DENISON HYDRAULICS

Proportional Amplifier EC01 A2C

Part No. 701–00631–8 and 701–00632–8

Publ. 9-EN 6040-A

 CONTENTS

CONTENTS CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. SUPPLY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. REFERENCE VOLTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. COMMAND INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 COMMAND INPUT WITH DIFFERENTIAL INPUT FUNCTION . . . . . . . . . 6
3.2 COMMAND INPUT WITHOUT DIFFERENTIAL INPUT FUNCTION . . . . . 6
3.2.1 0 . . . ± 20 mA Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.2 + 4 . . . + 20 mA Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.3 0 . . . ± 5 V Command Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.4 0 . . . ± 10 V Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.5 Customised Command Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.6 Command Value From An External Potentiometer . . . . . . . . . . . . . . . . . . 7
3.2.7 Command Value From An External Signal Source . . . . . . . . . . . . . . . . . 7
4. DITHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 DITHER FREQUENCY 250 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 DITHER FREQUENCY 150 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 DITHER AMPLITUDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. MAXIMUM CURRENT RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Maximum Current 3000 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Maximum Current 1600 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. CONTROL INPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.1 STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 RAMP OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. SENSOR INPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Sensor 1 = Valve transducer feedback signal (current). . . . . . . . . . . . . 9
7.2 Sensor 2 = Valve transducer feedback signal (voltage). . . . . . . . . . . . . 9
8. CONTROL OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9. JUMPER JP1–JP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.1 COMMAND MEASURING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.2 JUMPER JP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.3 JUMPER JP4, JP5, JP6, JP7, JP8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.4 CURRENT MEASURING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
9.5 FEEDBACK MEASURING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10. TRIMMING POTENTIOMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.1 IMIN Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.2 IMIN Step Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10.3 IMAX Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. RAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12. TEST AND SET UP INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
13. LAYOUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14. STANDARD PIN ASSIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
15. SCHEMATIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16. CONNECTION DIAGRAM (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
17. JUMPER AND DIP SWITCH SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
17.1 For 4DP02T/4DP03T/4DP06T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
18. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2
 MODEL CODE, REFERENCE TABLE

MODEL CODE Model Number: EC01 A 2 C

Series

A = Analogue version

2 = for valves with two solenoids

C = Closed loop

REFERENCE TABLE Factory setting

Dither Current
Series Sol. Order No. Frequency Amplitude lnom lmin
4DP02T 12 V 701-00631-8 150 Hz 300 mA 2800 mA 0 mA
4DP03T
12 V 701-00632-8 250 Hz 150 mA 2200 mA 0 mA
4DP06T

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 DESCRIPTION, FEATURES, SPECIFICATION

DESCRIPTION The proportional amplifier EC01 A2C has been developed to control several
DENISON hydraulic proportional valves with a transducer, which operate with two
(2) solenoids.
The various requirements of the valves, for example nominal current, dither can be
selected on the proportional amplifier by DIP switch settings.
The factory settings are shown on page 15.

FEATURES x 24 VDC supply

x reverse polarity supply voltage protection
x solenoid output short circuit protected
x an external signal can start and stop the proportional amplifier (Stop-function)
x an external signal can switch the ramp function on and off
x linear and, over a wide range, customer adjustable ramp up and ramp down time
x dither amplitude adjustable
x three different dither frequencies selectable by DIP switch settings
x all industry standard command signals can be connected
x DIN 41612 connector type F (48 pin B-D-Z)
x fulfils all the requirements of EMV and is CE certified

SPECIFICATION x Dimensions Euro card format 160 x 100 mm

x Front plate dimensions 3U / 8HP (128.5 x 40.4 mm)
x Weight approx. 250 g
x Connector DIN 41612, type F, 48 pin
x Supply voltage 24 VDC nominal
x Voltage range 20 . . . 32 VDC (battery or AC voltage,
rectified and smoothed, ripple < 5 %)
x Current approx. 350 mA (+ solenoid current)
x Reference voltages ± 15 V (± 5 %) Ø 50 mA
± 10 V (± 0.5 %) Ø 10 mA
x Five Inputs Command signal must be positive!
1. Voltage 0...± 5 V
2. Voltage 0 . . . ± 10 V
3. Voltage customised selectable, R83 = 20 k ¸ / V
(see layout diagram page 13)
4. Current 0 . . . ± 20 mA
5. Current + 4 . . . + 20 mA
x Output voltage 24 V PWM for the solenoids
x Output current l MAX approx. 2700 mA
x Range of adjustments:
− l MAX A, B lMIN . . . 2700 mA
− l MIN A, B 0 . . . approx. 50 % of lMAX
− Ramp up 1 . . . 50 V/s (± 20 %)
− Ramp down 1 . . . 50 V/s (± 20 %)
x Dither amplitude 0 . . . 300 mA
x Dither frequency 100 Hz, 150 Hz, 250 Hz
(selectable by DIP switch,
see layout diagram page 13)
x Storage temperature − 40 hC . . . + 125 hC
x Operating temperature 0 hC . . . + 70 hC

4
 FUNCTIONAL DESCRIPTION

1. SUPPLY VOLTAGE The proportional amplifier requires an external DC power supply. A diode on the
input protects the board against a power supply connected with the wrong polarity.

Because the amplifier operates as a DC/DC converter the current consumption is

less than the solenoid current.

Several amplifiers can be connected to one power supply, which then has to meet
the following requirement:

PMAX = n x P1
(P1 = requirement for one board, n = number of boards connected in parallel).

The DC voltage must be between 20 and 32 VDC.

B/D28 = + VSupply
B/D30 = 0 VSupply
Z2, Z32 = Earth (necessary for EMV)

There is a current compensating coil in the supply line, with the result that the 0 V
line of the supply voltage is not identical with the ground potential of the amplifier.
For this reason no connection may be made between the 0 V line of the supply
voltage and the analogue ground of the amplifier!

2. REFERENCE VOLTAGES The reference voltages ± 15 V and ± 10 V (stabilised) are generated by a switched
mode DC/DC converter on the board.

B2 = + 15 V unstabilised approx. 50 mA
B4 = − 15 V unstabilised approx. 50 mA
D2 = + 10 V stabilised approx. 10 mA
D4 = − 10 V stabilised approx. 10 mA

The reference voltages are used additionally to power external command potentio-
meters, transducers or external electronic components for example 5-channel
command card.

Furthermore the amplifier has a stabilised 24 VDC supply for transducers, position
switches etc.

D6, D32 = + 24 V stabilised approx. 80 mA

B6 = GND

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 FUNCTIONAL DESCRIPTION

3. COMMAND INPUT Five different current and voltage signals can be connected to the proportional
amplifier. This accommodates all the industry standard input signals. The
command input is set up as a differential input.
Adaptation for the different input voltages and compensation for the different input
currents is made by setting the DIP switches and jumpers (JP4 and JP5) on the
main board (see page 13) accordingly.

It is essential that the correct jumper and DIP switch settings are made.

If the jumper and/or DIP switch settings are incorrect then the amplifier will not be
able to generate the correct output current corresponding to the command signal.

D12 = positive command voltage

B12 = negative command voltage

3.1 COMMAND INPUT WITH

DIFFERENTIAL INPUT FUNCTION
Because a differential amplifier can only work correctly when, for the input and
feedback resistances, particular resistance combinations are selected
(SW2/1...8), this amplifier can only be used as a differential input amplifier when
it is set up for a 10 V input signal.
The diagram to the left shows the settings for a 10 V input signal with differential
input function.

SW2 Jumper ”JP4“ and ”JP5” must be open.

DIP switches SW2/2 & SW2/4 must be closed (ON).

3.2. COMMAND INPUT WITHOUT

DIFFERENTIAL INPUT FUNCTION

3.2.1 0 . . . ± 20 mA COMMAND SIGNAL

Jumper ”JP5“ must be closed

DIP switch SW2/6 must be closed (ON)!
An input signal current of 0 . . . + 20 mA generates an output current of 0 . . . l MAX A
respectively 0 . . . – 20 mA generates an output current of 0 . . . l MAX B.
SW2
The input impedance is 100 ¸.

3.2.2 + 4 . . . + 20 mA COMMAND SIGNAL

Jumper ”JP4“ must be closed

DIP switch SW2/5, SW2/7 and SW2/8 must be closed (ON)!
An input signal current of + 4 . . . + 12 mA generates an output current of l MAX B . . . 0
respectively + 12 mA . . . + 20 mA generates an output current of 0 . . . l MAX A.
SW2
The input impedance is 100 ¸.

3.2.3 0 . . . ± 5 V COMMAND SIGNAL

Jumper ”JP4“ and Jumper ”JP5“ must be open

DIP switch SW2/3 must be closed (ON)!

An input signal voltage of 0 . . . + 5 V generates an output current of 0 . . . l MAX A

SW2 and an input signal voltage of 0 . . . – 5 V generates an output current of 0 . . . l MAX B.
This command signal is normally used in conjunction with processor controllers.

The input impedance is 100 k ¸.

6
 FUNCTIONAL DESCRIPTION

COMMAND INPUT WITHOUT

DIFFERENTIAL INPUT FUNCTION
(continuation)

3.2.4 0 . . . ± 10 V COMMAND SIGNAL

Jumper ”JP4“ and Jumper ”JP5“ must be open

DIP switch SW2/4 must be closed (ON)!

An input signal voltage of 0 . . . + 10 V generates an output current of 0 . . . l MAX A

SW2 and an input signal voltage of 0 . . . – 10 V generates an output current of 0 . . . l MAX B.

This command signal is normally used when an external command signal potentio-
meter is used.
See also the description below:
Command from external potentiometer (see 3.2.6) or external signal source (see
3.2.7).

The input impedance is 200 k ¸.

3.2.5 CUSTOMISED COMMAND SIGNAL

Jumper ”JP4“ and Jumper ”JP5“ must be open

DIP switch SW2/1 must be closed (ON)!

If a command signal voltage is used which does not correspond to any of the above
SW2 values (for example 0 . . . ± 15 V corresponding to 0 . . . ± 100 % command signal)
the appropriate DIP switch has to be correspondingly set and the resistor R83 (see
page 13) has to be calculated according to the maximum voltage level and fitted to
the board.

The value of the resistance is calculated as follows:

R83 = V IN x 20 k ¸ / V
Example:
Command signal 0 . . . ± 15 V.
R83 = 15 V x 20 k ¸ / V = 300 k ¸.

The existing resistor must be then replaced with a resistor having the value calcula-
ted as above.

The input impedance is equal the new value of R83.

3.2.6 COMMAND VALUE FROM AN EXTERNAL POTENTIOMETER

As standard a 10 k ¸ command potentiometer (minimum 4.7 k ¸) should be used.

This is then connected to + 10 V amplifier reference voltage (pin D2) and the – 10 V
(pin D4). The wiper of the potentiometer is connected to the command signal input
(pin D12).

3.2.7 COMMAND VALUE FROM AN EXTERNAL SIGNAL SOURCE

An external signal source can also be used as a command signal (for example a
PLC analogue output). In this case the ground of the signal source and the ground
of the control board (pin B6) must be connected and also the signal output
connected to the command input (pin D12). The DIP switch must be set according
to the maximum input command voltage.

When the command signal value is to be used as a differential input then the
external signal source must be connected to D12 and B12. The DIP switch settings
and the level of the command voltage must be set as described under ”Command
Input with Differential Input Function” (page 6).

7
 FUNCTIONAL DESCRIPTION

4. DITHER The proportional amplifier has a square wave generator. This dither signal is
superimposed on the command for the output current. Both signals together give
the valve current. The superimposed AC-content of the current reduces the
hysteresis and friction of the valve. The 4 pole DIP switch SW6 permits 1 from
3 preset frequencies to be selected.
Important! Only one (1) DIP switch must be set in the closed (ON) position!
SW6/1 = closed (ON) 250 Hz
SW6/2 = closed (ON) 150 Hz
SW6/3 = closed (ON) 100 Hz

4.1 DITHER FREQUENCY 250 Hz

The dither frequency must be set to 250 Hz for the following valve:
– 4DP03T / 4DP06T
DIP switch SW6/1 in the closed (ON) position.
For factory setting see page 15.
SW6

4.2 DITHER FREQUENCY 150 Hz

The dither frequency must be set to 150 Hz for the following valve:
– 4DP02T
DIP switch SW6/2 in the closed (ON) position.
For factory setting see page 15.
SW6

4.3 DITHER AMPLITUDE

The dither amplitude can, if necessary, be accurately set within the range 0 . . . 300
mA by adjustment of the ”dither” potentiometer RTR5 (see layout diagram
page 13).
The factory setting is
150 mA for 4DP03T / 4DP06T
300 mA for 4DP02T
Adjusting the potentiometer in an anticlockwise direction increases the amplitude
and vice versa.

5. MAXIMUM CURRENT RANGE The maximum output current at 100 % command signal value can be set by
adjusting the SMD multi turn potentiometer RTR3 on the main board. The adjust-
ment using the SMD potentiometer should not normally be made by the customer.
Caution: Wrong adjustments can cause malfunctions or serious damages at the
proportional amplifier and the proportional solenoid.
On the main board there are two (2) 4 pole DIP switches (SW3, SW4) with which the
maximum current value can be selected (see layout diagram page 13).
Important! Only one switch of SW3 and one switch of SW4 in the closed (ON)
position.
SW3/1 and SW4/1 = closed (ON) 400 mA
SW3/2 and SW4/2 = closed (ON) 800 mA
SW3/3 and SW4/3 = closed (ON) 1600 mA
SW3/4 and SW4/4 = closed (ON) 3000 mA

SW3 SW4 5.1 Maximum Current 3000 mA

The maximum current should be set to 3000 mA for the following valves:
– 4DP02T
– 4DP03T / 4DP06T
DIP switch SW3/4 and SW4/4 in the closed (ON) position.

SW3 SW4 5.2 Maximum Current 1600 mA

At the moment there is no valve released for which this current is recommended.

8
 FUNCTIONAL DESCRIPTION

6. CONTROL INPUTS The amplifier has two digital control inputs. Each input is optically isolated, which
permits isolated voltage control of these functions.
When an external voltage supply is used for digital control then it is essential that
the 0 V of the voltage source is connected with pin B20 (digital GND).
When voltage isolation is not essential then the 24 VDC supply from the amplifier
(pin D6 or D32) can be used for the control. In this case it is essential however, to
connect pin B20 (digital GND) to one of the pins Z28, Z30 or B6 (analogue GND).
The permitted voltage level + Vdigital must be in the range + 4 VDC to 32 VDC.
The current consumption is approx. 5 mA per input at 24 V.

6.1 STOP The stop input can be used to switch the amplifier on and off. This input is a
normally closed contact, in other words when there is no voltage at the input the
”Fail Safe” LED is on and the amplifier is in the ”Stop” state. The ramp generator is
bypassed and the output stages are switched off.

B16 = + Vdigital
B20 = GND digital

6.2 RAMP OFF With this input the ramp function can be switched on or off. This input is a normally
closed contact, in other words when voltage is applied to the input, the LED “Ramp
OFF” is on and the output current to the solenoid corresponds to the command
signal without delay.

B18 = + Vdigital
B20 = GND digital

7. SENSOR INPUTS The proportional amplifier has two (2) analogic inputs (sensor 1 and sensor 2).
Both sensor inputs are designed to adapt the position transducer signal of the
valve to the required values of the PID controller on the proportional amplifier.
Herewith the feedback control system of the valve is closed. By setting the
associated switch of SW1 an impedance converter can be switched in line or is
bypassed.

7.1 SENSOR 1 = VALVE TRANS- The input sensor 1 (pin D8) is designed for the use of LVDT position transducer with
DUCER FEEDBACK SIGNAL a D.C. output current of 4 . . . 20 mA. As a current source must be terminated with a
(current) low impedance the associated impedance converter must be bypassed.
For 4DP02T / 4DP03T / 4DP06T DIP switch SW1/1 in the open (OFF) position and
DIP switch SW1/2 in the closed (ON) position

7.2 SENSOR 2 = VALVE TRANS- The input sensor 2 (pin B8) is designed for the use of LVDT position transducer with
DUCER FEEDBACK SIGNAL a D.C. output voltage of 7.5 V ± 4.5 V. The input can operate with or without an
(voltage) impedance converter. With that an optimal adaptation of the connected external
sensor is achieved.
Notice! Only one of switch SW1/3 and SW1/4 must be set into closed (ON)
position!
SW1/3 = on Sensor 2 with impedance converter
SW1/4 = on Sensor 2 without impedance converter

8. CONTROL OUTPUTS For the analogic closed loop amplifier there are no control outputs available.

9
 FUNCTIONAL DESCRIPTION ANALOGUE SUB BOARD

The following functions are to be found on the analogue sub board!

9. JUMPER JP1-JP2 The signal at the test socket “COMMAND” can be selected with these jumpers.

Only jumper JP1 or JP2 may be closed!

9.1 COMMAND MEASURING POINT When jumper JP1 is closed the signal after the ramp generator and the lMIN and lMAX
settings can be measured at the test socket “Command”.

0 . . . ± 100 % command value = 0 . . . ± x V

(x ≤ 10 depending on the l MIN and l MAX settings)

When the jumper JP2 is closed the signal after the first amplifier stage can be
measured at the test socket “Command”.

0 . . . ± 100 % command value = 0 . . . ± 10 V

(independent of whether the command value to the amplifier is a
current or voltage signal)

Troubleshooting
In the event of a fault jumpers JP1 and JP2 can be used to identify the source of the
problem. If the jumper JP2 is closed and when the command value is changed a
corresponding change in the range 0 . . . ± 10 V is observed at the test socket
“Command” then the main board is operating correctly.
If the jumper JP1 is closed and it is observed that the signal at the test socket
“Command” is affected when the lMIN or lMAX potentiometers are adjusted then it can
be assumed that the sub board is operating correctly.
The fault can then only be in the final stage of the current control, the dither genera-
tor or the PWM generator on the main board.

9.2 JUMPER JP3 This jumper is for special functions of other valves or valve groups. If the amplifier is
used with the proportional directional valve 4DP02T / 4DP03T / 4DP06T then the
jumper JP3 must be closed.

9.3 JUMPER JP4, JP5, JP6, JP7, JP8 These jumpers are for special functions for different valves or valve groups. If the
amplifier is used with the proportional directional valve 4DP02T / 4DP03T / 4DP06T
the following jumper configuration applies:

JP4 = closed
JP5 = not closed
JP6 = closed
JP7 = not closed
JP8 = closed

(see also jumper and DIP switch setting pages 15).

9.4 CURRENT MEASURING POINT At this measuring point there is a voltage signal proportional to the current.
1 V ‰ 1 A ± 10 %.

9.5 FEEDBACK MEASURING POINT At this measuring point there is a voltage signal proportional to the transducer
current or voltage.
4 mA ≈ - 5 V 12 mA ≈ 0 V 20 mA ≈ + 5 V

10
 FUNCTIONAL DESCRIPTION ANALOGUE SUB BOARD

10. TRIMMING 10.1 l MIN Setting

POTENTIOMETERS The minimum output current and so the initial valve flow can be adjusted with the
lMIN potentiometer. The range of adjustment for lMIN is between 0 mA and 50 % of lMAX
I MAX A
and is not effective up to 1.5 % of the max. command signal (see 10.2).

Clockwise adjustment of the potentiometer increases the lMIN value and vice versa.
50 % of I MAX A

– 100 % 10.2 l MIN Step Function

IM I N A
Command The lMIN step function is necessary when the valve current should be 0 mA with a
IM I N B + 100 % command of 0 V. At 0 V command there is no current to the valve. When the
Command command is only slightly above 0 V (approx. 1.5 % of the maximum command
50 % of I MAX B value) then the current jumps from 0 to lMIN (see 10.1).

10.3 l MAX Setting

I MAX B
The maximum output current can be limited by adjusting the lMAX potentiometer. In
this way it is possible to limit the maximum flow of the valve to a lesser value than
the rated flow. The value of lMAX can be set in the range lMIN to 2700 mA.

Clockwise adjustment of the potentiometer increases the lMAX value and vice versa.

11. RAMPS The amplifier has a ramp generator.

Without the ramp function the output current follows the command signal directly.

With two potentiometers the acceleration and deceleration rate can be separately
and independently set up in the range 1 . . . .50 V/s (± 20 %).

Clockwise adjustment of the potentiometer reduces the acceleration time (more

time for the flow increase) and vice versa.

1 V/s corresponds to 10 s ramp time for a command jump from 0 to 10 V.

50 V/s corresponds to 200 ms ramp time for a command jump from 0 to 10 V.

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 TEST AND SET UP INSTRUCTIONS

12. TEST AND SET UP x Connect the amplifier with one of the valves according to the connection diagram
INSTRUCTIONS shown below.
x Connect a current meter (range 0 . . . 3 A) in each solenoid coil circuit or one volt
meter (range 0 . . . 5 V) in the test sockets on the front panel (1. Current = ± V
and 2. = GND).
The relationship is 1 V/A.
x Connect a current meter (range 0 . . . 20 mA) in the feedback circuit or volt
meter (range 0 . . . 5 V) in the test socket for feedback on the front panel
(1. Feedback = + V and 2. = GND).

Command
Potentiometer

Sol. B 4DP02T Sol. A

STOP Sol. B + Sol. A +

Sol. B – Sol. A –

Ramp OFF

Sol. B Sol. A

+ V Supply
0 V Supply 4DP03T
4DP06T

x Set command potentiometer, both ramp potentiometers, “l MIN A, B” and “l MAX A, B”

potentiometers to zero.
x Connect the power supply and check if the LED ”Power on” is on. The LED “Fail
safe” should be off and the ramp function should be switched off (LED “Ramp off”
is on) so that the set up is easier.
x With unplugged solenoid connectors measure the transducer current and – if
necessary – adjust to 12 mA with the zero point potentiometer of the transducer.
x The measurement of the voltage signal at the feedback measuring point should
be 0 V. If necessary adjust with the balance potentiometer on the sub board.
x Re-connect the amplifier and valve according to the connnection diagram.
x Set the command value to approx. + 10 % of the maximum value (for example 1 V
for 10 V maximum value).
x With the potentiometer l MIN A adjust the valve current to compensate for the dead
zone.
x Set the command value to approx. – 10 % of the maximum value (for example
– 1 V for – 10 V maximum value).
x With the potentiometer lMIN B adjust the valve current to compensate for the dead
zone.
x Using the command potentiometer slowly increase the command value to
the maximum. Monitor the associated feedback signal. Set the desired flow end
value with the potentiometer lMAX A .
x Using the command potentiometer slowly decrease the command value to the
minimum. Monitor the associated feedback signal. Set the desired flow end value
with the potentiometer lMAX B.
x Set the ramp times for stepwise changes in the command value from 0 to 100 %
(respectively from 0 to – 100 %) and vice versa with the corresponding ramp
potentiometers to the desired values (clockwise adjustment of the potentiometer
increases the ramp up (and ramp down) time.
x After setting up the proportional amplifier switch on the system and observe the
behaviour. Adjust as necessary.
x Because the lMAX and lMIN adjustments are not independent the setting up
sequence must be strictly adhered to:
1. set l MIN A, B and l MAX A, B to zero
2. adjust l MIN A, B to the required value and
3. adjust l MAX A, B to the required value

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 LAYOUT DIAGRAM AND STANDARD PIN ASSIGNMENT

13. LAYOUT DIAGRAM

main board

sub board
balance pot.
front view rear view
POWER ON
FAIL SAFE
RAMP OFF

I MAX A
I MAX B
I MIN A
I MIN B

Ramp up
Ramp down

14. STANDARD PIN ASSIGNMENT

+ 10 V ref. + 15 V ref.

– 10 V ref. – 15 V ref.

+ 24 V out GND
4...20 mA 7.5 V ± 4.5 V
sensor 1 sensor 2

command diff.
sensor 5 sensor 6

stop
dig. 7 in
ramp
dig. 8 in

dig. in GND

sol. A + sol. B +

sol. A – sol. B –
supply
+V +V GND

0V 0V GND

+ 24 V out

13
 SCHEMATIC & CONNECTION DIAGRAM

15. SCHEMATIC DIAGRAM (Example 4DP03T / 06T, 4DP02T accordingly)

Feedback

reference voltage

Command Power
potentiometer POWER ON supply
recomm. reference voltage
10 k¸
(min.4.7 k¸)
To run with several
proportional amplifiers,
please use common
zero volts
diff. input
when no differential function
is used connect b12 to GND
STOP
UP DOWN
RAMP OFF

Command Solenoid
signal current

Sol. B Sol. A

4DP03/06T

16. CONNECTION DIAGRAM (Example)

Command
Potentiometer

Sol. B 4DP02T Sol. A

STOP Sol. B+ Sol. A+

Sol. B- Sol. A-
Ramp OFF

Sol. B Sol. A

+ V Supply
0 V Supply
4DP03T
4DP06T

Note:
This wiring example shows the command signal generated from a potentiometer and the control inputs
using the internal 24 V from the amplifier.
See pages 5, 6 & 8 when other commands and / or control signals are used.

14
 JUMPER AND DIP SWITCH SETTING

17. JUMPER AND DIP SWITCH

SETTING
17.1 For 4DP02T
Order No. 701-00631-8
For 4DP03T / 4DP06T
Order No. 701-00632-8

main board

sub board front view

sub board rear view

15
 TROUBLESHOOTING

18. TROUBLESHOOTING

Fault Possible Cause Corrective Action

LED ”Power ON” − no supply voltage − check supply voltage

is off
− supply voltage not in permitted range − check supply voltage

− short circuit at the valve connection − check connection and/or resistance

of solenoid coil

− short circuit at the reference voltage − check external unit (command value
transducer, amplifier, potentiometer)

− amplifier power pack defect − return amplifier to manufacturer for repair

LED ”Fail Safe” − stop input incorrectly wired − check wiring

is on
− main board or sub board defect − return amplifier to manufacturer
for repair

− feedback signal failure − measure feedback current in the range

of 4 mA . . . 20 mA when moving the
main spool. When there is no current
(or less than 3 mA) check wiring and
supply voltage of the transducer

− check proper fitting and working of the

transducer

− command signal − check wiring and measure command

4 . . . 20 mA current selected and signal in the range of 4 mA . . . 20 mA
broken wire situation

No solenoid coil current − wiring between amplifier and valve defect − check wiring

− sub board defect − check operation of the sub board as

described on page 9

− output stage defect − return amplifier to manufacturer

for repair

The product described is subject to continual development and the manufacturer reserves the right to change the specifications without notice.

16