EDC220, EDC222, EDC580...EDC2V-5V_long_en.doc 5 EDC220√, EDC222√, EDC580√ 1 System Overview...

EDC2V-5V_long_en.doc

EDC220√, EDC222√, EDC580√

www.doli.de

EXTERNAL DIGITAL CONTROLLER

EDC220√

EDC222√

EDC580√

2 EDC2V-5V_long_en.doc

EDC220√, EDC222√, EDC580√

State 150212 LOCATIONS

Corporate Name: DOLI Elektronik GmbH

Headquarters: Adi-Maislinger-Straße 7, 81373 München, Germany +49-(0)89-20 243-0

Fax +49-(0)89-20 243-243 e-mail [email protected]

Production: Ulmer Straße 34, 89584 Ehingen, Germany +49-(0)7391-58039-0 Fax +49-(0)7391-58039-71 e-mail [email protected]

Sales: Mühlstr. 26, 55271 Stadecken-Elsheim, Germany +49-(0)6130-944 250

Fax +49-(0)6130-944 251 e-mail [email protected]

Internet: www.doli.de www.flexometer.com

mailto:[email protected]

EDC2V-5V_long_en.doc 3

EDC220√, EDC222√, EDC580√

Contents

1 SYSTEM OVERVIEW ........................................................................................................................................... 5

1.1 EDC220√/EDC222√ ........................................................................................................................................... 6 1.1.1 Block Diagram EDC220√/EDC222√ .......................................................................................................... 6 1.1.2 Casing Box EDC220√ ................................................................................................................................ 7 1.1.3 Casing Box EDC222√ ................................................................................................................................ 8

1.2 EDC580√ ........................................................................................................................................................... 9 1.2.1 EDC580√ Block Diagram ........................................................................................................................... 9 1.2.2 Casing Box EDC580√ .............................................................................................................................. 10

1.3 Connections and their Functions ................................................................................................................ 11

1.4 RMCs (Remote Machine Controls) for EDC220√, EDC222√ and EDC580√ ............................................. 12 1.4.1 RMC1 ....................................................................................................................................................... 12 1.4.2 RMC6 ....................................................................................................................................................... 12 1.4.3 RMC7 ....................................................................................................................................................... 13 1.4.4 RMC Hub.................................................................................................................................................. 13

2 TECHNICAL DATA – COMPARISON EDC220√ - EDC222√ - EDC580√ ......................................................... 14

3 POSSIBLE SYSTEM VERSIONS ...................................................................................................................... 15

3.1 Communication EDC – Testing Instrument ................................................................................................ 15 3.1.1 Version 1: 10Volt .................................................................................................................................... 15 3.1.2 Version 2: Hydraulics ............................................................................................................................... 15 3.1.3 Version 3: 12W, 160W or 320W DC-Power-Amplifier ............................................................................ 16 3.1.4 Version 4: 1100W or 2500W .................................................................................................................... 16

4 SCOPES OF THE EDC SYSTEM ...................................................................................................................... 17

4.1 Plug-in boards for the I4- and I2-bus ........................................................................................................... 17 4.1.1 Plug-in boards overview ........................................................................................................................... 17 4.1.2 Description ............................................................................................................................................... 18

4.1.2.1 4FAD ................................................................................................................................................. 18 4.1.2.2 Specification of 4ETF and 2CFA ...................................................................................................... 18 4.1.2.3 Specification of X14 Load Channel on the EDC220 and 2DCA ....................................................... 19 4.1.2.4 2DCEX .............................................................................................................................................. 19 4.1.2.5 Specification of 4INC and 2INC ........................................................................................................ 20 4.1.2.6 4SSI .................................................................................................................................................. 20 4.1.2.7 4IO .................................................................................................................................................... 20 4.1.2.8 4DA ................................................................................................................................................... 20 4.1.2.9 4ADA ................................................................................................................................................. 20 4.1.2.10 4ADA-Box ......................................................................................................................................... 20

4.2 Sensor Plugs.................................................................................................................................................. 21

4.3 Power Amplifiers ........................................................................................................................................... 23 4.3.1 Internal Power Amplifiers ......................................................................................................................... 23

4.3.1.1 VAI32 – 300mA Servo Valve Amplifier for EDC220√ ....................................................................... 23 4.3.1.2 VAI35 – 300mA Servo Valve Amplifier for EDC222√, EDC580√ ...................................................... 23 4.3.1.3 DC12- 12Watt for EDC222√, EDC580√ ............................................................................................ 23 4.3.1.4 DC160- 160Watt for EDC222√, EDC580√ ........................................................................................ 23


EDC220√, EDC222√, EDC580√

4.3.1.5 DC320- 320Watt for EDC222√, EDC580√ ........................................................................................ 23 4.3.2 External Power Amplifiers ........................................................................................................................ 24

4.4 Options inside the EDC ................................................................................................................................. 25 4.4.1 ANA2 Analogue Output for 4ETF, 2CFA and 2DCA ................................................................................ 25 4.4.2 Safety Shield Control................................................................................................................................ 25 4.4.3 RS232-Connection ................................................................................................................................... 25 4.4.4 RS232/RS485-Converter ......................................................................................................................... 25 4.4.5 Synchronisation of several EDCs ............................................................................................................. 25

4.5 External Options – ready for plug and play ................................................................................................ 26 4.5.1 Draw Wire Transducer ............................................................................................................................. 26 4.5.2 DC Servo Motors ...................................................................................................................................... 26 4.5.3 Valves ....................................................................................................................................................... 26 4.5.4 Container for electronic mounting ............................................................................................................ 26 4.5.5 X2-Terminal .............................................................................................................................................. 26

4.6 EDC – Test Tools ........................................................................................................................................... 27 4.6.1 Drive-Monitor for EDC-Drive Interface (X4) ............................................................................................. 27 4.6.2 DOLI Installation Center ........................................................................................................................... 27 4.6.3 DoPE Programming Interface and DoPE TestCenter .............................................................................. 27

5 SOFTWARE ........................................................................................................................................................ 28 5.1.1 Test Description“Soft“............................................................................................................................... 28 5.1.2 Test Description“Hard“ ............................................................................................................................. 28 5.1.3 Test Description “Concrete“ ..................................................................................................................... 28 5.1.4 Application "External Command" ............................................................................................................. 29 5.1.5 Test Description "Position and Load Cycles" ........................................................................................... 29 5.1.6 Creep Test ................................................................................................................................................ 30 5.1.7 Statistics EDC .......................................................................................................................................... 30

5.2 Test&Motion PC Software............................................................................................................................. 31


EDC220√, EDC222√, EDC580√

1 System Overview

The EDC220V, EDC222V and EDC580V electronics from DOLI are powerful and cost effective systems especially designed for data acquisition and closed loop control of testing instruments. The EDC220V/222V/580V systems technically succeed the well established EDC Family, starting with EDC5, EDC25 and EDC100 up to EDC60 and EDC120.

EDC220√

The EDC220V is a built-in unit without keys and display and has been designed for static testing instruments. All measuring channels for a basic testing instrument, as well as an output channel to control an actuator, are on-board. The EDC220V has two I2-Bus-Extension-Slots for e.g. extensometers. The on-board load channel of the EDC220V has a resolution of ±180,000 steps. The EDC220V fits for:

screw driven instruments. The EDC220V has a load channel with DC supply, an incremental position channel and a controlled ±10Volt output for power amplifiers.

hydraulic instruments with a valve driven with ±10Volt. The EDC220V has a load channel, an incremental- or

SSI position channel and a controlled ±10Volt output for valves.

further load cells, LVDTs, strain gauges, extensometers, 2-channel-incremental-extensometers, serial controlled extensometers, safety shields, further I/Os, synchronising several EDCs in a multi channel application. For these applications further options are needed!

EDC222√

Basically, the EDC222V complies with the EDC220V looking at it from the technical side. However, it has a power supply unit and desk top case as the EDC580V and therefore, is available with display and keyboard and with the same drive variations as the EDC580V.

EDC580√

The EDC580V is a desk top unit with keys and display. It has been designed for static and dynamic testing instruments. Eight general purpose I4-Bus-Extension-Slots are on-board. The EDC580V fits for:

screw driven instruments with a specially adapted power amplifier for DC-servo motors. For servo motors with 12, 160 or 320Watt, integrated amplifiers will be used. These motors are available ready for plug-and-play. For servo motors with 1,000 or 2,500Watt, external amplifiers will be used.

screw driven instruments with any power amplifier. They are driven by a ±10Volt output or a digital command output. All necessary control signals to drive an external power amplifier are provided by the EDC.

hydraulic instruments, which are driven by a ±10Volt powered valve.

hydraulic instruments, which are driven by a servo-valve.

dynamic instruments, which are driven either hydraulically / pneumatically by a servo-valve or by a linear motor.

further load cells, LVDTs, strain gauges, extensometers, 2-channel incremental extensometers, serial controlled extensometers, safety shields, further I/Os, synchronising several EDCs in a multi channel application. For these applications further options are needed!


EDC220√, EDC222√, EDC580√

1.1 EDC220√/EDC222√

1.1.1 Block Diagram

EDC220√/EDC222√

Specifications

Control Processor Vortex 86DX CPU 800MHz

Load resolution ±180,000 steps, two ranges 2mV/V and 4mV/V

RS485 Interface for external keyboard/display, supports a maximum of four devices

Drive Interface ±10V (16bit) analogue command output, digital command output and safety functions

PC communication via USB or Ethernet

Two I2-Bus-Extension-Slots

Internal socket for serial sensors (COM 1)

Internal socket for debug (COM 2)

Internal socket for synchronising several EDCs

Interface for servo valve amplifier

Counter

EDC220V EDC222V

8 digital Inputs 8 digital Outputs

Load

Sensor plug A/D Converter

180.000

steps ±10 Volt

2mV/V

4mV/V

USB and Ethernet

Drive Interface

24 Volt 800mA

RS485 Keyboard/Display

Control Processor 800MHz

Communication

Data acquisition

Closed loop controller

Machine Contol

Two I2-Bus-Extension-

Slots


EDC220√, EDC222√, EDC580√

1.1.2 Casing Box EDC220√

Rear View

Side View

Dimensions: L 190 x W 200 x H 65 mm

Connections: external connections on the rear side internal connections on the side


EDC220√, EDC222√, EDC580√


Front View

(available with blank panel in combination with RMC1, RMC6 or RMC7, also)

Rear View (standard)

Rear View with Options


Display: OLED-graphics display 128x64 dots

Connections: Plug-in connection in the rear

Keys: UP, DOWN and STOP (machine control) numerical and function keys (value input, programming)

Digipoti: Crosshead / cylinder positioning Scroll of display and positioning of data input


EDC220√, EDC222√, EDC580√

1.2 EDC580√

1.2.1 EDC580√ Block Diagram

Specifications

Interface & Control Processor Vortex 86DX CPU 800MHz

RS485 Interface for external keyboard/display, supports a maximum of four devices

Drive Interface ±10V (16bit) analogue command output, digital command output and safety functions

PC communication via USB or Ethernet

Eight I4-Bus-Extension-Slots

Internal socket for serial sensors (COM 1)

Internal socket for debug (COM 2)

Internal socket for synchronising several EDCs

Interface for servo valve amplifier, 12, 160 and 320 Watt DC-drive amplifier

Counter

EDC580√

8 digital Inputs 8 digital Outputs

USB and Ethernet

Drive

Interface

Eight I4-Bus-

Extension-Slots

100-265 Volt AC Power Supply

RS485 Keyboard/Display

Interface & Control Processor 800MHz

Communication

Data aquisition

Closed loop controller

Machine Contol


EDC220√, EDC222√, EDC580√


Front View

(available with blank panel in combination with the RMC1, RMC6 or RMC7, also)

Rear View




Keys: UP, DOWN and STOP (machine control) numerical and function keys (value input, programming)



EDC220√, EDC222√, EDC580√

1.3 Connections and their Functions The following table shows the connections of the EDC and their functions.

Number Function of the connection EDC220V EDC222V EDC580V

X2 Universal-I/Os and X2-Terminal

X4 Drive Interface

X5 RMC: Connection for RMC1, RMC6 or RMC7

X6 Option (e.g. for cable output ON-LED, ON-key)

X7 X-Head: Connection for DWT, INC- or SSI-transducer (SGS_9IL, _9IT, __9IS, _9ISU, _9SSIL)

X8 Debug Interface

X10 Safety Shield Control

X11 Synchronisation, SYNC In

X12 Synchronisation, SYNC Out

X14 Load: Load input for SGS_1mV, SGS_2mV, SGS_4mV -

X15 ANA2 (analogue output of the on-board load channel) -

X16 Ethernet Interface

X17 USB Interface

X18 Motor connection or 10V-Command-Output, Moog valve, internal power amplifier

X19 24V-Voltage-Supply

X21 Slot 1 for I2-(EDC220/222) or I4-Bus-Extension (EDC580V)

X22 Slot 2 for I2-(EDC220/222) or I4-Bus-Extension (EDC580V)

X23 Slot 3 for I4-Bus-Extension - -






Y1 RS232/RS485-Converter and RS232-Option for the connection of serial sensors

-


EDC220√, EDC222√, EDC580√

1.4 RMCs (Remote Machine Controls)

for EDC220√, EDC222√ and EDC580√

The new remote machine controls do fit for the new EDC220V, EDC222V and EDC580V and can be used in addition to them. The different keys do bear the same functions as the ones with the EDC580V.

1.4.1 RMC1

The RMC1 corresponds to the operating panel of the EDC580V and therefore has completely the same functions. It can be used either directly as front plate of this EDC (mounted within the case of the EDC580V) or in a separate case mounted somewhere else at the testing instrument. It has no magnetic foil.




Keys: UP, DOWN and STOP (machine control) numerical and function keys (value input, programming) emergency stop


1.4.2 RMC6

Generally, the RMC6 is the substitute for the preceding RMC5. It is a small handheld unit (cable 3m) directly connected to the EDC. The control keys F1, F2, F3, UP, DOWN, STOP as well as the ‘mode changer’ for the Digipoti and the Digipoti itself are on the front. It has a small display and control LEDs for the TEST- and the POWER-function. The RMC6 has a magnetic foil on its back and therefore can be placed at an ergonomic position.



Connections: Cable 3m connects to RMC connector at the EDC

Keys: UP, DOWN and STOP (machine control and value input) function keys



EDC220√, EDC222√, EDC580√

1.4.3 RMC7

The RMC7 is a handheld unit (cable 3m) directly connected to the EDC. It offers completely the same functions as the operating panel of the EDC580V and, by means of that, as the RMC1. Just like the RMC6, the RMC7 has a magnetic foil on its back and therefore can be placed at an ergonomic position.



Connections: Cable 3m connects to RMC connector at EDC220 and EDC580V

Keys: UP, DOWN and STOP (machine control) numerical and function keys (value input, programming) emergency stop


1.4.4 RMC Hub

The RMC hub is used to connect up to four RMCs to the EDC. This is an advantage for e.g. very long testing systems, such as chain- or rope testers. This way, the teste can be operated from more than one location. Furthermore, a hub is necessary, when an EDC with keys and display is mounted inside the DOLI Container and an RMCs has to be used in addition. The possible cable lengths for the RMC and the hub is up to 70m.


EDC220√, EDC222√, EDC580√

2 Technical Data – Comparison EDC220√ - EDC222√ - EDC580√

EDC220V EDC222V EDC580V

Control Processor Vortex 86DX CPU 800MHz Vortex 86DX CPU 800MHz

Lowest control frequency 1kHz 5kHz

Data transfer frequency to PC 1kHz 5kHz simultaneous for all channels (max.16)

PC-Communication-Interface USB 2.0 Full speed and Ethernet 10/100Mbit

“on-board” Load Channel 180,000 steps 2mV/V or 4mV/V

no load channel on-board

Encoder SSI-Input-Channel

square input max 32MHz counting frequency / 8MHz signal frequency

app. 300kHz

Digital inputs with 24Volt level 8

Digital outputs with 24Volt level 8

Serial Sensor Interface COM1 (internal)

Debug Interface COM2 115kB

Synchronisation of data acquisition and motion control with additional EDC-units

Option

Slot for Safety Shield Control Yes

I2-Bus-Extension-Slot Two -

I4-Bus-Extension-Slot - Eight

Power Supply 24V DC 100-250V AC

Power Input 800mA Power pack included

Power pack included

Internal 24Volt/2A-DC-Power-Supply for external devices

No Yes Yes

Drive Interface 10V-Command-Output with 15Bit resolution digital command output

I/Os and relays for safety functions

Any external DC / AC power amplifier possible

Hydraulic power pack Option

Internal servo valve amplifier up to 300mA Option

Internal 12Watt DC-Power-Amplifier No Option Option




EDC220√, EDC222√, EDC580√

3 Possible System Versions

3.1 Communication EDC – Testing Instrument

Testing Instrument

F

Fmax

P3 Fb

P2

Energie

P1

dL Fmax dL Fb

dL Load

Upper LS

Lower LS

Strain

Encoder for X-head position

Motor

any power amplifier

EDC220V, EDC222V

or EDC580V

10V plus Control-I/O

3.1.1 Version 1: 10Volt

Digital Position-, Load- and Strain Control

Control of an external drive amplifier either with ±10V- or with digital command output

Load resolution: EDC220V/222V: ±180,000 steps EDC580V equipped with 4ETF: ±180,000 steps 4FAD: ±180,000 steps

Incremental transducer or transducers with SSI-Interface for X-Head-Travel

Applications: screw driven testers linear motors

Testing Instrument F Fmax

P3 Fb

P2 E nergie P1

dL Fmax dL Fb

dL

Load

Position

EDC220V, EDC222V or EDC580V

3.1.2 Version 2: Hydraulics


Control of a proportional- or servo valve by a build-in amplifier

Load resolution: EDC220V/222V: ±180,000 steps EDC580V equipped with 4ETF: ±180,000 steps 4FAD: ±180,000 steps

Draw wire transducer, any LVDT position transducer or transducers with SSI-Interface for X-Head-Travel

Applications EDC220V/222V: static with single sided actuators

Applications EDC580V: static with single sided actuators, dynamic with double sided actuators


EDC220√, EDC222√, EDC580√

Testing Instrument

F

Fmax

P3 Fb

P2

Energie

P1

dL Fmax dL Fb

dL Load

Upper LS

Lower LS

Strain


Motor

EDC222V or EDC580V

3.1.3 Version 3: 12W, 160W or 320W DC-Power-Amplifier


Direct drive of a motor with 40V/0.3A (DC012) max. power 12Watt, 48V/3.3A (DC160) max. power 160Watt 80V/8A (DC320) max. power 320Watt by the internal power amplifier

Limit switches have a direct effect on the power amplifier

Load resolution: EDC222: ±180,000 steps EDC580V equipped with 4ETF: ±180,000 steps 4FAD: ±180,000 steps


Possible machine data: (Efficiency 0.66) DC160 (160W) DC320 (320W) 100kN 50mm/min 100mm/min 50kN 100mm/min 200mm/min 20kN 250mm/min 500mm/min 10kN 500mm/min 1000mm/min 5kN 1000mm/min 2000mm/min 2kN 2500mm/min (5000mm/min)

Testing Instrument

F

Fmax

P3 Fb

P2

Energie

P1

dL Fmax dL Fb

dL Load

Upper LS

Lower LS

Strain


Motor

DC1100 / DC2500 Power Amplifier

EDC222V or EDC580V

3.1.4 Version 4: 1100W or 2500W


Direct drive of a motor with 105V/11A (DC1100) max. power 1100W 150V/16,5A (DC2500) max. power 2500W by external power amplifiers

Limit switches have a direct effect on the power amplifier

Load resolution: EDC222V: ±180,000 steps EDC580V equipped with 4ETF: ±180,000 steps 4FAD: ±180,000 steps


Possible machine data: (Efficiency 0.66) DC1100 (1100W) DC2500 (2500W) 250kN 100mm/min 250mm/min 100kN 300mm/min 800mm/min 50kN 600mm/min 1200mm/min 20kN 1500mm/min 10kN 3000mm/min


EDC220√, EDC222√, EDC580√

4 Scopes of the EDC System

4.1 Plug-in boards for the I4- and I2-bus

4.1.1 Plug-in boards overview

Order No

Name

Description

Type

EDC

220V/222V

580V

1520 4FAD Measurement amplifier board with fast A/D-Converter for strain gauge and LVDT, 5kHz carrier frequency excitation, A/D-Conversion ±180,000 steps

I4 -

0725 4ETF Measurement amplifier board with A/D-Converter for strain gauge and LVDT, 5kHz carrier frequency excitation, A/D-Conversion ±180,000 steps

I4 -

1712 2CFA I2 -

1711 2DCA Measurement amplifier board with A/D-Converter for strain gauge, 10V-DC-Excitation, A/D-Conversion ±180,000 steps

I2 -

1796 2DCEX Measurement amplifier board with A/D-Converter for strain gauge, 10V-DC-Excitation, A/D-Conversion ±180,000 steps, one channel for incremental encoders or transducers with SSI-interface, ±10V-Analog-Output (16 Bit), 24Volt-I/Os (4 inputs, 4 outputs)

I2 -

1206 4INC Counter board for the direct connection of incremental transducers, two encoder channels, 24Volt-I/Os (6 outputs, one relay, 5 inputs)

I4 -

1742 2INC I2 -

1398 4SSI Counter board for the direct connection of SSI-transducers, 24Bit I4 -

1239 4IO I/O-board with 24Volt-I/Os (6 outputs, one relay, and 5 inputs) I4 -

1491 4DA Converter board with 16Bit D/A-Converter and 24Volt-I/Os (7 outputs, one relay, and 7 inputs)

I4 -

2138 4ADA Converter board with 4x18bit A/D-converter and 4x16Bit D/A-converter, drive and control of external components.

I4 -

Legend: I4: I4-Bus-Interface I2: I2-Bus-Interface


EDC220√, EDC222√, EDC580√

4.1.2 Description

4.1.2.1 4FAD

The 4FAD is a measurement amplifier board with a carrier frequency of 5kHz and A/D-Conversion of ±180,000 steps (0.2ms detection rate, linearity 0.01%, accuracy 0.025%). It is used for strain gauges, inductive transducers (1.16 – 1,625V/V) and analogue signals. The 4FAD has been developed for static and dynamic applications with a test frequency of up to 500Hz and a data acquisition frequency of 5,000Hz.

4.1.2.2 Specification of 4ETF and 2CFA

The 4ETF and 2CFA are measurement amplifier board with a carrier frequency of 5kHz and with A/D-Conversion of ±180,000 steps, especially for strain gauge and inductive transducers (LVDT). The boards allow DC-Signal-Input, also.

Excitation and Amplifier

Carrier frequency 5kHz Sinusoidal

Supply voltage adjustable via software (Veff) 1.1 - 2.5 - 5.5 Volt

Transducer sensitivity adjustable via software 1.16 – 1,625mV/V

Minimum resistance transducer 85

Source resistance signal source (CF operation) 1.1k

Source resistance external reference (CF operation) 1.1k

DC input adjustable via software ± 5.8mV - ± 1,625V

Input resistance (DC measurement) > 15M

Common mode range ± 6.5V

Common mode suppression (Input gain.: x3.1; x34.6; x387)

80dB, 95dB, 105dB

Filter Bessel Filter 3rd order, 100Hz

Converter

Type U/f-Converter

Resolution at 20ms integration time ± 180,000 parts

Resolution at 250ms integration time ± 2,250,000 parts ± 400,000 parts reproducible

Linearity of amplifier and converter typical 0.01% (0.025%max)

Linearity at saturation of max. 20% ca. 2%

Temperature influence per °Kelvin (CF-measurement)

Offset 0.001%/°K Gain 0.01%/°K

Display noise The value of a connected non-operative sensor is allowed to vary ±0.5% from 0.4% of the nominal value

Conditions:

1. Tester non operative, integration time 100ms, load cell unloaded.

2. Tester running, integration time 100ms, load cell not inside the tester but connected electrically.


EDC220√, EDC222√, EDC580√

4.1.2.3 Specification of X14 Load Channel on the EDC220 and 2DCA

The built-in load channel of the EDC220, available at X14 and the I2-board 2DCA are measurement amplifiers with A/D-Converters. The 10Volt-DC-Excitation suits strain gauges and an A/D-Conversion of ±180,000 steps.

Excitation and Amplifier

Excitation voltage 10 Volt DC

Nominal transducer sensitivity adjustable via software

2mV/V or 4mV/V

Minimum resistance of transducer 85

Input resistance > 15M

Common mode range ± 6.5V

Filter Bessel Filter 3rd order 100Hz

Converter

Type U/f-Converter

Resolution at 20ms integration time ± 180,000 parts

Resolution at 250ms integration time ± 2,250,000 parts

± 400,000 parts reproducible

Linearity of amplifier and converter typical 0.01% (0.025%max)

Temperature influence per °Kelvin Offset 0.001%/°K

Gain 0.01%/°K

Display noise The value of a connected non-operative sensor is allowed to vary ±0.5% from 0.4% of the nominal value

Conditions

1. Tester non-operative, integration time 100ms, load cell unloaded. 2. Tester runs, integration time 100ms, load cell not inside the tester, but connected electrically.

4.1.2.4 2DCEX

The 2DCEX board has been designed to control automatic extensometers. It is a measurement amplifier with A/D-Converter (±180,000 steps) for strain gauge and a 10V-DC-Excitation. The features are:

One analogue input channel for strain gauge transducers (same specification as 2DCA)

One channel for incremental encoders or transducers with SSI-Interface

One ±10Volt-Analog-Output with 16Bit resolution

Four 24Volt/100mA outputs

Four 24Volt/11mA inputs


EDC220√, EDC222√, EDC580√

4.1.2.5 Specification of 4INC and 2INC

The 2INC and 4INC boards are used for direct connection of incremental transducers and magnetostrictive transducers e.g. for extensometers or thickness gauges. They do have two encoder channels and 24Volt-I/Os (6 outputs, one relay, 5 inputs). The I/Os of the 4INC / 2INC allow the control of further equipment e.g. arms and grips of the extensometer. The two incremental inputs do have a digital quadruplication of the transducer resolution. Each channel can be adjusted via the sensor plug to the respective transducer.

Two incremental inpts

Six 24 Volt/100mA outputs

One relays output

Five 24 Volt/11mA inputs

External 24 Volt supply

4.1.2.6 4SSI

Counter board for transducers with SSI-Interface (e.g. magnetostrictive transducers), 24Bit.

4.1.2.7 4IO

Variation of the 4INC board to control grips etc. I/O-board with 24Volt-IO/s (6 outputs, one relay and 5 inputs).

Six 24 Volt/100mA outputs

One relay output

Five 24 Volt/11mA inputs

External 24 Volt supply

4.1.2.8 4DA

Conversion board with 16Bit D/A-Conversion, a ±10V-Analog-Output to drive external components and 24Volt-I/Os (7 outputs, one relay, and 7 inputs). Application: e.g. to drive extensometers, for Lo-approach with automatic strain transducers or clamping force control of hydraulic clamps.

4.1.2.9 4ADA

Conversion board with 4x18bit A/D-converter and 4x16Bit D/A-converter, drive and control of external components, e.g. for the control of strain transducers, clamps etc. For example: External 10-Volt-signals can be fed in as controller outputs (e.g. temperatures etc.). Adjusted signals for load and position are possible as output signals. Incremental transducers for example, can be given out as 10-Volt signals.

4.1.2.10 4ADA-Box

The 4ADA-Box is a connection box for the 4ADA-board. The four analogue in- and outputs (±10V) of the 4ADA-board can be accessed via BNC-sockets. In addition, the 4ADA-box has four ±2V-inputs accessible via 6-pin DIN-round-sockets. The box and the 4ADA-board are connected via a cable.


EDC220√, EDC222√, EDC580√

4.2 Sensor Plugs A small PCB (printed circuit board) within a plug case is available in order to identify and calibrate transducers, such as load cells, extensometers etc. Load cells can be calibrated in house for production or for service. They can either be used in production or be send to customers in a ready calibrated manner. The calibration along with other data is stored inside the plug. The EDC reads the data at switch-on or on request.

Reference bridge to adjust the transducer sensitivity

EEPROM to store transducer data

The cables of the transducer are soldered directly to the PCB. The software to program the EEPROM is delivered, also.

Sensor Plugs for analogue Signals

Order No Short Code Description

Sensor plugs for all interfaces

0745 SGS_1mV SGS sensor plug 15-pin for analogue transducers 1mV/V



Sensor plugs for strain gauge and LVDT (for 4ETF, 4FAD, 2CFA, only)








Sensor plugs for DC-Signals (for EDC220, 2DCA, 2DCEX)

2036 SGS_D10V SGS sensor plug 15-pin for analogue transducers 10VDC

2073 SGS_20mA SGS sensor plug 15-pin for analogue transducers 0-20mA

Sensor plugs for DC-Signals (4ETF and 2CFA, only)

1057 SGS_1V SGS sensor plug 15-pin for analogue transducers 1VDC





EDC220√, EDC222√, EDC580√

Sensor Plugs for incremental Signals


Incremental Sensor plugs, 9-pin (EDC220V, EDC222V, EDC580V, DCEXA)

0792 SGS_9IL SGS sensor plug 9-pin for incremental transducers with line driver output signal

0793 SGS_9IT SGS sensor plug 9-pin for incremental transducers with TTL output signal

1762 SGS_9IS SGS sensor plug 9-pin for incremental transducers with sine 11A with an analogue times-ten multiplication

1766 SGS_9ISU SGS sensor plug 9-pin for incremental transducers sine 1V with an analogue times-ten multiplication

1665 SGS_9SSIL SGS sensor plug 9-pin for SSI-transducer

Incremental Sensor plugs, 37-pin (4INC and 2INC only)

1763 SGS_7IS1 SGS sensor plug 37-pin for one incremental transducer with sine 11A with an analogue times-ten multiplication

1764 SGS_7IS2 SGS sensor plug 37-pin for two incremental transducers with sine 11A with an analogue times-ten multiplication

0797 SGS_7IT1 SGS sensor plug 37-pin for one incremental transducer with TTL output signal

0798 SGS_7IT2 SGS sensor plug 37-pin for two incremental transducers with TTL output signal

0795 SGS_7IL1 SGS sensor plug 37-pin for one incremental transducer with line driver output signal

0796 SGS_7IL2 SGS sensor plug 37-pin for two incremental transducers with line driver output signal

1767 SGS_7ISU1 SGS sensor plug 37-pin for one incremental transducer with sine 1V with an analogue times-ten multiplication

1768 SGS_7ISU2 SGS sensor plug 37-pin for two incremental transducers with sine 1V with an analogue times-ten multiplication

Sensor Plug for 4SSI


1399 SGS_SSIL SGS sensor plug 37-pin for 4SSI


EDC220√, EDC222√, EDC580√

4.3 Power Amplifiers

4.3.1 Internal Power Amplifiers

4.3.1.1 VAI32 – 300mA Servo Valve Amplifier for EDC220√

Application: Servo valve

Nominal current adjustable via software from 5 to 300mA.

Dither amplitude and frequency adjustable via software, frequency range 50 to 1250Hz

4.3.1.2 VAI35 – 300mA Servo Valve Amplifier for EDC222√, EDC580√

Application: Servo valve

Nominal current adjustable via software from 5 to 300mA.


4.3.1.3 DC12- 12Watt for EDC222√, EDC580√

Application: DC-Motor from 0.005 to 0.3A

Nominal current adjustable via software from 0.005 to 0.3A

Maximal current 0.4A or twice nominal current

Voltage adjustable via software from 20 to 40 Volt



Application: DC-Motor from 0.3 to 3.3A

Nominal current adjustable via software from 0.3 to 3.3A

Maximal current 4.4A or twice nominal current

Voltage adjustable via software from 6 to 48 Volt



Application: DC-Motor from 0.8 to 8A

Nominal current adjustable via software from 0.8 to 8A

Maximum current 10.6A or twice nominal current

Voltage adjustable via Software from 6 to 80 Volt

Total power must not exceed 320 Watt!


These power amplifiers are designed to be continuously operated at either 50% load with 100% speed or 100% load with 50% speed. For a short period of time (approximately 1 minute), it is possible to operate with 100% load and 100% speed. An excess temperature detection will switch off the drive, if the drive operates too long at 100% power.

0.5

1

1 0.5

Load (Fmax = 1)

Speed (vmax = 1)

P = PN * 0.5


EDC220√, EDC222√, EDC580√

4.3.2 External Power Amplifiers

Four external power amplifiers for DC-Servo-Motors are available:

Model DC1100 DC2500

Nominal output power 1,100Watt 2,500Watt

Rated current 1.25-11A 2-16.5A

Maximum current 2 * Rated current maximum 14A

2 * Rated current maximum 20A

Voltage 15-105V 22-150V

PWM 20kHz 20kHz

Peak reverse power Continuous reverse power

1,200W for 0.5s 50W

1,200W for 2.4s 200W

Power supply 115 / 230V AC 230V AC

Supply for motor brake 24V/1A 24V/1A

Dimensions [mm] 276 x 118 x 300 276 x 175 x 445

Weight 12kg 28kg

Enclosure protection IP31 IP31

Common features:

Digital Interface with the EDC220V, EDC222V, EDC580V

Inrush current limitation

Closed loop current controller

Brake resistant at output

During deceleration, the reverse motor energy is switched back into the intermediate circuit.

The controller electronics guarantees the safety low voltage PELV according to EN60204 (V< 60V)

The power amplifier supply is disconnected at fault (emergency stop, limit-switches etc.).


EDC220√, EDC222√, EDC580√

4.4 Options inside the EDC

4.4.1 ANA2 Analogue Output for 4ETF, 2CFA and 2DCA

The option ANA2 provides a ±10V analogue output e.g. to display a strain gauge signals via a X-Y-recorder. The output voltage is not calibrated. A 10V-Output is approximately equivalent to the nominal value of the connected transducer.

4.4.2 Safety Shield Control

This option controls safety shields with and without locking. The option delimits the maximum load and the maximum speed while the safety shield is open. The Safety Shield Control has a connection for a loose-key switch, that is used to override the option for the set-up of the instrument.

4.4.3 RS232-Connection

The EDC main boards have an internal connector with a RS232 serial line. The RS232 option is a small cable assembly with a 9-pin D-SUB-connector leading to the back side of the EDC. Application: e.g. for a video-extensometer with RS232-o output. The big advantage: the signal input via the RS232 into the EDC can be used as control input. Within the system, the RS232 Interface can be selected as a control input just as with a 4ETF.

4.4.4 RS232/RS485-Converter

The EDC main boards have an internal connector with a RS232 serial line. The RS232/RS485-Converter converts the RS232 signals to RS485.

4.4.5 Synchronisation of several EDCs

This option is needed for synchronisation of data acquisition and motion control amongst several EDC systems. All necessary signals are transmitted via a serial RS485-bus. Up to 32 EDC-Units may be connected to this bus. The master EDC generates the basic system clock “SpeeT” and the position controller time base “PosT” as well as additional signals. For perfect results, the set-up parameters “SpeeT”, “PosT” and “DaRate” must be adjusted to the same values for all synchronised EDCs. Application: Tension-/Torsion Tests, Two-/Three-Axis Testing Systems, etc.

Master EDC FuncID:1000

Slave EDC FuncID:1001

Slave EDC FuncID:1002


EDC220√, EDC222√, EDC580√

4.5 External Options – ready for plug and play

4.5.1 Draw Wire Transducer

The Draw wire position transducer has a resolution of 0.82µm and a measuring range of 2m. The standard cable length is 5m, the DWT is equipped with a sensor plug SGS_9IS. (Order No 1011)

4.5.2 DC Servo Motors

Different servo motors are available; with encoder 1000 steps / revolution, line driver output signal, 3m motor cable with connection plug, 3m cable for encoder with SGS_9IL sensor plug, completely assembled and tested. They are suitable for the power amplifiers DC160 (drive unit with 48V, 3,3A, 160W) and DC320 (drive unit with 80V, 8A, 320W), e.g. the DC-Servo-Motor, 0.3Nm at 3.3A, 3800rpm at 48V (see picture, Order No 1282).

4.5.3 Valves

Valves and other accessories for hydraulic driven instruments are available, e.g. the Manifold (Order No 1331) for Moog-D633-valve. As the connecting bores of the manifold do correspond to ISO 4401-03-03-0-94 (NG6), it can be used other valves,commercially available, too. This manifold already contains a pressure sequence valve as well as a safety valve and the measuring point as quick acting closure. A sufficient working pressure for the valve will be guaranteed. Hence, the aggregate produces less heat. The manifold fits for the 4/4-Way-Proportional-Valves Moog-D633 R08 and R16. However, as valves from other manufacturers can be used, also.

4.5.4 Container for electronic mounting

A complete container with base shell and top shell (with multiple socket, without cable conduit, without EDC) for mounting the EDC and other electronics. Removable mounting plate with top head rails and cable channels for an easy mounting of contactors or power amplifiers etc. outside of the shell. Earthing bar for all metal shields. Strain relief clamp and earthing bar for shielded cables. Two shielded multiple sockets are available inside the container (Order No 1725)

4.5.5 X2-Terminal

The X2-Terminal X2T (order no. 2028) is an I/O-Terminal, used to transfer digital and analogue signals between external appliances and the EDC. The X2T has 16 digital in- and outputs each (I/Os), one impulse counter input, one analogue input with A/D-converter and an analogue output with D/A-converter. Up to four X2-terminals can be connected with each other, either in linear or star-shaped alignment. Hence, max 64 digital in- and outputs are possible.

X2-Terminal 1

EDC580V

X2-Terminal 2 X2-Terminal 3 X2-Terminal 4

EDC580V X2-Terminal 1 X2-Terminal 2

X2-Hub

X2-Terminal 3 X2-Terminal 4

Linear alignment of 4 X2-Terminals.

Star-shaped alignment of 4 X2-Terminals with X2-Hub.


EDC220√, EDC222√, EDC580√

4.6 EDC – Test Tools

4.6.1 Drive-Monitor for EDC-Drive Interface (X4)

The Drive-Monitor has been developed to quickly solve problems with the communication between measurement electronics and testing instrument. It will be connected to the drive Interface (X4) of the EDC.

All incoming signals are represented by LEDs on the Drive-Monitor, all kinds of switches can be simulated.

Using the "short-circuit-plug" - which in fact replaces the testing instrument - the signals of the EDC will be shown exclusively.

The monitor can be connected between the EDC and the testing instrument, hence facilitating the trouble-shooting with the EDC as well as with the testing instrument.

The operative range of the Drive-Monitor goes from the “research&development” over the “production” up to the “service department”.

4.6.2 DOLI Installation Center

The DOLI Installation Center has been developed to support users while equipping testing instruments with the EDCs from DOLI. The initiation of a testing instrument as well as calibrations to be carried out later on are simplified by using this program. The DOLI Installation Center consists of four components:

EDC Setup Editor

Closed Loop Setup Program

Adjustment Program

Calibration Program

4.6.3 DoPE Programming Interface and DoPE TestCenter

The DoPE Programming Interface is a DLL-software for the communication between a custom-made application software and the PC. It enables the customer to adapt his software to the EDC fast and easy and to drive the EDC even without Test&Motion. “Closed loop control” of different testing systems in all three control types is possible as well as bumpless transfer between these control types. The communication between the PC and the EDC happens via USB or LAN using a secured DPX-log. Communication drivers and header files are available as well as documentations and demo software for different programming languages. The DoPE TestCenter represents a test software for the programming interface. It can be used to check settings and their functions and display all instrument parameters at once. All in all, DoPE is a powerfull tool to support DOLI-customers in developing their own testing software.


EDC220√, EDC222√, EDC580√

5 Software

The EDC can be operated either “stand alone“ or as “machine control interface” in connection with a PC. For the “stand alone“ version, special stand-alone-software is available. The tests “Soft”, “Hard” and “Concrete” are implemented in the EDC already for no extra cost. Whereas for the tests “Position and Load Cycles”, “External commands” and “Creep test”, licences must be bought. For the PC, we offer the software Test&Motion.

5.1.1 Test Description“Soft“

Tension and Compression Test for Plastics and Rubber

Tear Test for Elastomeres and Equivalent Tests

5.1.2 Test Description“Hard“

Determination of Maximum- and Breakload (Fmax, Fb)

Offset Yield Stress Rp, Rt

E-Modulus, Tensile Yield Strength Reh, Rel

5.1.3 Test Description “Concrete“

Pressure Test (DIN 1048)

The specimen will be loaded with a constant speed of compression stress of 0,5 N/mm

2/sec (adjustable) up to break.

The test speed is calculated from the measured side length of the specimen.

Calculations are the max. load in N and the compression strength in N/mm

2.

The test results will be shown numerically on the display and can be printed on a serial printer.

Bending Tensile Test (DIN 1048)

The specimen will be loaded with a constant speed of bending tensile stress of 0,05 N/mm2/sec (adjustable)

up to break.

The max. load is the bending tensile strength.


Brasilian Test (DIN 1048)

The specimen will be loaded with a constant speed of compression stress of 0,05 N/mm2/sec (adjustable) up

to break.

The maximum load is used to calculate the Brasilian Test result for cylindrical and rectangular specimens.


Circle Bending Test (DIN 4032)

The specimen will be loaded with a constant speed of compression stress (adjustable) up to break.

The load at break is used to calculate the Circle Bending Test result for round and egg-shaped specimens.


F

Fb


EDC220√, EDC222√, EDC580√

5.1.4 Application "External Command"

In this test, the position command for position or load is given via an A/D-Converter (4ETF / 4FAD). This way, an external function generator can be connected to the A/D-converter. The command input is shown in % of the nominal value within a band, positioned in the middle of the EDC display (zero point in the middle of the band).

Test Structure

Approaching the external command: After test start, the actual value of the external command is approached with speed V1. This approach happens in position control. While approaching the external command, this command must not be changed. Therefore, the calibration contact must be open thus signalizing that the external command must not be changed. After reaching the position, the calibration contact will be closed, signalizing that the external command now is allowed to be changed.

Following the external command: Now, the control type will be changed to command control. This condition will remain, until the test either is stopped with the “Test End Key” or aborted by means of reaching a limit. Speed and acceleration, that are caused by the external command, are delimited to the nominal values from the tester Set-up. The set position is delimited to the predefined positions (Pos+ and Pos-).

Test end As desired, either a position controlled halt or an automatic return to the starting position will happen.

5.1.5 Test Description "Position and Load Cycles"

This test type is for simple fatigue tests. The specimen will be loaded sinusoidal with the predefined frequency and amplitude. It is possible to run in load- or position control. The test is done, when either the predefined load cycles are reached or one of the predefined limits has been exceeded.

Test Structure

Offset approach The predefined offset will be approached with the speed V1. The approach is defined position controlled.

Approach of the upper peak The upper peak will be approached with a ramp in the predefined control type (position or load controlled).

Cycling The load changes between the upper and lower peak are done in a sinusoidal manner. During the test run, the peak values are kept constant with a command pilot control. Further on, the channel which is not in control (load for position control and position for load control) will check the predefined limits.

Test end After reaching the given load cycles or after exceeding a limit, there are two possibilities to follow: either a position controlled halt or an automatic return to the starting position.

Application Life time tests, cycle tests etc. used for testing the exhaust pipes of cars with a testing system driven by a linear motor, testing furniture with a testing system driven by pneumatic actuators, etc.

s/F

......

t

Offset

Amplitude

Starting position Return position

Outer Limit +

Outer Limit -

Inner Limit +

Inner Limit -

s/F

t

Starting position Return position

Starting value of the external set value

Upper limit of the uncontrolled

channel

Lower limit of the uncontrolled channel


EDC220√, EDC222√, EDC580√

5.1.6 Creep Test

The creep and rupture test (on-board of the EDC) controls the complete test course of a creep testing instrument. The test runs as stand-alone test on the EDC, i.e. for the whole test control, no PC is necessary. The test parameters can be entered manually at the EDC or via the PC, the measurement values will be stored inside the EDC, even over a period of several days (depending on the pre-defined data detection rate). The PC can access and read out these data for the test evaluation. This way, it is guaranteed that the test can be performed without having a permanent connection to the PC. The test course is defined as a block program with up to 12 steps. For each step, it is possible to approach a position, load, strain or a temperature with a ramp and then keep the value constant for a definite period of time. As an alternative, it is possible to drive a definite number of sine, triangle or rectangle cycles within a step.

5.1.7 Statistics EDC

During the input of test parameters, statistical parameters can be chosen at the EDC. Invalid test results can be cancelled directly after a test in order to have valid results in the statistics, only. At the end of a series, the statistics are calculated with the function key “N-Series“. The statistic values are:

Minimum value

Maximum value

Mean value

Standard deviation

Coefficient of variation

Statistical values are available at a printer only.

t 1 2 4,5 6

Start Position LE

Position Control

e.g. return position P0

Load Control

......

P0

P1

Control mode P1

Load Control

Position Control

TEnd

Temperature

T0

T1

Position, load, strain,

temperature

Communication principle of creep testing instruments. Communication EDC - PC via Ethernet, number of connected EDCs unlimited.


EDC220√, EDC222√, EDC580√

5.2 Test&Motion PC Software The test and evaluation software Test&Motion is used to operate the EDC as a Machine Control Interface in connection with a PC.

„A test software should be able to

display everything I want evaluate everything I need

give everything out the way I like it!“

DOLI combined these tasks in the Test&Motion Software.

Program Structure

The WINDOWS™ based testing program Test&Motion has been developed in a modular design. It consists of the basic software containing a simple but adaptable tension / compression test and different modules for almost all kinds of testing applications.

Modules

T&M Basis - the basic software with a simple tension/compression test, platform for all application modules

Application Modules - the perfect module for each application type

Free Programming - absolutely individual design of test courses

Sequence Control - absolutely free design of test sequences with any number of runs (with individual

performance criteria and test speeds for each run)

The Software shows different information in different windows at the same time. All sorts of signal sources can be displayed. Load, position and strain are standard, but other transducers or calculated results can be displayed, also. Sample diameter, temperature, scales, etc. are possible as well as results via I/Os. Variables are shown as curves in X- or Y-direction or are listed digitally. The variable names can be changed (e.g. load or F), the graphic can be zoomed several times and remarks can be stored within the graphic. If a larger view of the curves is needed, the graphic window can be drawn up to screen size. Due to the organisation in separate windows, you have the possibility to move important values to a point where you can still see them. Applications are available for all kinds of tests: Metal, plastic, rubber, glass, food, wood, etc.


EDC220√, EDC222√, EDC580√

DynPack

The Test&Motion DynPack module is the software for dynamic tests. DynPack offers the collection, processing and display of measurement data from up to ten channels at the same time. Whereas up to five channels are processed with a data acquisition rate of 5kHz. DynPack displays the following information in parallel windows on the screen: measured values in a digital manner, on-line graph with reduction of data, the covering curve and the oscilloscope window. It is possible to assign simple limits as well as inner and outer limits to the amplitude for each working block. The assignment can be done in a relative and in an absolute manner. DynPack communicates with several EDCs simultaneously. Hence, a two- or three-axis-system can be controlled easily. A function generator with ramp, triangle and sinusoidal functions is included. Furthermore, it is possible to sweep between frequencies and amplitudes and to superimpose different curve forms. The EDC580V and DynPack are best friends of your dynamic tester.

DOLI OEM Products are compatible among themselves! If you have developed (or adapted your existing) software for a

DOLI electronics system once, you can connect to a new DOLI product very fast. EDC5, EDC25, EDC100, EDC60, EDC120,

EDC220, EDC222, EDC580, EDC220V, EDC222V, EDC580V and the following products - you choose the desired electronics with the exact resolution and the exact price for the exact application

for your best profit!

DOLI digital controllers are running in approx. 33,000 testing systems worldwide!

EDC220, EDC222, EDC580...EDC2V-5V_long_en.doc 5 EDC220√, EDC222√, EDC580√ 1 System Overview...

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