XS module has four (4) digital outputs (on/off) for controlling solenoid valves or relays. (4) Digital outputs DOUT-A ... DOUT-D

CAN related functions The master uses the CAN-bus (CAN = Control Area Network) to communicate with the modules. The CAN-bus is a robust communication protocol that is widely used and well proven within the automotive industry.

Instruction book, IQAN- XS

6

General 4

4

Safety

Safety

General In order to fulfil high safety demands, the XS module uses a real-time operating system for fault tolerant embedded systems. The XS module has an internal watchdog function. If the watchdog detects any software errors, necessary precautions will be activated. Polarity reversal The XS module is protected against power supply polarity reversal, provided an external fuse, max 10 A (Fast) is being used. Polarity reversal can damage the unit if the fuse is not used. CAN-bus interruption The XS module has special safety functions if the CAN-bus is interrupted. Each module checks for any interruptions in the CAN-bus communication. If an error occurs the master will present a related message on the display. The XS module will also indicate the error with an error code. Input/ output Protection All inputs on the XS module are designed to withstand the maximum specified supply voltage. The outputs are protected against short circuit. Furthermore, an error on one input/output will not influence other input/outputs.

System Diagnosis The green firm LED on the top of the module indicates power on. If there is an error detected, the module will present a status indication through a green blinking LED. This gives an immediate diagnosis as to the nature of the error that has occurred.

LEDs on top of IQAN-XS module

To get further information about the error messages, see Appendix B, on page 22.

Instruction book, IQAN- XS

7

Mounting the module 5

5

Mounting

Mounting

Mounting the module The IQAN-XS module should be mounted according to the following instructions: • Locate the module eliminating the risk for the cabling to be folded, crushed or damaged in any way. Ensure the cabling cannot pull, twist or induce sideload on the connector. • Locate the module so that severe physical impact is avoided, e.g impact from falling objects or the module being used as a step. • Locate the module so that air can circulate to eliminate excess heat. Ensure that no external heat, e.g. from the engine or heater, is transferred to the module. • Locate the module to protect it fromoutdoor environment, pressure washing or similar stresses. • Locate the module so that the cable connectors are facing down. • Locate the module so that the LEDs are visible.

Protect the IQAN-XS from moisture

N OTICE

The IQAN-XS module must not be placed in any marine related or similar continuously damp environment without external protection.

Instruction book, IQAN- XS

8

Mounting the module 6

6

Installation

Installation

CAN 1 and CAN 2 Connector kit

PARKER 5031016

Housing

AMP no. 929504-2

Pin type

AMP no. 927779-1

Cable

0,75-1,0 mm2

IQANtool kita

Parker 5031061

1

3

5

2

4

6

a.Further information about IQANtool kit, see datasheet, IQAN accessories

Symbol

Pin No

Symbol

Pin No

Symbol

Pin No

-BAT

1

ADR-H

3

+BAT

5

CAN-H

2

ADR-L

4

CAN-L

6

Connector C1 Connector kit

PARKER 5031016

Housing including casing

AMP no. 1-963226-1 AMP no. 962371-1

Pin typesa

AMP no. 962945-2 (MT)

AMP no. 927777-1 (JPT)

Cables

0,75-1,0 mm² (MT)

1,5-2,5 mm² (JPT)

IQANtool kitb

Parker 5031061

42 28 14

29 15 1

a.The connector contains two types of terminals; MT (Micro Timer) and JPT (Junior Power Timer). b.Further information about IQANtool kit, see datasheet, IQAN accessories.

Instruction book, IQAN- XS

9

Mounting the module 6

Installation

Connector C1 pin assignments +BAT

ADDR-H

-BAT

ADDR-L

+VRE F

CAN-H

-VREF

CAN-L

XS VIN

DOUT

DIN

Symbol

Pin No

Input/Output

Function

+BAT A

28

-

Power Supply

-BAT

14

-

Power Supply

+VREF

15

-

Voltage reference for external sensors. Sourcing +5V.

-VREF

1

-

Voltage reference for external sensors. Return (0V).

2 3 4 5 16 17 18 30 31 32

I I I I I I I I I I

VIN-A VIN-B VIN-C VIN-D VIN-E VIN-F VIN-G VIN-H VIN-I VIN-J

9 10 11 12 13 22 23 24 25 26 27 37 38 39 40 41

I I I I I I I I I I I I I I I I

DIN-A DIN-B DIN-C DIN-D DIN-E DIN-F DIN-G DIN-H DIN-I DIN-J DIN-K DIN-L DIN-M DIN-N DIN-O DIN-P

VIN

DIN

Instruction book, IQAN- XS

10

Supply Voltage 6

Installation

DOUT

20 21 35 36 NC

O O O O

6

DOUT-A DOUT-B DOUT-C DOUT-D Not connected

7 8 19 29 33 34 42 Shaded positions are Micro Timer pins. Unshaded positions are Junior Power Timer pins. See above for wire, seal, pin number and crimping tool information.

Supply Voltage Before any installation of the IQAN system can take place, make sure the ignition lock is turned off and the battery is disconnected. Emergency stop Make sure an Emergency Stop disconnecting the power supply, is easily accessible at any time. The figure below shows how to connect the emergency stop. Connecting of Supply Voltage The supply voltage, should be within the operating interval, see Appendix A, on page 24. Connect the supply voltage to +BAT A. Protect the module by using a fuse. Requisite fuse level should be 10 A for +BAT A. Ground connection is made from -BAT, pin 14 to negative pin on the battery.

42 28 14

Emergency stop

29 15 1 10 A

+

-

Connecting the emergency stop and voltage supply.

N OTICE

Do not use the chassis as the negative terminal.

Instruction book, IQAN- XS

11

Supply Voltage 6

Installation

Connecting multiple modules to voltage supply

When connecting several XS modules, all of the units will have to be separately connected to the battery voltage and protected with fuses. EXAMPLE XS-0

10 A

10 A

10 A

XS-3

XS-2

XS-1

* Symbol for disconnecting switch for battery, ignition lock and other fuses.

10 A

* +

-BAT

-

+BAT

Connecting several modules to the power supply.

Instruction book, IQAN- XS

12

IQAN-XS addressing/terminating 6

Installation

IQAN-XS addressing/terminating Addressing Each XS module will have a specific address, enabling the master module to communicate with the modules through the CAN-bus. When operating, the system distinguishes between different modules by first verifying the module type and secondly, through the modules having unique addresses. EXAMPLE

If having an XS module with address 0, the system will denote this one as XS-0. Addressing is carried out by putting a jumper in the connector for the cabling of the CAN-bus. There can be a maximum of four modules of the same type in a system, address 0, 1, 2, 3. CAN2

CAN1

Address 0 Address 1 Address 2 Address 3

Addressing the IQAN-XP

Terminating To eliminate interference in the communication, through the CAN-bus, the CAN-bus must be terminated. If an IQAN-XS is located at the end of the CAN-bus, the CAN-bus must be terminated in the connector (CAN1 or CAN2) at IQAN-XS. The terminator is connected to pin 2 and 6 in connector CAN1 or CAN2. The terminator is ordered from the manufacturer, part no 5030082. It is the terminators task to end the signals on the CAN-bus to eliminate interference in the system’s communication. If there is no terminator, there can be complete or partial interference with the communication on the CAN-bus. CAN1 or CAN2 0

12

Termination of IQAN-XS.

N OTICE

The CAN-bus should not be terminated using an external regular terminating resistor.

Instruction book, IQAN- XS

13

Voltage inputs 6

Installation

Voltage inputs Connecting sensors to the voltage inputs The sensor signal range must be 0-5 Vdc. To detect signal errors such as short circuits or interruptions the active signal range be within 0.5-4.5 Vdc. [V 5

Error detection range Active signal

0

Error detection range t

Active signal range.

The current consumption related to the voltage input is negligible. The positive terminal of the sensor is connected to the +VREF position and the corresponding negative terminal to the -VREF position. The sensor signal is connected to appropriate VIN position. Connection as per illustration. EXAMPLE

Connect the positive and negative terminals of the position sensor to +VREF-A, position 15, and -VREF-A, position 1, respectively. Then connect the sensor signal to VIN-A, position 2.

VIN-A +VREF -VREF

Connecting VREF and sensor signal.

N OTICE

The negative terminal of the sensor must not be connected to the chassis. Maximum load for VREF position, see Appendix A, on page 20.

Instruction book, IQAN- XS

14

Voltage inputs 6

Installation

Connecting a temperature sensor to the voltage inputs When you connect a temperature sensor you may need to use a pull up resistor on the input signal. Please check the technical data for your specific temperature sensor. EXAMPLE

Connect the negative terminal of the temperature sensor to -VREF, position 1, and the signal to VIN-A, position 2. The pull up resistor will be connected between VIN-A, position 2 and +VREF, position 15.

+VREF

4,7k

Pull up

-VREF VIN-A

Pull up +VREF -VREF

Connecting -VREF and temperature sensor signal VIN-A.

The pull up resistor is 4,7 k ohm. Connecting switches to the voltage inputs Switches could be connected to the voltage inputs, to create a digital on/off signal. The switches should be connected to +VREF and VIN respectively for 5V signal. The current consumption for the voltage input is negligible. EXAMPLE

Connect the positive and negative terminals of the switch to +VREF, position 15, and VIN, e.g. position 31, respectively.

VIN e.g. pin 31

+V REF pin 15

Connecting a switch to VIN-A.

N OTICE

Maximum load for VREF position, see Appendix A, on page 20. Do not connect switches to +BAT to supply VIN.

Instruction book, IQAN- XS

15

Digital inputs 6

Installation

Digital inputs For the current range, see Appendix A, on page 25. The supply voltage to the switch is taken from +BAT. EXAMPLE

The switch signal is connected to its respective DIN input.

DIN e.g pin 13

+

-

IQAN-XS, digital in.

Instruction book, IQAN- XS

16

Digital outputs 6

Installation

Digital outputs The digital outputs are activated by e.g the control levers’ switches (built-in or connected). For the maximum load per output see Appendix A, on page 25. Connection as per the figure. Each digital output, DOUT, is connected to its load. The ground connection on the load is connected to chassis. The load must be provided with a quenching diode. The diode shall be mounted as close the load as possible, i.e not close to the IQAN-XS. Use diode d1: 1N4004 The diodes must be mounted in the right direction. EXAMPLE

d1

DOUT e.g pin 20

IQAN-XS, digital out.

If the load is controlled in parallel with another system, the digital output shall be protected with a diode connected in series with the output. Use diode d2: 1N4004. EXAMPLE

+BAT d2 d1

DOUT e.g. pin 18

IQAN-XS, digital out override.

Instruction book, IQAN- XS

17

Start-up procedures 7

7

Start-up

Start-up

Start-up procedures This chapter contains instructions for action to be taken in connection with the initial start. W ARNING

Risk of injury! If the control system is not fitted properly, the machine could move uncontrollably. The machine’s engine shall not be started before the control system is completely fitted and its signals are verified. Starting the control system Start the control system as follows:

• Prior to start, all modules and cables are to be fitted correctly. • Check fuses, i.e. make sure that the supply voltage to the modules is equipped with the correct fuse. • Make sure that connections for supply voltage and return lines are correct in the cable’s conductor joint. • Make sure the emergency stop works. The emergency stop should disconnect the supply voltage to all modules.

Emergency stop

Dump valve

Emergency stop.

Alternatively, the emergency stop may also shut off the diesel engine or a dump valve, and with that depressurize the hydraulic system.

Instruction book, IQAN- XS

18

Start-up procedures 7

Start-up

Prepare for system start W ARNING

Make sure no one is in dangerous proximity to the vehicle to avoid injuries when it starts. Prepare for the initial system start as follows:

• The engine for the hydraulic system’s pump shall be in off position. • Make sure that all connectors are properly connected. • Turn on the control system. • Make sure that voltage is being supplied to all modules, the green diode shall be illuminated on all modules. Also make sure that master is in contact with all modules by reading the master’s display. Error messages are displayed if the master is not in contact with one or more of the modules. • Make sure the emergency stop is functioning properly. Start the system Start the system as follows:

• Start the engine for the hydraulic system’s pump, assuming that the above mentioned inspections have been carried out and shown correct values. • Calibrate and adjust input and output signals according to the instructions related to the master menu system and check each and every output function carefully. • In addition to these measures, the machine shall also meet the machine directives for the country in question.

Instruction book, IQAN- XS

19

IQAN-XS Technical Overview Appendix A

Appendix A IQAN-XS Technical Overview Absolute maximum ratings TA = +25 °C (unless otherwise specified) Parameter

Limit values min.

typ.

Unit

max.

Operating ambient temperature, TA Storage temperature

– 40 – 40

+80 +100

°C

Voltage supply, VBAT

6

34

V

34

V

Analog input levels, VIN

Remark

Digital input levels DIN Load current, DOUT

A

Load current, total all outputs

5

internally limited

A

Environmental ratings Parameter

Limit values min.

EMI ISO 11452-2 ISO 11452-4

typ.

Unit

max. 50 75

V/m V/m

ISO 14982 EN 50022 ISO 7637-2, -3 ESD IEC/EN 61000-4-2

Remark

Ref. EMC requirement spec. (DMS30521) 15 6

kV

Air contact

Mechanical environment IEC 68-2-64 Fh (random, 10 - 250 Hz) IEC 68-2-27 Ea (shock, 11ms) IEC 68-2-29 Eb (bump, 6ms)

0.1 40 40

g2/Hz g g

10 - 250 Hz

Climate environment IEC 68-2-18 Ra1 (water) IEC 68-2-30 Db (var1: damp, cyclic) IEC 68-2-3 Ca (damp, heat steady state) IEC 68-2-2 Bb (heat) IEC 68-2-1 Ab (cold) IEC 68-2-14 Nb (change of temperature)

10 72 21 72 16 10 x 6

min hour days hour hour hour

10 mm/h 25-55°C, 95% RH 44°C, 93% RH 70°C -30°C -30 - 70°C

Instruction book, IQAN-XS

20

IQAN-XS Technical Overview Appendix A

Operation -25 °C < TA <+70 ° C (unless otherwise specified) Parameter

Limit values min.

typ.

Unit

max.

Ambient temperature (no load), TA

– 25

+70

°C

Voltage supply, VBAT

11

32

V

Output voltage, VREF

4.9

5.1

V

5.0

Maximum load current, VREF VBAT =14V VBAT = 28V

Remark

mA

VREF

mA

outputs = off

100 50

Current supply VBAT =14V VBAT =28V

100 100

I/O -25 °C < TA< +70 °C (unless otherwise specified) Parameter

Limit values min.

typ.

Unit

Remark

max.

VIN (Voltage input) Signal range low Signal range high

4.9

Input resistance

0

0.05

V

5.0

5.1

V kΩ

62

Signal resolution

5

mV

Total unadjusted error

TBD

mV

(vref as source)

DIN (Digital input) Signal range low Signal range high Input resistance

4.0

0

1.2

V

5.0

5.1

V kΩ

2.8

DOUT (Digital output) Load current each channel active (A,B,C,D)

100

Voltage drop (VBAT -VDOUT )

V

load IL = 0,1A

TBD

Short Circuit current limit

8

Instruction book, IQAN-XS

mA

A

21

Error codes, messages and actions Appendix B

Appendix B Error codes, messages and actions If one of the following error is detected, a message will be presented on the display together with an errror code on the module, indicated by LED (B) for heart is out and LED (C) for arrow flashes with a green light. LED (A) with a firm green light on the top of the module indicates power on . In some cases, the module will turn off or at least shut down the outputs, to increse the safety. W ARNING

Don’t use the machine if an error message is activated.

B

A

C

The following sections will present what measures to take for different error situations put into appropriate context. LED indicator showing different XS modes Status

Blink (LED for heart (B) and arrow (C) flashes alternately)

Normal (no errors) Error code

Error

1

I/O and voltage errors

2

High temperature

3

CAN error

4

Hardware error

Instruction book, IQAN-XS

Blink (LED for heart (B) is out and LED for arrow (C) flashes with a green light)

22

Error codes, messages and actions Appendix B

The XS unit does not have current outputs nor temperature sensing, so therefore only supports Codes 3 and 4. MODULE IS OFFLINE Error code

Situation

Action XS

Comment

3

CAN-bus off

All outputs shuts off.

Check CAN-bus

OUTPUT HIGH Error code

Situation

Action XS

Comment

4

DOUT: Internal driver failure

-

Contact supplier

Instruction book, IQAN-XS

23

Dimensioning of the IQAN-XS module Appendix C

Appendix C

6 mm/M5

75

75

197

207

54

Unit = mm

Dimensioning of the IQAN-XS module

Instruction book, IQAN-XS

24

For latest information visit our website www.iqan.com

Parker Hannifin Electronic Controls Division SE-435 35 Mölnlycke Sweden Tel +46 31 750 44 00 Fax +46 31 750 44 21 www.parker.com

Information in this instructionbook is subject to change without notice

Parker Hannifin Electronic Controls Division 1651 N. Main Street Morton, IL 61550 USA Tel +1 309 266 2200 Fax: +1 309 266 6674

Publ no HY33-8331-IB/UK Edition 08/2009