IQAN_XA2_Instructions.pdf

Instruction bookIQAN-XA2Publ no HY17-8385-IB/UK Edition 0505

II

Contents

Instruction book, IQAN-XA2

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6IQAN-XA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Mounting the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

IQAN-XA2 addressing/terminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reference voltage, VREF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Voltage inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Frequency inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Quadrature and directional frequency inputs . . . . . . . . . . . . . . . . . . . . . . . . 22

Proportional outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Error codes, messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Appendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Dimensioning of the IQAN-XA2 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

1 Introduction1 Introduction

These instructions are to be used as a reference tool for the vehicle manufacturers design, production, and service personnel.The user of these instructions should have basic knowledge in the handling of elec-tronic equipment.

ATTENTIONSections regarding safety, marked with the IQman symbol shown in the left margin, must be read and understood by everyone using the system, carrying out service work or making changes to hardware/software.Contact the manufacturer if there is anything you are not sure about or if you have any questions regarding the product and its handling or maintenance.The term "manufacturer" refers to Parker Hannifin Corporation. 3Instruction book, IQAN- XA2

General safety regulations2 Precautions2 Precautions

General safety regulationsWork on the hydraulics control electronics may only be carried out by trained person-nel who are well-acquainted with the control system, the machine and its safety regu-lations.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.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.Electronic control systems in an inappropriate installation and in combination with strong electromagnetic interference fields can, in extreme cases, cause an uninten-tional change of speed of the output function. 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 connec-tions 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 regulationsThe 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 operators station.

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

Safety during start-upThe 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. 4Instruction book, IQAN- XA2

General safety regulations2 PrecautionsSafety during maintenance and fault diagnosisEnsure that the following requirements are fulfilled before any work is carried out on the hydraulics 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. 5Instruction book, IQAN- XA2

IQAN-XA23 Product description3 Product description

IQAN-XA2The IQAN-XA2 is a flexible expansion module designed for controlling hydraulic systems in vehicles and machinery, using 12/24 Vdc power supply.

The IQAN-XA2 module.

I/O overview

InputsThe IQAN-XA2 module has eight (8) voltage inputs VIN-A thru VIN-H for connection of 0-5 Vdc signals. The inputs VIN-E thru VIN-H are multi-purpose and for flexibility may be configured in other ways. The two input pins VIN-E and VIN-G can be configured as frequency inputs for measuring frequency. The group of four pins VIN E thru VIN H can be configured as quadrature or directional inputs for measuring directional frequency. Voltage inputs, frequency inputs, quadrature inputs and directional inputs share positions, see below.

(8) Voltage inputs VIN-A, VIN-B, VIN-C, VIN-D.....VIN-Hor

(6) Voltage inputs VIN-A thru VIN-D,VIN-F and VIN-H. (2) Frequency inputs FIN-A and FIN-B use positions VIN-E and VIN-G.or

(4) Voltage inputs VIN-A thru VIN-D. (2) Quadrature or Directional inputs DFIN-A+/DFIN-A- and DFIN-B+/DFIN-B- use positions VIN-E thru VIN-H.

or

(8) Digital inputs DIN-A, DIN-B.....DIN-H use positions VIN-A thru VIN-H.

+BAT ADDR-H

ADDR-L

CAN-H

CAN-L

PORT 1

PORT 2

-BAT

+VREF

-VREF

PORT 0

XA2 6Instruction book, IQAN- XA2

IQAN-XA23 Product descriptionProportional outputsThe XA2 module has six (6) double proportional outputs for controlling proportional valves. These outputs can control six bi-directional valve sections or six single sole-noid devices (ie. proportional cartridge valves). The proportional outputs can be used in two different modes. Either Current mode (current closed loop) or PWM mode (voltage open loop) signals can be selected and the parameters configured using IQAN software. For flexibility these outputs may also be configured as up to six (6) on/off outputs and up to twelve (12) on/off intputs. The proportional outputs, on/off outputs and on/off inputs share positions, see below.

In order to increase the performance of proportional outputs when controlling propor-tional valves, the dither frequency can be adjusted.

High power On/Off outputsThe XA2 module has six (6) on/off outputs that are high-side power outputs. These outputs may not be configured as proportional, see below.

CAN related functionsThe master uses the CAN-bus (CAN = Controller 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.

(6) double proportional outputs COUT-A thru COUT-For

(6) on/off outputs DOUT-G thru DOUT-L, each pair of return pins may then be used as (2) on/off inputs, (12) total, DIN-I thru DIN-T.

(6) On/off outputs DOUT-A thru DOUT-F 7Instruction book, IQAN- XA2

General4 Safety4 Safety

GeneralIn order to fulfill the highest safety demands, the XA2 module uses a real-time oper-ating system for fault tolerant embedded systems. The XA2 module has an internal watchdog function. If the RTOS (real time operating system) detects any software errors, necessary precautions will be activated and the watchdog will reset the mod-ule.

Polarity reversalThe XA2 module is protected against power supply polarity reversal, provided an external fuse, max 20 A (Fast) is being used. If this fuse is not used, polarity reversal can damage the unit.

CAN-bus interruptionThe XA2 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 unit will present a related message on the display. The module also indicates the error with an error code ref, section System Diagnostics, on page 9.

Input/ output ProtectionAll inputs on the XA2 module are designed to withstand the maximum specified sup-ply voltage. The outputs are protected against short circuit. Furthermore, an error on one input/output will not influence other inputs/outputs.

Current checkFor the proportional outputs when used in current mode, a current check is per-formed. If an error occurs, the user will be notified through an error message on the display and the modules LED will show an appropriate error code.The XA2 module can detect open-circuit, short-circuit to +BAT/-BAT or short-circuit to other proportional output and return pins. In these cases the module will shut off the affected output in order to increase safety.

Built-in testThe XA2 module will execute a self-test during operation to verify the hardware and the software.The test includes CAN- bus verification, memory integrity check and an internal sig-nal verification. If any error is detected appropriate precautions will be activated. 8Instruction book, IQAN- XA2

System Diagnostics4 SafetySystem DiagnosticsThe yellow blinking LED on the top of the module indicates normal status. If there is an error detected, the master will present a message on the display. The XA2 module also indicates error status through the red blinking LED. This gives an immediate diagnosis as to the nature of the error that has occurred.

The location of the LED indicators on the IQAN-XA2 module.

The green LED indicates power on. The yellow/red LED, will be blinking red when an error has been detected. To get futher information about the error messages, see Appendix B, on page 33

A small recommendation...You can use the internal diagnostics in the master to get more information about the XA2 module. The following values are supervised:

Internal temperature [C]Power supply [V]Reference voltage [V]CAN address voltage [V]

Green, power on

Yellow/ red, status 9Instruction book, IQAN- XA2

Mounting the module5 Mounting5 Mounting

Mounting the moduleThe IQAN-XA2 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 fall-ing objects or the module being used as a step.

Locate the module so that air can circulat 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 from high pressure washing or similar. Locate the module so that the cable connector is facing down . Locate the module so that the LEDs are visible.

Non approved placing.

OBSERVEThe IQAN-XA2 module must not be placed in any marine related or similar continu-ously damp environment without external protection.

Assembling of the ID-TagThe ID-Tag will be placed in the connector in order to address/ terminate the module, ref section IQAN-XA2 addressing/terminating, on page 15. The ID-Tag will be mounted under the connector casing. Bend the ID-Tags cables toward the opposite side of where the other cables enter the connector.

Assembling of the Id-Tag. 10Instruction book, IQAN- XA2

Mounting the module6 Installation6 Installation

Connector C1

Connector pin assignments

Connector kit Parker no. 5031063

Housing Amp no. 1-963226-1

Casing Amp no. 0-965643-1

Plane sealing, 42 p Amp no. 963225-1

Pin types* Amp no. 963711-2 (MT) Amp no. 929938-1 (JPT) Cables 0,75-1,0 mm (MT) 1,5-2,5 mm (JPT) Seals Amp no. 963530-1 (MT) Amp no. 828905-1 (JPT)Plugs (empty pos.) Amp no. 963531-1 (MT) Amp no. 828922 (JPT)IQAN crimping tool references

Blue handle, pos. Ause blue extraction tool

Red handle, pos. Buse yellow extraction tool

IQAN tool kit Parker no. 5031061

Logical Symbol

Pin No.

(I)nput or (O)utput

Function description and/or Signal name(s)

+BAT 28 - Power supply, positive.

-BAT 15 - Power supply, negative ground

+VREF 42 - Voltage reference for external sensors. Sourcing +5V.

-VREF 29 - Voltage reference for external sensors. Return (0V).

ADDR-H 1 - High side to address tag. Sourcing +5V.

ADDR-L 14 - Low side to address tag. Return (0V).

CAN-H 26 27

-

-

CAN high voltage bus line, will be HIGH in dominant state.

CAN-L 40 41

-

-

CAN low voltage bus line, will be LOW in dominant state.

*= The connector contains two types of terminals; MT (Micro Timer) and JPT (Junior Power Timer).

422814

29151

+BAT ADDR-H

ADDR-L

CAN-H

CAN-L

PORT 1

PORT 2

-BAT

+VREF

-VREF

PORT 0

XA2 11Instruction book, IQAN- XA2

Mounting the module6 InstallationShaded positions are Junior Power Timer pins. Unshaded positions are Micro Timer II pins. See above for wire, seal, pin number and crimping tool information. The IQAN tool kit is found in the IQAN accessories datasheet.

Logical Symbol

Pin No.

(I)nput or (O)utput

Function description and/or Signal name(s)

P0

P0.0P0.1P0.2P0.3P0.4P0.5P0.6P0.7

1011121324253839

IIIIIIII

P0 is an 8 pin input port with alternate functions on four inputs.

VIN DIN DFIN FIN

VIN-A DIN-A - -VIN-B DIN-B - -VIN-C DIN-C - -VIN-D DIN-D - -VIN-E DIN-E DFIN-A+ FIN-AVIN-F DIN-F DFIN-A- -VIN-G DIN-G DFIN-B+ FIN-BVIN-H DIN-H DFIN-B- -Note: DIN-A to DIN-H have high impedance inputs (62K Ohm).

P1

P1.0P1.1P1.2P1.3P1.4P1.5

8922233637

OOOOOO

P1 is an 6 pin output port.

DOUT

DOUT-ADOUT-BDOUT-CDOUT-DDOUT-EDOUT-F

P2

P2.0P2.1P2.2

P2.3P2.4P2.5

P2.6P2.7P2.8

P2.9P2.10P2.11

P2.12P2.13P2.14

P2.15P2.16P2.17

21630

31731

41832

51933

62034

72135

OO/IO/I

OO/IO/I

OO/IO/I

OO/IO/I

OO/IO/I

OO/IO/I

P2 is an 18 pin input/output port with alternative functions.

COUT PWMOUT DIN DOUT

COUT-A PWMOUT-A - DOUT-GCRET-A+ PWMRET-A+ DIN-I -CRET-A- PWMRET-A- DIN-J -

COUT-B PWMOUT-B - DOUT-HCRET-B+ PWMRET-B+ DIN-K -CRET-B- PWMRET-B- DIN-L -

COUT-C PWMOUT-C - DOUT-ICRET-C+ PWMRET-C+ DIN-M -CRET-C- PWMRET-C- DIN-N -

COUT-D PWMOUT-D - DOUT-JCRET-D+ PWMRET-D+ DIN-O -CRET-D- PWMRET-D- DIN-P -

COUT-E PWMOUT-E - DOUT-KCRET-E+ PWMRET-E+ DIN-Q -CRET-E- PWMRET-E- DIN-R -

COUT-E PWMOUT-E - DOUT-LCRET-E+ PWMRET-E+ DIN-S -CRET-E- PWMRET-E- DIN-T -

Notes: If a COUT block (COUT-x, CRET-x+, CRET-x-) is used, all three pins are configured for COUT.

If a PWMOUT block (PWMOUT-x, PWMRET-x+, PWMRET-x-) is used, all three pins are configured for PWMOUT.

If a DIN-x or DOUT-x is used in a block (COUT-x, CRET-x+, CRET-x-), all three pins are configured as corresponding DIN-x and DOUT-x.

DIN-I to DIN-T are equipped with clamping diode, risk for backending.See section Connecting switches to the digital inputs, on page 20

12Instruction book, IQAN- XA2

Supply voltage6 InstallationSupply voltageBefore any installation of the IQAN system can take place, make sure the ignition lock is turned off and the battery is disconnected.

Emergency stopMake sure an Emergency Stop disconnecting the power supply, is easily accessible at any time. Further relevant regulations are to be found in Machinery Directives 9837/EC. The figure below shows how to connect the emergency stop.

Connecting of Supply VoltageThe supply voltage, should be within the operating interval, see Appendix A, on page 28. Connect the supply voltage to +BAT, position 28 and -BAT, position 15. Protect the module by using a fuse. Requisite fuse level should be 20 A, fast (F).

Connecting the emergency stop and voltage supply.

OBSERVEDo not use the chassis as the negative terminal.

+ -

422814

Emergency Stop

29151

+BAT, pos. 28 20 A

-BAT, pos.15

*

* Symbol for disconnecting switch for battery, ignition lock and other fuses. 13Instruction book, IQAN- XA2

Supply voltage6 InstallationMultiple modules connected to voltage supplyWhen connecting several XA2 modules, all of the units will have to be separately connected to the battery voltage and each unit protected with a fuse. Requisite fuse level should be 20 A, fast (F).

EXAMPLE

Connecting several modules to the power supply.

+ -

XA2-A0 XA2-A1 XA2-A2 XA2-A3

- + - + - + - +

+BAT, pos. 28-BAT, pos. 15

-BAT +BAT

20 A

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

* 14Instruction book, IQAN- XA2

IQAN-XA2 addressing/terminating6 InstallationIQAN-XA2 addressing/terminatingAddressingEach XA2 module will have a specific address, enabling the master module to com-municate with the modules through the CAN-bus. When operating, the system distin-guishes between different modules by first verifying the module type and secondly, through the modules having unique addresses.

The maximum number of similar modules in a system is four or eight depending on the master module, denoted in the first case as addresses 0, 1, 2, 3 respectively. In order to assign any XA2 module a unique CAN-address, an ID-Tag will have to be connected to the positions ADDR-H and ADDR-L.

Connecting of Id-Tag.

TerminatingTo eliminate interference in the communications through the CAN-bus, the CAN-bus must be terminated. Because the master module is always located at the beginning of the bus, the master is provided with an internal termination. You will only need to terminate the end of the bus.If an IQAN-XA2 is located at the end of the CAN-bus then use an ID-tag having a combined address and terminating function. This is denoted with a "T" for terminat-ing, after the appropriate address such as; 0T, 1T, 2T...

Selecting appropriate Id-Tag Check the address number of the module. If the module is located at the end of the CAN-bus then select the appropriate ID-

Tag denoted with a "T".

OBSERVEThe CAN-bus must not be terminated at the XA2 using an external regular terminat-ing resistor, due to the fact that terminating is made from within the XA2 module in conjunction with the ID-Tag.

EXAMPLEIf having an XA2 module with address 0, the system will denote this one as XA2-A0, The letter "A" refers to CAN-bus A.

29151

ADDR-H, pos.

422814

ADDR-L, pos.

ID-Tag 15Instruction book, IQAN- XA2

Reference voltage, VREF6 InstallationReference voltage, VREFThe XA2 module is internally equipped with a voltage regulator to generate the refer-ence voltage VREF. The standard reference voltage will feed different kinds of sen-sors and potentiometers.

VREF positions.

OBSERVEMaximum load for the VREF is different according to 12/24 Vdc power supply, see Appendix A, on page 28.

-VREF, pos 29

+VREF, pos 42 16Instruction book, IQAN- XA2

Voltage inputs6 InstallationVoltage inputsConnecting sensors to the voltage inputsThe 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.

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 corre-sponding negative terminal to the -VREF position. The sensor signal is connected to appropriate VIN position.

OBSERVEThe negative terminal of the sensor must not be connected to the chassis. Maximum load for VREF position: see Appendix A, on page 28.

EXAMPLEConnect the positive and negative terminals of the position sensor to +VREF, posi-tion 42, and -VREF, position 29, respectively. Then connect the sensor signal to VIN-A, position 10.

Connecting VREF and sensor signal VIN-A.

0

5[V]

Active signal range

Error detection range

Error detection range

t

-VREF, pos. 29

+VREF, pos. 42

VIN-A, pos. 10

Position Sensor

422814

29151 17Instruction book, IQAN- XA2

Voltage inputs6 InstallationConnecting a temperature sensor to voltage inWhen 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 tempera-ture sensor.

EXAMPLEConnect the negative terminal of the temperature sensor to -VREF, position 29, and the signal to VIN-A, position 10. The pull up resistor will be con-nected between VIN-A, position 10 and +VREF, position 42.

Connecting -VREF and temperature sensor signal VIN-A.

The pull up resistor is 4,7 K.

VIN

VREF-

VREF+

Pull up

Pull up

4,7k

-VREF pos 29VIN-A pos 10

+VREF pos 42

29151


Voltage inputs6 InstallationConnecting switches to the voltage inputsSwitches could be connected to the voltage inputs, to create a digital on/off signal. The switches should be connected to +VREF and VIN/DIN respectively for 5V sig-nal. The current consumption for the input is negligible.

OBSERVEMaximum load for VREF position, see Appendix A, on page 28.It is recommended to connect system voltage +BAT to the input through a switch in order to reserve 5Vdc VREF for sensors and potentiometers.

DIN-A to DIN-HThese 8 digital inputs share pins with VIN-A to VIN-H and have high impedance characteristics. The above examples apply to these inputs.

DIN-I to DIN-TThese 12 digital inputs share pins with the RET pins of the proportional output chan-nels. They have low impedance characteristics and an internal power clamping diode. If used they must be connected in a way that prevents "backending". See the follow-ing section for more information.

EXAMPLEConnect the positive and negative terminals of the switch to +VREF, position 42, and VIN-A/DIN-A, position 10, respectively.

Connecting a switch to VIN-A/DIN-A and VREF.

EXAMPLEConnect the positive and negative terminals of the switch to supply or the units +BAT, position 28 and VIN-A/DIN-A, position 10, respectively.

Connecting a switch to VIN-A/DIN-A and +BAT.

VIN-A/DIN-A, pos. 10

+VREF, pos. 42

29151

422814

+BAT, pos. 28

29151

422814

VIN-A/DIN-A, pos. 10 19Instruction book, IQAN- XA2

Voltage inputs6 InstallationConnecting switches to the digital inputsWhen connecting switches to the digital inputs DIN-I thru DIN-T, extra precautions should be taken.

OBSERVEBy sharing pins with the RET positions of the proportional outputs there is a possibil-ity of backending the XA2 unit when using those pins as digital inputs. The internal circuitry has power clamping diodes between RET pins and +BAT. This arrangement creates a risk of inadvertently supplying power to the unit by forward biasing the clamping diodes. There are two methods to avoid this:1 The switch could be powered by the same source as the units +BAT.

This needs to be after any switch that would shut off power to the XA2.

2 The switch could be connected to DIN through a 1K ohm resistor to limit the current source capability.

EXAMPLEConnect the positive and negative terminals of the switch to +BAT, position 28 and DIN-I, position 16, respectively.

Connecting a switch to DIN-I and +BAT.

EXAMPLEConnect the positive and negative terminals of the switch to supply and DIN-I through a 1K resistor, to position 16, respectively.

Connecting a switch to DIN-I and supply thru a resistor.

+BAT, pos. 28

29151

422814

DIN-I, pos. 16

+ -

Supply

29151

422814

DIN-I, pos. 16 1K ohm 20Instruction book, IQAN- XA2

Frequency inputs6 InstallationFrequency inputsConnecting sensors to the frequency inputsFrequency inputs can operate in 2 modes. Speed which is frequency and position which is a pulse count. For the frequency ranges and trigger levels, see Appendix A, on page 28.

Simple frequency sensorThe positive terminal of the frequency sensor is connected to the +VREF and the neg-ative terminal to the -VREF respectively. The sensor signal is connected to the FIN position.If the current consumption for the sensor exeeds the maximum load for the VREF, the sensor could be connected to the +BAT/-BAT positions.

OBSERVEThe negative terminal of the sensor must not be connected to the chassis. Maximum load for VREF position, see Appendix A, on page 28.

EXAMPLEConnect the positive and negative terminals of the frequency sensor to +VREF, position 12, and -VREF, position 13, respectively. Then connect the sensor signal to FIN-A, position 37.

Connecting of frequency sensor.

Frequency sensor

-VREF pos. 29

FIN-A pos. 24

+VREF pos. 42

29151


Quadrature and directional frequency inputs6 InstallationQuadrature and directional frequency inputsConnecting sensors to the inputsQuadrature sensors are phase dependent. These sensors have two 90 degree out of phase "square wave" type signals for direction indication, and frequency. Directional sensors are level dependent. These sensors have one "square wave" type signal for speed or position and one signal that is high or low to indicate the direction.Quadrature and directional inputs can operate in 2 modes. Speed which is frequency with direction and position which is a pulse count with direction. For the frequency ranges and trigger levels, see Appendix A, on page 28.

Quadrature sensorThe positive terminal of the quadrature sensor is connected to the +VREF and the negative terminal to the -VREF respectively. The sensors channel A is connected to DFIN-A+ and channel B to DFIN-A- positions.

Directional frequency sensorThe positive terminal of the directional sensor is connected to the +VREF and the negative terminal to the -VREF respectively. The sensor output is connected to DFIN-A+ and the sensor direction signal to DFIN-A- position.

If the current consumption for the sensor exeeds the maximum load for the VREF, the sensor could be connected to the +BAT/-BAT positions.

OBSERVEThe negative terminal of the sensor must not be connected to the chassis. Maximum load for VREF position, see Appendix A, on page 28.

EXAMPLEConnect the positive and negative terminals of the sensor to +VREF, position 42, and -VREF, position 29, respectively. Then connect the sensor signals to DFIN-A+, position 24 and DFIN-A-, position 25.

Connecting of quadrature or directional frequency sensor.

Quadrature or

-VREF pos. 29

DFIN-A+ pos. 24

DFIN-A- pos. 25

29151

422814

+VREF pos. 42Directional sensor 22Instruction book, IQAN- XA2

Proportional outputs6 InstallationProportional outputs The current /PWM outputs control proportional valves and devices. For the current range and loads, see Appendix A, on page 28.

FrequencyTo obtain the best performance from proportional valves the control produces a cur-rent mode (closed loop) output signal or a PWM voltage (open loop) output signal. The type of output is selectable in IQAN software. The units have an adjustable fre-quency which can be changed using IQAN software. The table below shows the XA2 frequency possibilities. Any frequency may be entered in your application and is translated according to this table. The bold values are the actual frequencies in Hz output by the XA2 for proportional valve control..

Frequency (Hz) entered in appl.

Frequency (Hz) output by MDL

Frequency (Hz) entered in appl.

Frequency (Hz) output by MDL

25 25 50-52 50

26 26 53-55 53

27 27 56-58 56

28 28 59-62 59

29 29 63-66 63

30 30 67-70 67

31 31 71-76 71

32 32 77-82 77

33 33 83-90 83

34-35 34 91-99 91

36 36 100-110 100

37 37 111-124 111

38-39 38 125-142 125

40-41 40 143-166 143

42 42 167-199 167

43-44 43 200-249 200

45-47 45 250-332 250

48-49 48 333+ 333 23Instruction book, IQAN- XA2

Connecting loads to proportional outputs6 InstallationConnecting loads to proportional outputsConnecting a load, e.g. one proportional valve section, to the current mode or PWM mode outputs is done by using the COUT/CRET paired positions.

OBSERVEDO NOT install diodes across coils for Current or PWM modes!

EXAMPLEPositive direction: Connect the proportional valve to the COUT-A, position 2 and the CRET-A+, position 16 respectively. Negative direction: Connect the proportional valve to the COUT-A, position 2 and the CRET-A- , position 30 respectively.

Connecting a load to a proportional output.

422815

29151

COUT-A

CRET-A-CRET-A+

Directional Valve 24Instruction book, IQAN- XA2

Digital outputs6 InstallationDigital outputs The digital outputs control relays and on/off valves. For the maximum load per output see Appendix A, on page 28.

Connecting loads to digital outputsConnecting of loads to the digital outputs such as on/off valves is done by using the DOUT-A thru DOUT-F positions and chassis as ground.

Protection against voltage transientsA clamping diode must be placed between the digital output and ground, as close to the load as possible. This protects the output against high voltage transients. Use the diode: 1N5408 (3A/1000V). Depending on the load, other clamping diodes might be used instead.

EXAMPLEConnect the on/off valve to the digital output using the DOUT-A, position 8, and the chassis as ground. A clamping diode must be placed as close to the load as possible, see figure below.

Connecting a load to the digital output.

OBSERVEIf the load is controlled in parallel with another system, the digital output must be protected with a diode.

Digital output protected with a diode.

29151

d1

DOUT-A

DOUT-A, pos.21

422814

DOUT-A, pos.21

+BATd2

d1

29151


Start-up procedures7 Start-up7 Start-up

Start-up proceduresThis chapter contains instructions for action to be taken in connection with the initial start, for example, setting values, calibrating and testing the system.

OBSERVERisk of injury! If the control system is not fitted properly, the machine could move uncontrollably. The machines engine shall not be started before the control system is completely fit-ted 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

cables conductor joint. Make sure that the ID-tag is connected properly. Make sure the emergency stop works.

The emergency stop should disconnect the supply voltage to all modules.

Emergency stop.

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

+BATDump valve 26Instruction book, IQAN- XA2

Start-up procedures7 Start-upPrepare for system startOBSERVEMake 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 systems 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 mod-ules by reading the masters 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 systems pump, assuming that the above men-

tioned 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. 27Instruction book, IQAN- XA2

Appendix AAppendix AIQAN-XA2 Technical Overview

Absolute Maximum Ratingsa

a.The Absolute Maximum Ratings table lists the maximum limits to which the device can be subjected without damage. This doesnt imply that the device will function at these extreme conditions, only that, when these conditions are removed and the device operated within the Recommended Operating Conditions, it will still be func-tional and its useful life wont have been shortened.

ParameterLimit values

Unit Remarkmin. typ. max.

Ambient temperature, TA Storage temperature

40 40

+90+100

C

Maximum voltage supply on +BAT 34 V Reverse polarity protected with 20A fuse.

Voltage on any pin withrespect to -BAT

34 V

Maximum current into -VREF 2 A

Maximum current sourced by all outputs 20 A

Environmental ratings



EMIISO 14982:1998EN 55025:2003ISO 11452-2:1995ISO 11452-4:2001ISO 7637-3:1995ISO 7637-2:1990EN 61000-4-8:1993

10015080

100

MHzMHzV/mmAV

A/m

30-1000 MHz0.15-30 MHz20-1000 MHz1-200 MHz

1a,2,3a,3b,4,5

ESDISO 10605:2001 15

84

kV aircontacthandling

Mechanical environmentIEC 68-2-64:1993 FhIEC 68-2-29:1987 Eb

0.440

g2/Hzg

15- 250 Hz, 10 hours6 ms

Climate environmentIEC 68-2-18:2000 Rb2IEC 68-2-30:1985 DbIEC 68-2-3:1969 CaIEC 68-2-2:1993-01 BbIEC 68-2-1:1993-02 AbIEC 68-2-14:1984 Nb

3610721610 x 6

mincyclesdayshourhourhour

30kPa, 12.5 l/min+55C, 95% RH44C, 93% RH70C-40C-40C to 70C

Chemical environmentIEC 68-2-52:1996 Kb 72 hour 28Instruction book, IQAN-XA2

Appendix ARecommended Operating Conditionsa

a.Recommended operating conditions are given for maximum and minimum conditions where normal performance is still available from the device. Once the normal operating conditions are exceeded, the performance of the device may suffer.



Ambient temperature, TA 40 +70 C

Voltage supply, VBAT 11 32 V

Total load on COUT/PWMOUT/DOUT 20 A

SystemTA = +25 C (unless otherwise specified)



Start-up delay 250 ms Power to activated output

Dither frequency, DF 25 333 Hz

Sample rate local I/O 1000 Hz

CAN message response time 1 ms

Output voltage on VREF 4.9 5.0 5.1 V load < 40mA

Maximum load current on VREF VBAT =11V to 32V

40 100150

mA Vdrop < 25mV (0.5%)Vdrop < 50mV (1%)Vdrop < 100mV (2%)

Current supplyVBAT =14V VBAT =28V

9575

mAoutputs = offno load on VREF 29Instruction book, IQAN-XA2

Appendix AI/OTA = +25 C (unless otherwise specified)



VIN (Voltage input) Signal range low 0 0.05 V

Signal range high 4.9 5.0 5.1 V

Input resistance 62 k

Signal resolution 5 mV

Total unadjusted error -35-100

35100

mV VREF as source

Appendix AFIN (Frequency input) Input low 1.0 V

Input high 4.0 V

Input resistance 62 k

Input frequency low(Speed mode)

220

Hz normal responsefast response

Input frequency low(Position mode)

0 Hz

Input frequency high 30.000 Hz

Step response time(Speed mode)

500 ms

Step response time(Position mode)

1 ms CAN sample time

Zero detection time(Speed mode, start or stop

Appendix APWMOUT (open-loop mode)Signal range 0 95 %

MR

Pulse width low 63 us

Pulse width high T-0.5ms

s

Error limits min (open load) 50 mA Dependent on load, power supply and dither frequency.

Error limits max (over load) 2000 mA Dependent on load, power supply and dither frequency.

Voltage drop (VBAT -VPWMOUT)load IL = 0.5Aload IL = 2A

0.20.8

V

Off-State output current: 1.8 mA

Short Circuit current limit 6 A

Dither frequency, DF 25 333 Hz

Resolution 0.1 % MR

DOUT (on/off output)Load current 2 A

Voltage drop (VBAT -VDOUT)load IL = 0.5Aload IL = 2A

0.20.8

V

Off-State output current: 101.8

uAmA

DOUT-A to DOUT-FDOUT-G to DOUT-L

Max load inductance: 2001000

mH @ 2A@ 1A

Short Circuit current limit 6 A

I/OTA = +25 C (unless otherwise specified)



T 1DF--------= 32Instruction book, IQAN-XA2

33

Error codes, messages and actionsAppendix B


Appendix B

Error codes, messages and actionsIf one of the following error is detected, a message will be presented on the display together with an error code on the module. In some cases, the module will turn off or at least shut down the outputs, to increase safety.

The location of the LED indicators on the IQAN-XA2 module.

OBSERVEDont use the machine if an error message or error code is activated.The following sections will present what measures to take for different error situations put into appropriate context.

LED indicator showing different XA2 modes

Status Flash

Normal operation (yel.)

Error code

Error Primary Flash (red) Error category

Secondary Flash (yellow) Error description

1:n See note a

a. Error groups 1:n and 2:n are controlled by the master.

2:n See note a

3:1 CAN error

3:2 Address error

4:1 Memory errorb

b. FRAM memory error.

FE Fatal error

Green, power on

Yellow/ red, status LED

Failure ModesAppendix C Appendix C

Failure ModesThe following tables contain information about the different possible failures that could occur for each module subsystem. In most cases when an error is detected, a message will be presented on the master display together with an error code on the module. In some cases, the module will turn off or at least shut down the outputs, to increase safety.

Failure modes for VREF

Failure modes for CAN interface

Failure mode Effect

1 +VREF Open VIN out of range, will create a VIN error => VIN=Predefined error value.a

a. Measure is controlled by CAN master and application as a result from the CAN error message. Turning outputs off is controlled by CAN master unit and therefore delayed maximum 2 bus cycles.

2 -VREF Open VIN out of range, will create a VIN error => VIN=Predefined error value.a

3 +VREF Short-circuit to -VREF VREF error => VIN out of range, will create a VIN error => VIN=Predefined error value.a

4 +VREF Short-circuited to +BAT VREF error => VIN out of range, will create a VIN error => VIN=Predefined error value.a

5 +VREF Short-circuited to -BAT VREF error => VIN out of range, will create a VIN error => VIN=Predefined error value.a

6 -VREF Short-circuited to +BAT External fuse (if

Failure ModesAppendix C Failure modes for VIN

Failure modes for DIN

Failure modes for FIN

Failure modes for DFIN

Failure mode Effect

1 VIN Open VIN out of range, will create a VIN error => VIN=Predefined error valuea

a. Measure is controlled by CAN master and application as a result from the CAN error message. Turning outputs off is controlled by CAN master unit and therefore delayed maximum 2 bus cycles.

2 VIN Short-circuited to +BAT VIN out of range, will create a VIN error => VIN=Predefined error valuea

3 VIN Short-circuited to -BAT VIN out of range, will create a VIN error => VIN=Predefined error valuea

Failure mode Effect

1 DIN Open No effect on module, not detected

2 DIN Short-circuited to +BAT No effect on module, not detected

3 DIN Short-circuited to -BAT No effect on module, not detected

Failure mode Effect

1 FIN Open No effect on module, not detected

2 FIN Short-circuit to +BAT No effect on module, not detected

3 FIN Short-circuit to -BAT No effect on module, not detected

Failure mode Effect

1 DFIN Open No effect on module, not detected

2 DFIN Short-circuit to +BAT No effect on module, not detected

3 DFIN Short-circuit to -BAT No effect on module, not detected 35Instruction book, IQAN-XA2

Failure ModesAppendix C Failure modes in Current ModeThe table below presents failure modes and effects on I/O.

Failure mode Effecta

a.Turning off outputs are controlled by CAN master and therefore delayed by maximum 2 bus cycles. If local error handling is enabled the output will turn off locally without delay.

1 COUT Open COUT error, output turned off

2 RET (active) Open COUT error, output turned off3 RET (passive) Open Not detected, will not influence function4 COUT Short-circuit to RET

(active)COUT error, output turned offb

5 COUT Short-circuit to RET (passive)

Not detected, will not influence function

6 COUT Short-circuit to +BAT COUT error, output turned off

7 COUT Short-circuit to - BAT COUT error, output turned offb

8 RET (active) Short-circuit to +BAT

COUT error, output turned offb

9 RET (active) Short-circuit to - BAT

COUT error, output turned off

10 RET (passive) Short-circuit to +BAT


11 RET (passive) Short-circuit to - BAT


12 COUT Short-circuit to 2:nd COUT (passive)


13 COUT Short-circuit to 2:nd RET (active)

COUT error, output turned offb

b.Turned off by integrated protection functions in IC.

14 COUT Short-circuit to 2:nd RET (passive)


15 RET Short-circuit to 2:nd RET (active)


16 RET Short-circuit to 2:nd RET (passive)


17 Insufficient Voltage COUT error, output turned off 36Instruction book, IQAN-XA2

Failure ModesAppendix C Failure modes in PWM modeTable below presents failure modes and effects on I/O.

Failure mode Effecta

a. Turning off outputs are controlled by CAN master and therefore delayed by maxi-mum 2 bus cycles. If local error handling is enabled the output will turn off locally without delay.

1 H-side Open PWMOUT error, output turned off

2 L-side (active) Open PWMOUT error, output turned off3 L-side (passive) Open Not detected, will not influence function4 H-side Short-circuit to L-side

(active)PWMOUT error, output turned offb

b. Turned off by integrated protection functions in IC.

5 H-side Short-circuit to L-side (passive)


6 H-side Short-circuit to +BAT PWMOUT error, output turned off

7 H-side Short-circuit to - BAT PWMOUT error, output turned offb

8 L-side (active) Short-circuit to +BAT

PWMOUT error, output turned offb

9 L-side (active) Short-circuit to - BAT


10 L-side (passive) Short-circuit to +BAT


11 L-side (passive) Short-circuit to - BAT

Not detected, + and - direction activated without movement as result.

12 H-side Short-circuit to 2:nd L-side (active)

PWMOUT error, output turned offb

13 H-side Short-circuit to 2:nd L-side (passive)


14 L-side Short-circuit to 2:nd L-side (active)


15 L-side Short-circuit to 2:nd L-side (passive)


16 Insufficient Voltage Not detected, lower max speed limit on function 37Instruction book, IQAN-XA2

38

Dimensioning of the IQAN-XA2 moduleAppendix D


Appendix D

Dimensioning of the IQAN-XA2 module

7 m

m/M

6(x2)

142

164

60

32

67

52

75U

nit =

m

m

1 Introduction2 PrecautionsGeneral safety regulationsConstruction regulationsSafety during installationSafety during start-upSafety during maintenance and fault diagnosis

3 Product descriptionIQAN-XA2I/O overviewInputsProportional outputsHigh power On/Off outputs

CAN related functions

4 SafetyGeneralPolarity reversalCAN-bus interruptionInput/ output ProtectionCurrent checkBuilt-in test

System DiagnosticsA small recommendation...

5 MountingMounting the moduleAssembling of the ID-Tag

6 InstallationConnector C1Connector pin assignmentsSupply voltageEmergency stopConnecting of Supply VoltageMultiple modules connected to voltage supply

IQAN-XA2 addressing/terminatingAddressingTerminatingSelecting appropriate Id-Tag

Reference voltage, VREFVoltage inputsConnecting sensors to the voltage inputsConnecting a temperature sensor to voltage inConnecting switches to the voltage inputsDIN-A to DIN-HDIN-I to DIN-T

Connecting switches to the digital inputs

Frequency inputsConnecting sensors to the frequency inputsSimple frequency sensor

Quadrature and directional frequency inputsConnecting sensors to the inputsQuadrature sensorDirectional frequency sensor

Proportional outputsFrequency

Connecting loads to proportional outputsDigital outputsConnecting loads to digital outputsProtection against voltage transients

7 Start-upStart-up proceduresStarting the control systemStart the control system as follows:

Prepare for system startPrepare for the initial system start as follows:

Start the systemStart the system as follows:

Appendix AAppendix BError codes, messages and actions

Appendix CFailure ModesFailure modes for VREFFailure modes for CAN interfaceFailure modes for FINFailure modes for DFINFailure modes in Current ModeFailure modes in PWM mode

Appendix DDimensioning of the IQAN-XA2 module

IQAN_XA2_Instructions.pdf

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