MU8244_V2_EN_V1.9
Transcript of MU8244_V2_EN_V1.9
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TechnicalManualEDITION : 13 May 2008 - VERSION : 1.9
HPRHPRHPRHPR
High Pressure Regulator
EFS 8244 V2
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10.2. RCO HP REGULATION SYSTEM 29
10.3. RCO BP REGULATION SYSTEM 30
10.4. MODBUS REGISTER 32 TO 34 USE 31
11. MODBUS COMMUNICATION PROTOCOL 32
11.1. SERIAL LINE CHARACTERISTICS 32
11.2. PROTOCOL 32
11.3. MODBUS OUTPUT BITS 33
11.4. MODBUS OUTPUT REGISTERS 35
11.5. MODBUS INPUT BITS 40
11.6. MODBUS INPUT REGISTERS 41
12. ASAP3 COMMUNICATION PROTOCOL 42
12.1. PHYSICAL CONNECTION 42
12.2. COMMANDS TABLE 42
12.3. PARAMETERS TABLE 42
13. LIST OF ERROR CODES 43
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1. INTRODUCTION
The HPRHPRHPRHPR module ensures the pressureregulation in "common rail" system.
2. UNPACKING
List of items delivered :
electronic rack HPRHPRHPRHPR power cord connectors to make cable RS232 cable (3 metres) WINWINWINWINHPRHPRHPRHPRsoftware (on CD) with its
documentation HPRHPRHPRHPRtechnical manual
3. SPARES LISTS
Part Number for spare parts :
Rack84TE without actuator card HPR2-T1-RACK
42TE without actuator card HPR2-T2-RACKPowerInternal power card Option(only available with the84TE rack)
HPR2-ALIM
CableRS232 cable to connectwith a standard PC (Sub-D9 points female femalecrossed)
HPR2-CABRS3
For the actuator card, please refer to thechapter 10.1 : Regulation system types.
4. OPERATING
The equipment is connected to asupervisor PC throw a serial line (RS232or RS485) and use the MODBUS protocol.
The WINWINWINWINHPRHPRHPRHPR software (working under
Windows
98, Windows
2000) allows theoperating parameters configuration andthe pressure setting definition.
The equipment is powered by a 230V or115V (50/60Hz) single phase powersupply and by a 10 to 36Vcc isolatedcontinuous power supply.
A pressure sensor mounted on the railgives the feedback signal for the regulation
loop.
One (or more) electro-mechanical actuatorallows the high-pressure regulation.
The command is adapted for each systemtype depending upon :
the number and the functioningprinciple of the actuators
the signals from the pump
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5. SPECIFICATION
Pressure sensor input :
voltage input 0..5V (impedance 10k) current input 0..32mA
The 2 inputs are available, the choice ofwhich one is used is done by software.
filter : 0..1kHz Acquisition : 16 bits.
Power supply for the pressure sensor :
supply 1 : +5V 100mA supply 2 : +12V 100mA
Pump Synchronisation signals:
"1/Rev" signal : differential input for
variable reluctance sensor
"SYNCHRO" signal : differential inputfor variable reluctance sensor
Characteristics for these 2 inputs
input impedance : 10k
The negative input can be connected to
ground
It is possible to add a negative signal(-2.5V) on the input signal
Option for zero crossing detection(falling edge) :
- automatic trigger level
- fixed trigger level at 200mV
- fixed trigger level at 0V
Actuators driving :
1 or 2 driving output(s)s on a singleEFS1522 card (depending upon thetype)
maximum average current for one card1522 : 10A
maximum instantaneous current forone actuator driving output : 8A
protection against short-circuits
detection of actuator presence
internal power supply (in option) 10 to36V to drive the actuators
the internal actuators power circuit isisolated from ground
Regulation :
PID type with the possibility to set the 3parameters P, I and D.
instantaneous and average errors areavailable
in case of error greater than a pre-setupper limit the regulator automaticallygoes in SECURITY mode.
Control :
Throw a serial line with MODBUSprotocol.
WINWINWINWINHPRHPRHPRHPR software running on a PC
under Windows 98 or Windows2000.
Logical Input/Output for connection
with a PLC
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6. STARTING OPERATION
The next connections need to be donebefore starting regulation.
For the description of each connector,
refer to the chapter Equipment
description .
1. Connect the power supply220VAC/50HZ on connector X1.
2. Install the Ground cable on X2.
3. Connect the battery supply on X3(except if the option HPR2-ALIM isinstalled)
4. Connect the actuators on theconnectors (X4, X5, X6 or X7)
5. Connect the pressure sensor (X10connector) Be aware to don't
connect the X10-5 to groundbecause a shunt is connectedbetween X10.5 and ground tomeasure the supplying current ofthe sensor.If this current is not between 4mAand 50mA, a "pressure sensorfault" will be generated.
The user, with the WINWINWINWINHPRHPRHPRHPRsoftware, needs to define if thepressure sensor delivers a voltageor a current and also to give thesensor curve (voltage in function ofpressure)
6. If your system needssynchronisation with the pumprotation, the SYNCHRO signal(X13) and the 3600/REV (X14)need to be connected.
It is not necessary to connect these
cables if you are using the EFS
1522 cards type 3 or 7 (number
written on the front end of the card)
7. Connect the RS485 cable (X18) orRS232 cable (X19) between theelectronic rack and the control PC.(You need to install and run theWINWINWINWINHPRHPRHPRHPRsoftware on the PC).
8. It is possible but not necessary toconnect the logical inputs/outputs(connector X8 and X9) to a PLC toenable this system to control theregulator (start regulation, security).
The pins 1 and 2 of X8 and X9connectors are from the same signal"EMERGENCY STOP". These are 2contacts (Normally Open) that areclosed when there is no fault.
The signal on X8-4 informs that thepressure in the rail is under a pre-setlower limit (in this case the contact isclosed). This information can beused by the PLC to open the doorsof a bench when the pressure is lowenough.
The user can now switch on the electronicrack.
At this time, the user can configure thepressure regulator with the WINWINWINWINHPRHPRHPRHPRsoftware.
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Depending upon the system, one or twoactuators can be controlled.
The regulation is done :
either by an ASYNCHRONOUScontrol of the actuator opening,which make a leakage or a filling thatmake pressure variation. The controlis generally of PWM type (PulseWidth Modulated).
or by a SYNCHRONOUS control ofthe actuator opening, generallysynchronized with a sensor placed inthe pump. The control can be ofPWM type (Pulse Width Modulated)or pulsing type.
The input SECURITY (X9-4), if active, willstop the regulation and the regulator willdrive the actuators so that the pressure
decreases. Depending upon the type ofCommon Rail System it will stop thecurrent in the actuator or on the contrary itwill set the current at the maximum value.
This signal has priority on all the others. Itdirectly controls the actuator card drivingstage.
Many relay outputs (X8-3 to X8-8) reportinformation (Status and faults) to externalequipments. Faults reset needs to be donevia MODBUS.
Two analogue outputs enable real time
display of the pressure in the rail..
The first one is the instantaneouspressure signal (pressure sensorsignal multiplied by 2 ).
The second one is the pressuresignal sampled at a time defined byan external signal (0v=sample,5V=Hold) or by an internal signal
generated at an angle defined by aMODBUS register.
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7. EQUIPMENT DESCRIPTION
7.1. FUNCTIONAL DIAGRAM
Actuator(s) output(s)
Fault output
Pressure sensor
Synchro inputs
Serial interface
Main supply Power supplyfor actuators
Validation control input
PRESSURE RAILREGULATOR
7.2. CARDS DESCRIPTION
The regulator is comprised of 5 to 8cards :
EFS 1520 card :
This card generates the power supply forthe pressure sensor and is the interfacecard for the pressure sensor signal(voltage or current) and also for the signals"3600/REV" and "SYNCHRO"..
EFS 1521 card :
This is the central unit for the pressure
regulator.
EFS 1526 card :
This is the interface card for the logicalinputs/outputs.
1 to 4EFS 1522 cards :
This is the driving card for one or two
actuators.
There are many types for this carddepending upon the type of CommonRail System to regulate. The electronicrack can received up to four 1522cards enabling it to drive up to fourdifferent systems (but notsimultaneously).
EFS 0900card :
Power supply +5V, +15V, -15V.
Battery supply(in option)
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7.3. INTERCONNECTION DESCRIPTION
The yellow arrowheads in the following diagram represent the interconnections :
INTERFACE
EFS1521
EFS8244
COMMON RAIL SYSTEM
SUPERVISOR
PRESSURE SENSOR ACTUATOR(S)
EXTERNALSECURITY
I/O
EFS 1522 A, B et CACTUATOR
CARD
B
F
C
AC/DCVbatt (*)
AEFS 0900
POWER SUPPLY+15V, -15V, +5V
FAULTDISPLAY
ED
EFS 1520PRESSURE SENSOR
CONDITIONING
CPU P 104C
(1)
G
F F
TESTBENCH
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7.3.1. INTERCONNECTION A
The control PC (supervisor) dialogs withthe regulator throws this interconnection.
It is a serial line, RS233 or RS485, anduses MODBUS protocol.
The supervisor PC can do the followingactions : Modify the pressure setting
Modify the regulation parameters (P, I,
D, etc..)
Read the faults
Reset the fault indicators
Read the instantaneous pressure in bar
7.3.2. INTERCONNECTION B
Interconnection between the bench andthe regulator.
The signals are :
Two dry contacts NO for the securityloops
6 dry contacts (with a common point) tosend information to PLC
6 isolated logical inputs (with acommon point) to receive informationfrom a PLC
7.3.3. INTERCONNECTION C
Interconnection between the pressuresensor conditioning card and the bench :
analogue output :instantaneous rail pressure (BNC)
analogue output :sampled rail pressure (BNC)
analogue input :Sample/Hold logical signal (BNC)
analogue input :3600/REV signal (BNC)
analogue input :SYNCHRO pump signal (BNC)
7.3.4. INTERCONNECTION D
Interconnection for the pressure sensor :
Power supplies for the pressuresensor : +5V, +12V.
Analogue signal from pressure sensor
7.3.5. INTERCONNECTION E
Interconnection between the actuatorsand the driving card.
7.3.6. INTERCONNECTION F
Power supply distribution.
7.3.7. INTERCONNECTION G
External battery supply for driving theactuators (10 to 36V dc).
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8. EQUIPMENT DESCRIPTION
The HPRHPRHPRHPRmodule is an aluminum rack 3U, 19 , (360 mm deep)
8.1. REAR PLATE PRESENTATION
12
3
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2
C B
E
G
A
F
34
2
1
34
2
1
34
2
1
34
2
1
X17
X12X13X14
X15X16
X19
X8 SECURITY INPUT
X11ACTUATORS DIODE
X9 SECURITY OUTPUTS
X10 SENSOR
SLOT 4
X7SLOT 3
X6SLOT 2
X5SLOT 1
X4
V BATT10-36VDC X3
ACTUATORS DRIVE OUTPUTS
X1MAIN
PE
X2
3600/T SYNCHRO
SAMPLINGINPUT
SAMPLEDPRESSURE
PRESSURE
NC
+
+
1
234
A2
A1
X18Rs485
Rs232
I
0
8.1.1. CONNECTORS LIST
X1 : Mains Incoming SwitchX2 : GROUND connectorX3 : Battery inputX4 : Actuators outputs for card 1X5 : Actuators outputs for card 2X6 : Actuators outputs for card 3X7 : Actuators outputs for card 4X8 : Security contact outputsX9 : Security inputsX10 : Pressure Sensor (Power supply and signal)X11 : Output for selected card external LEDs
X12 : Output "Instantaneous pressure"X13 : Input "PUMP-SYNCHRO"X14 : Input "3600/REV"X15 : not usedX16 : Input "Sample/Hold"X17 : Output "Sampled pressure"X18 : RS485 connectorX19 : RS232 connector
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8.1.2. CONNECTORS DETAILED DESCRIPTION
X1 MAIN SwitchMain witch
(fuse : 1AT)
X2 GROUNDTo connect the GROUND protection cable.
X3 BATTERY inputVBATT (10 to 36V)1 : +VBAT : battery terminal +2 : -VBAT : battery terminal -3 : not used
12
3
JAEGER (fastseries) female
3 points
X4 Actuators driving outputs ( card 1)1 : Terminal + actuator channel B
2 : Terminal + actuator channel A3 : Terminal - actuator channel A4 : Terminal - actuator channel B
3 4 2
1
JAEGER (fast
series) female4 points
X5 Actuators driving outputs ( card 2)1 : Terminal + actuator channel B2 : Terminal + actuator channel A3 : Terminal - actuator channel A4 : Terminal - actuator channel B
34
2
1
JAEGER (fastseries) female
4 points
X6 Actuators driving outputs ( card 3)1 : Terminal + actuator channel B2 : Terminal + actuator channel A
3 : Terminal - actuator channel A4 : Terminal - actuator channel B
34
2
1
JAEGER (fast
series) female4 points
X7 Actuators driving outputs ( card 4)1 : Terminal + actuator channel B2 : Terminal + actuator channel A3 : Terminal - actuator channel A4 : Terminal - actuator channel B
34
2
1
JAEGER (fastseries) female
4 points
The actuators terminals are active, and need to be free of any potential. The
outputs are protected against this type of error by a differential current sensor and bythe fuse (10AT) in the front plate.
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X8 Logical outputs 1526
MINICONNEC10 pins
1 : contact 2 for security loop
2 : contact 2 for security loop3 : Output "Actuator test OK"4 : Output "pressure < Pmin"5 : Output "Emergency Stop"6 : Output not used7 : Output not used8 : Output not used9 : not connected10 : Common for outputs
-
-OUT0OUT1
AUOUT2OUT3OUT4
--
1
2
3
4
5
6
7
8
9
10
X9 Logical inputs and outputs 1526
MINICONNEC10 pins
1 : contact 1 for security loop2 : contact 1 for security loop3 : Input "Actuator test"4 : Input "Security"5 : Input "Regulation"6 : Input not used7 : Input not used8 : Input not used9 : Power output 24V (125 mA max)10 : Common for Inputs
--IN0IN1IN2IN3IN4IN5
--
1
2
3
4
5
6
7
8
9
10
X10 pressure sensor 1520
MINICONNEC10 pins
1 : Power supply output +5V.2 : Power supply output +12V.3 : Voltage Signal input4 : Current Input Signal5 : Return for sensor power supply6 : Ground Shield
7 to 10 : not used
1
2
3
4
5
6
7
8
9
10
X11 Actuator card selected LEDs output 1522
MINICONNEC10 pins
1 : card 1 "selected", led +2 : card 1 "selected", led -3 : card 2 "selected", led +4 : card 2 "selected", led -5 : card 3 "selected", led +6 : card 3 "selected", led -7 : card 4 "selected", led +8 : card 4 "selected", led
9 to 10 : not used
Select-
Select-
Select-
Select-
1
2
3
4
5
6
7
8
9
10
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X12 Instantaneous pressure
Analogue output of the "instantaneouspressure" (pressure sensor signal multiplied by2)
Not isolated BNC
X13 Pump SYNCHROInput for variable reluctance sensor, TTLcompatible (falling edge) isolated BNC
X14 3600/REVInput for variable reluctance sensor, TTLcompatible (falling edge) isolated BNC
X15 not used
Not isolated BNC
X16 Sample/Hold inputTTL input for sample/hold signal
Not isolated BNC
X17 Sampled pressure
Output value of the sampled pressure. The timefor sampling "Instantaneous pressure" isdefined by the external signal "Sample/hold"(X16) or by software.
Not isolated BNC
X18 RS 4851 : RS 485 A2 : RS 485 - B 1
2
MINICONNEC2 pins
X19 RS 232
1 : Not used2 : RxD3 : TxD4 : Not used5 : GND6 : Not used7 : Not used8 : Not used9 : Not used
1
2
3
4
5
6
7
8
9
SUB-D9 points
male
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8.2. FRONT PLATE PRESENTATION
The electronic rack HPRHPRHPRHPRlooks like this :
U + 15V
U - 15V
Dfaut - 15V
Dfaut + 15V
Dfaut + 5V
- 15V
+ 15V
+ 5V
EFSElectronique
0900
Type2
EFSElectronique
1520
EFSElectronique
1522
EFSElectronique
1522
EFSElectronique
1522
EFSElectronique
1522
EFSElectronique
1526
AU
OUT0
OUT1
OUT2
OUT3
OUT4
IN 0
IN 1
IN 2
IN 3
IN 4
IN 5
EFSElectronique
1521
TypeType TypeType
8.2.1. 0900 CARD DESCRIPTION
0900 Card: Power supply +15V, -15V et +5V
+5V +5V OK
+5V DEFAULT +5V FAULT DETECTED
+15V +15V OK
+15V DEFAULT +15V FAULT DETECTED
-15V -15V OK
-15V DEFAULT -15V FAULT DETECTED
Electronique
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0900
U + 15V
U - 15V
- 15V Default
+ 15V Default
+ 5V Default
- 15V
+ 15V
+ 5V
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8.2.2. 1520 CARD DESCRIPTION
Pressure sensor interface
X1Filtered
pressure
X12BNC
ADC
Instantaneouspressure
Sampledpressure X17
BNC
Sample/HoldX16BNC
I/U
Voltage/Current selection
Current input (I)
Voltage input (U)
SensorPowersupply
x2
x1
x1
x1
Fc = 1 Khz
Fc = 5 Khz
+
- Currentmeasurement
WindowsComparator4 - 50 mA
+5V / +12V
SensorFault
Synchronisation signals interface
Fc = 340 Khz
Fc = 340 Khz
x10+
-
+-x10
Fallingfront
trigger3600/REV -
3600/REV +X14BNC
Synchro -
Synchro +X13InsulatedBNC
X7
X4
X6
X2
3600/REV
Synchro
2,5V
X5
X8
2,5V
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This card generates the power supplies for the pressure sensor and interfaces thepressure sensor signal.
Two power supplies are available : +5V and +12V. They are protected against short-circuitsand have a current limitation of 100mA.
This card can operate with a pressure sensor delivering a voltage signal (0..5V) or a currentsignal (0..32mA). Selecting Voltage or Current is done via a MODBUS register. The sensorsignal can be linearized by a curve in 10 segments, these segments can be set viaMODBUS registers.
An analogue output on BNC delivers the instantaneous pressure (sensor signal multiplied by2).
An other analogue output on BNC delivers the "instantaneous pressure" sampled at a timedefined by an external logical signal "Sample/Hold" or by software , in this case a MODBUSregister defines the angle at which the signal must be sampled.
Synchronisation signals ("3600/REV" et "PUMP-SYNCHRO") are also interfaced on thiscard. The two inputs are designed for variable reluctance sensor, but they are alsocompatible with TTL signals. The detection is made on the falling edge of the signals.
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There are the following configuration straps on the 1520 card :
Strap Function
X1Cut-Off frequency for the low-pass filter applied on the instantaneouspressure signal
1-2 : 1kHz (default value)2-3 : 5 kHz
This strap must NOT be modified buy the user.
X2Add a 2.5V constant signal on the PUMP-SYNCHRO signal before falling-
edge detection stage
NC : signal not modified (default value)1-2 : add 2,5V
X4 Connect Terminal of PUMP-SYNCHRO signal to GROUND
NC : Differential input2-3 : SYNCHRO- connected to GROUND (default value)
X5 Falling edge detection mode for PUMP-SYNCHRO signal
NC : automatic trigger level (default value)1-2 : fixed level = 200mv2-3 : fixed level = 0V
X6Add a 2.5V constant signal on the 3600/REV signal before falling-edgedetection stage
NC : signal not modified1-2 : add 2,5V (default value)
X7 Connect Terminal of 3600/REV signal to GROUND
NC : Differential input2-3 : 3600/REV - connected to GROUND (default value)
X8 Falling edge detection mode for 3600/REV signal
NC : automatic trigger level (default value)1-2 : fixed level = 200mv2-3 : fixed level = 0V
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8.2.3. 1521 CARD DESCRIPTION
1521 card : CPU card
SYSTEM ONLighting as soon as the system is initialised
BATTERY OKLighting when the battery voltage is correct
REGULATION ONLighting when the regulation is active
SECURITY Lighting when the regulator is in SECURITYmode (actuators are driven so that the rail
pressure is minimum)ERRORA fault as been detected
EFSElectronique
1521
The 1521 card manages the general functioning of the regulator and computes thepressure regulation.
The CPU communicates with other equipment throw a serial line (RS232 or RS485) inrespect with MODBUS protocol. It can equally communicates with a PLC (programmablelogic controller) via logical inputs/outputs interfaced by the 1526 card, for example the PLCcan start an "actuator test", or put the regulator in "security mode" or activate the regulation.
The pressure sensor signal is converted in numerical form with a 16 bits ADC / 250ksps.The software then computes the actuator command using a PID algorithm, the coefficientsP, I and D are available in MODBUS registers. A PLD (programmable Logic Device) thentransforms the PID numerical output in control signals, synchronized if necessary, with thepump rotation depending upon the Common Rail System type.
Refer to appendix REGULATION SYSTEM TYPES to get more information concerning the
functioning of these different systems.
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8.2.4. 1522 CARD DESCRIPTION
1522 card : actuators driving card
BATTERY ONBattery voltage available
SELECTActive Card
OUT A ERROR Fault on Actuator A (Short-circuit, over-current)
OUT B ERROR Fault on Actuator B (Short-circuit, over-current)
EFSElectronique
1522
Type
If the fuse is blown or if a differential current has been detected the 2LEDS are lighting together.
There are different 1522 card types that allow the regulator to work with different CommonRail System types.
Refer to appendix REGULATION SYSTEM to get more information these different regulation
types.
With the WINWINWINWINHPRHPRHPRHPRsoftware, you can select the type of regulation system you want to workwith, the 1522 card corresponding will be "selected", its LED "SELECT" will light (signals areavailable on the rear connector X11 to do an external display).
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The electronic rack can receive a maximum of 4 actuators card (whichever types).
Each card can drive 1 or 2 actuators and have the following specifications :
Power circuit (battery voltage) is completely isolated from the electronic command circuit(GROUND is not connected to BATTERY -)
Actuator impedance detector (settable level)
The current in the actuator can be chopped (settable levels)
Protection against short-circuit (fixed level = 8A) and against over-current (settable level)
Protection against differential current in the actuator
Automatic detection of blown fuse Automatic detection of battery not connected
SECURITY mode (actuators driven so that the pressure decrease) in case of errordetected.
Protection against battery over voltage (if the battery voltage exceed 36V the protectioncircuit will blown the front plate fuse).
Actuators test actuators current chopping
In case of over-current detection, the actuator power supply removing haspriority on the SECURITY mode.
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8.2.5. 1526 CARD DESCRIPTION
1526 card : Logical inputs/outputs card
AU EMERGENCY STOP
OUT 0 Output "ACTUATOR TEST OK" active
OUT 1 Output "PRESSURE < PMIN" active
OUT 2 Output 2 active
OUT 3 Output 3 active
OUT 4 Output 4 active
IN 0 Input "ACTUATOR TEST" active
IN 1 Input "SECURITY" active
IN 2 Input "REGULATION" active
IN 3 Input 3 active
IN 4 Input 4 active
EFSElectronique
1526
AU
OUT0
OUT1
OUT2
OUT3
OUT4
IN 0
IN 1
IN 2
IN 3
IN 4
IN 5
IN 5 Input 5 active
This card is used to interface logical input/output signals.
The LEDS are lighting when the corresponding inputs or the outputs are active.
The card provides a power supply 24 Vcc / 125mA isolated for driving the inputs.
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8.2.5.1.detailed description of the 1526 card INPUTS
electronic circuit for oneinput of the 1526 card
Min Nominal MaxETAT 1
- Voltage- current
15 V3 mA
24 V6 mA
30 V8 mA
ETAT0- voltage- current
-0.6 V0 mA
0 V0 mA
10 V1 mA
Response time 1 ms
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8.2.5.2. detailed description of the 1526 card OUTPUTS
OUT-0
OUT-1
OUT-2
OUT-3
OUT-4
COMMUN-RELAIS
Two dry contacts are also available for security loop.
FAULT
FAULT
EMERGENCY STOP
X9-1
X8-1
X9-2
X8-2
Securityloop 2
Securityloop 1
COMMON
}
}
X8-5
X8-10
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9. REGULATION PRINCIPLE
The regulation principle can be of two types :
The asynchronous mode The synchronous mode
9.1. THE ASYNCHRONOUS MODE
The actuator(s) command is done independently of the pump position and speed. Theactuator(s) command, calculated with the PID algorithm is transformed in a PWM (PulseWidth Modulated) signal.
The pressure regulation is done throw an actuator opening control.
Mechanical functioning of the pump
It is a proportional command.
The actuator valve position is controlled. The command is done throw a PWM signaloperating at a frequency of some kilohertz, this allows a control of the average current in theactuator solenoid.
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9.2. THE SYNCHRONOUS MODE
The actuator(s) command is done in function of pump position and/or speed. Theactuator(s) command, calculated by a PID algorithm is transformed in an actuator commandsynchronized with a signal generally generated by the pump itself.
The actuator command can be a PWM or a pulsed signal, this signal control the openingtime of the actuator(s).
Opening the actuator on a known position of the pump does the pressure regulation.
Mechanical functioning of the pump
It is a TRUE/FALSE control.
The actuator valve is opened or closed. Controlling the opening time of the valve does thecommand.
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10.APPENDIX
10.1. REGULATION SYSTEM TYPESThe following table list the different Common Rail System types that are supported by theHPRHPRHPRHPR. For each type, a specific 1522 card is available.
Type System Part Number Corresponding Common Rail System
1522-T1RCF BP SyANG
Bi actuatorsHPR2-ACT1
bi-actuators system, angular driving onlow-pressure, synchronized by the pump.
1522-T2RCO BP SyPWM
Bi actuatorsHPR2-ACT2
bi-actuators system, PWM driving on low-pressure, synchronized by the pump.
1522-T3RCO HP PWMMono actuators
HPR2-ACT3Mono-actuator system, asynchronousPWM driving on high-pressure.
1522-T4RCO BP SyPWMMono actuators
HPR2-ACT4Mono-actuators system, PWM driving onlow-pressure, synchronized by the pump.
1522-T5RCO HP inverse
PWMMono actuators
HPR2-ACT5Mono-actuator system, asynchronousinverse PWM driving on high-pressure.
1522-T6RCO BP PWMMono actuators
HPR2-ACT6Mono-actuator system, asynchronousPWM driving on low-pressure.
1522-T7RCO BP PWM
Bi actuatorsHPR2-ACT7
Bi-actuator system, asynchronous PWMdriving on low-pressure.
1522-T8RCO HP PWMMono actuators+ IMV BP PWM
HPR2-ACT8Mono-actuator system, asynchronousPWM driving on high-pressure, and PWMIMV driving on low-pressure.
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Abbreviation used to defined the regulation system typeAbbreviation used to defined the regulation system typeAbbreviation used to defined the regulation system typeAbbreviation used to defined the regulation system type ::::
RCO / RCF : Regulation Command Opened / Closed.Defines the actuator functioning, RCO means that the actuator is opened when there isno current (the fluid can circulate), on the contrary RCF means that the actuator isclosed when there is no current (The fluid cannot circulate).
BP / HP : Low pressure / High pressureDefines if the regulation is done on the pump entry (low pressure) or on the rail (high
pressure).
SyPWM : Synchronous System, PWM driving
SyAng : Synchronous System, angular driving
PWM : PWM driving, 0% drive give output always low.
inverse PWM: PWM driving, 0% drive gives output always high.
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10.2. RCO HP REGULATION SYSTEM
ActuatorA
PWM P
WMfrequency
(canbesetfrom150Hzto39KHz)
Functioning:The actuator, mounted on the rail, works like a valvehaving a pressure setting depending on the averagevalue of the flowing throw current.
The actuator is driven by a PWM signal having asettable frequency (generally between 150Hz and1kHz).
It is a PROPORTIONAL functioning mode, the actuatorbeing driven by an asynchronous PWM signal.
SECURITY mode :When the actuator is not powered, it drains the rail sothe pressure decreases.In SECURITY mode, the 1522 card switches off theactuators.
Synchronisation signals :No synchronisation signal is necessary.
Common Rail System on market :DELPHI System for car.BOSCH System for car.
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10.3. RCO BP REGULATION SYSTEM
ActuatorB
ActuatorA
PWM P
WMfrequency
(canbesetfrom150Hzto39KH
z)
Functioning:The actuator(s) are mounted on the high-pressurepump. They control the admission flow in the pump.
When the actuator is not powered, the admission flowis maximum so that the pressure in the rail increases.The flow in the actuator is controlled by the averagevalue of the current flowing throw it, it is why theactuator is driven by a PWM signal at a settablefrequency (generally between 150Hz and 1kHz).
It is a PROPORTIONAL functioning mode, the actuatorbeing driven by an asynchronous PWM signal.
SECURITY mode :When the actuator is not powered, the admission flowis maximum so that the rail pressure increases.In SECURITY mode, the 1522 card continuouslypowered the actuators.
Synchronisation signals :No synchronisation signal is necessary.
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10.4. MODBUS REGISTER 32 TO 34 USE
MODBUS registers parameters 1 to parameters 2, at addresses 32 to 34, have different useaccording to the E1522 card type.
Parameter 1 Parameter 2 Parameter 3Actuator card
Address 32 Address 33 Address 341522-T1 Pulse duration1522-T2 Not use1522-T31522-T41522-T5
1522-T61522-T7
Not use Not use
1522-T8
PWM period
IMV duty cycle IMV PWM period
Pulse duration : length of the command pulse, by step of 50s on 8 bits.
PWM period : PWM period of the actuator driving. The period is generate according to thisformula : P = (((parameter + 1 ) x 256) - 1 ) x 0,2s.The parameter on 8 bits, give an excursion from 51s (19,6KHz) to 13.1ms (76Hz).
IMV duty cycle : Duty cycle of the IMV command from 0 to 100%. The IMV PWM period isthe same than actuator PWM period.
PWM IMV period : PWM period of the IMV driving. The period is generate according to thisformula : P = (((parameter + 1 ) x 256) - 1 ) x 0,2s.The parameter on 8 bits, give an excursion from 51s (19,6KHz) to 13.1ms (76Hz).
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11.MODBUS COMMUNICATION PROTOCOL
11.1. SERIAL LINE CHARACTERISTICS
There are two possibilities to connect to the pressure regulator : an RS232 line or an RS485line. These two lines cannot be used together.
The RS232 line is available on connector X19 (male, 9 points SubD ).
The RS485 line is available on connector X18 (screw terminal).
Serial line parameters:
Speed : 38400 bauds
Number of bits : 8 bits
without parity
1 stop bit
11.2. PROTOCOL
The protocol used is the MODBUS RTU (binary mode) RTU
The pressure regulator identification has been fixed to 8.
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11.3. MODBUS OUTPUT BITS
(INFORMATIONS GIVEN TO THE REGULATOR)These values can be read and written by the supervisor.Write the bits via the MODBUS functions N5 or 15.Read the bits via the MODBUS function N1.
WRITEPERMISSION
Address DESCRIPTION
GENERALSTO
P
ACTUATORTE
ST
SECURITY
REGULATIONACTIVE
OPENLOOP
MST (*)
0
ACKNOWLEDGEThis bit needs to set to 1 to acknowledge a FAULT.The FAULT bits are all reset to 0. The regulator thenreset this bit to 0 after acknowledge and just before
signalling a FAULT.
X x x x x 0
1
SECURITY :When this bit is set to 1 the regulator goes intoSECURITY MODE that means that it does everythingneeded to make the pressure decreasing in the rail.This bit has the same effect as the logical input signal SECURITY .
X x x x X 0
2
OPEN_LOOP :When this bit is set to 1 , the regulator goes in OPENLOOP MODE, the setting becomes the PID output
(the value must be between 0 and 100%)
x x x x x 0
3
REGULATION :When this bit is set to 1, the regulator goes intoREGULATION MODE that means that the regulatorcontrol the rail pressure. This bit has the same effectas the logical input signal REGULATION .
X x x x X 0
4
ACTUATOR_TEST :When this bit goes from 0 to 1 the regulator starts anactuator test. This bit has the same effect as the logicalinput signal ACTUATOR_TEST.
X x X X x
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5
SAMPLE/HOLD :
(0 : internal, 1 : external)This bit defines if the instantaneous pressure needs tobe sampled by using the external signal (BNC X11) orif the sampled time is defined by the MODBUS register30.
X X X X X
6 Pressure sensors input type (0 : current, 1 : voltage) X X X bank
7RESET :CPU reset
X X X 0
8EXIT :Ask program to stop
X X X 0
9
END_TEST_ACTU:This bit is set at the end of the actuator test. This bitneeds to be reset to 0 by the supervisor before startingan actuator test.
X X X X X 0
10MEASURE_TRANSFER :ask to transfer to supervisor all the acquisition data :pressure value, pressure setting, PID output in %
X X X X X 0
11 Special Mode to start an external program LL3 X X X 0
(*) The MST column :(*) The MST column :(*) The MST column :(*) The MST column : gives the value taken just after power on. When the box is yellow, the value istaken from the EEPROM (that means that value is saved by the regulator)
The indication The indication The indication The indication bankbankbankbank : means that this parameter is stored in EEPROM in a table depending uponthe REGULATION SYSTEM TYPE. (Output register 0) which is itself stored in EEPROM.
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11.4. MODBUS OUTPUT REGISTERS
(information GIVEN TO THE REGULATOR)These values can be read and written by the supervisor.Write the bits via the MODBUS functions N6 or 1*6.Read the bits via the MODBUS function N3.
WRITE PERMISSION
Address DESCRIPTION
GENERAL
STOP
ACTUATO
R_
TEST
SECURITY
REGULAT
IONACTIVE
OPENLOOP
MST
0 Regulation System TYPE : between 1 and 16 X X X
1PRESSURE SETTING : must be between 0 and maxpressure setting
X X X X X
2 order to start writing coefficients in EEPROM X X X X X
3
Pressure Sensor curve : voltage value in mV (10
values) X X X X X bank
13 Pressure Sensor curve : Pressure in bar (10 values) X X X X X bank
23 PID : Proportional band in bar X X X X X bank
24 PID : overlaying band in bar X X X X X bank
25 PID : Integral coefficient in ms X X X X X bank
26 PID : Derivative coefficient in ms X X X X X bank
27PID : part of the integral action to take into account (0to 100%)
X X X X X bank
28PID : part of the derivative action to take into account(0 to 100%)
X X X X X bank
29Slope of the ramp in bar/s used when the pressuresetting is modified
X X X X X bank
30Sample/hold angle (from the 1/REV signal) used tohold instantaneous pressure
X X X X X
31Number of cylinders used to define the number ofsample/hold during one revolution.
X X X X X
32 Flex Parameter 1 X X X X X bank
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WRITE PERMISSION
Address DESCRIPTION
GENERALSTOP
ACTUATOR_
TEST
SECURITY
REGULATIONACTIVE
OPENLOOP
MST
33 Flex Parameter 2 X X X X X bank
34 Flex Parameter 3 X X X X X bank
35Sampling period for the instantaneous pressure (unit =500s)
X X X X X bank
36 PID Output maximum Value (de 0 to 100%) X X X X X bank
37Low Pressure Level (in bar) used to activate the logicaloutput signal PRESSURE < PMIN
X X X X X bank
38
TOLERANCE 1 :Maximum tolerance on the average pressure.The average pressure need to be always between
PRESSURE_SETTING TOLERANCE 1 et PRESSURE_SETTING + TOLERANCE 1 otherwise the regulator signals ALARM 2
X X X X X bank
39
TOLERANCE 2 :Maximum tolerance on the average pressure.The average pressure need to be always between PRESSURE_SETTING TOLERANCE 2 et PRESSURE_SETTING + TOLERANCE 2 otherwise the regulator goes into SECURITY MODEand signals a fault.
TOLERANCE 2 needs to be higher than TOLERANCE 1 .
X X X X X bank
40
TOLERANCE 3 :idem TOLERANCE 1 but the test is done on theinstantaneous value of the pressure. The alarmactivated if necessary is the ALARM 3
X X X X X bank
41TOLERANCE 4 :idem TOLERANCE 2 but the test is done on theinstantaneous value of the pressure.
X X X X X bank
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WRITE PERMISSION
Address DESCRIPTION
GENERALSTOP
ACTUATOR_
TEST
SECURITY
REGULATIONACTIVE
OPENLOOP
MST
42
TOLERANCE 5 :
Level in bar used to detect oscillation of the pressure.This test is done every 2 seconds after the stabilisationtime.
X X X X X bank
43
Stabilisation time allowed when the pressuresetting is growing :Time in ms after changing the pressure setting duringwhich no test will be done.
X X X X X bank
44
Stabilisation time allowed when the pressuresetting is decreasing :Time in ms after changing the pressure setting during
which no test will be done..
X X X X X bank
45Number of samples for averaging :Number of samples used to compute the averagepressure (between 2 and 5000)
X X X X X bank
46Number of samples for the average pressure usedby the PID : (value between 2 and 5000).
X X X X X bank
47
These registers are the calibration data for the ADC. (itis necessary to start again after a modification of thesevalues)
X X X
57 These registers are the calibration data for the ADC. X X X
67
Forcing the output OUT 0 :PRESSURE < PMIN(0=no forcing, 1=force to 1, 2= force to 0)
X X X X X 0
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WRITE PERMISSION
Address DESCRIPTION
GENERALSTOP
ACTUATOR_
TEST
SECURITY
REGULATIONACTIVE
OPENLOOP
MST
68Forcing the output OUT 1 :TEST_ACTUATOR_OK
(0=no forcing, 1=force to 1, 2= force to 0)
X X X X X 0
69Forcing the output OUT 2 :(0=no forcing, 1=force to 1, 2= force to 0)
X X X X X 0
70Forcing the output OUT 3 :(0=no forcing, 1=force to 1, 2= force to 0)
X X X X X 0
71Forcing the output OUT 4 :(0=no forcing, 1=force to 1, 2= force to 0)
X X X X X 0
72Forcing the output AU(0=no forcing, 1=force to 1)
X X X X X 0
73HIGH_CURRENT :Value (in mA) used to chop the actuator current.
X X X X X bank
74LOW_CURRENT :Value (in mA) used to chop the actuator current.
X X X X X bank
75TEST_CURRENT :Value (in mA) that must be reached during the testactuator to decide that the actuator is connected.
X X X X X bank
76
MAX_CURRENT :Maximum instantaneous value of the current in one
actuator (value in mA), if this value is reached thepower is switched off on the actuator card and a fault isgenerated.
X X X X X bank
77
STARTING_MODE :Mode in witch the regulator will start after power on.The possible values are :
0 : GENERAL STOP1 : ACTUATOR TEST2 : SECURITY3 : REGULATION4 : OPEN LOOP
X X X X X
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WRITE PERMISSION
Address DESCRIPTION
GENERALSTOP
ACTUATOR_
TEST
SECURITY
REGULATIONACTIVE
OPENLOOP
MST
78
MAX_PRESSURE_SETTING :This value will limit the pressure setting parameter
(register 1). This value can be between 0 and 1800bars.
X X X X X bank
68ACTUATOR TEST LENGTH : actuator test durationfrom 0.1ms to 6.3ms (value between 1 to 63)
X X X
69PROTOCOLE : communication protocol choice, needto restart the system to validate : 0 = MODBus / 1 =ASAP
X X X X X
70ASAP switch : Flag used by the ASAP protocol forchoosing between OFFLINE (0) and ONLINE (1) mode.
X X X X X
71 VERSION COEFF : coefficient calibration version, usedwhen updating the system.
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11.5. MODBUS INPUT BITS
( information GIVEN BY THE REGULATOR)The supervisor cannot modify these values.Read the bits via the function MODBUS N2.
Address Description
0 State of IN 0 input
1 State of IN 1 input
2 State of IN 2 input
3 State of IN 3 input
4 State of IN 4 input
5 State of IN 5 input
6 State of AU (Emergency Stop) output
7 State of OUT 0 output
8 State of OUT 1 output
9 State of OUT 2 output
10 State of OUT 3 output
11 State of OUT 4 output
12 ALARM 1 : Serial buffer Overload (this bit is reset after one reading)
13 ALARM 2 : Pressure out of tolerance 1
14 ALARM 3 : Pressure out of tolerance 3
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11.6. MODBUS INPUT REGISTERS
(INFORMATIONS GIVEN BY THE REGULATOR)The supervisor cannot modify these values.Read the registers via the MODBUS function N4.
Address Description
0 Working MODE :
0 : GENERAL STOP
1 : ACTUATOR TEST
2 : SECURITY
3 : REGULATION
4 : OPEN LOOPThis register gives the actual WORKING MODE of the regulator. The workingmode can be changed via logical inputs or via MODBUS OUTPUT BIT N1,2,3and 4.
1 FAULT : value of the error code (0 = no fault)
2 Card type detected in place 1 (on the left part of the rack) : 0 = no card
3 Card type detected in place 2
4 Card type detected in place 35 Card type detected in place 4
6 Average pressure in bar
7 Average pressure in bar used by the PID
8 Instantaneous pressure in bar (signed value)
9 instantaneous pressure (output of the 16 bits ADC)
10 PID output : 0 to 10000 (10000 means 100%)
11 PID output for the FLEX (The exact value written in the FLEX register)
12 Soft version
13 Soft version (extension)
14 INSTANTANEOUS PRESSURE SETTING : this pressure setting take intoaccount the possible ramp.
20 Error message (40 registers are used -> 80 ASCII characters)A 0 ends the string.
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12.ASAP3 COMMUNICATION PROTOCOL
12.1. PHYSICAL CONNECTIONThe connection is the same as for the MODBus protocol. This communication is workingthrough an RS232 or RS485.
Serial link characteristics
Baud rate : 38400. Bits data : 8. No parity. 1 stop bit.
12.2. COMMANDS TABLE
Command Code DefinitionINIT : 2 Start the communication.IDENTIFY : 20 Return the version of the installed protocol with
the system name.EXIT : 50 Exit from the program (reboot).SET PARAMETER : 15 Set Parameters.GET PARAMETER : 14 Get parameters.SWITCH ON LINE/OFF LINE : 13 Set the working mode in ON or OFF line for the
regulator which means :
OFF line mode : all modified parameters arestored in the RAM file but not taken intoaccount.
ON line mode : All parameters stored in thememory are activated when the system isentering in On line and all new set parameteris activated in real time.
12.3. PARAMETERS TABLE
MODE Working mode see page 39 MODBus table.ACTION Value of the PID action, value between 0 and 10000.PROTOCOLE Protocol choice (0 = MODBus and 1 = ASAP3).ACKNOLEDGE Error acknowledge (1 = Ack).SYSTEME TYPE Type of regulation to activate.ERROR CODE Error code (see defect table).PRESSURE MEASURE Measured pressure in Bar. (Read only)PRESSURE SETTING Pressure setting.
The protocol modification is valid only after reboot.
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13.LIST OF ERROR CODES
CODE DESCRIPTION
GENERALSTOP
ACTUATORTEST
SECURITY
REGULATION
OPENLOOP
WORKING MODEafter the FAULT
EMERGENCYSTOP
1 EEPROM out of order x x x x x GENERAL STOP x
2 FLEX out of order x x x x x GENERAL STOP x
3Incorrect Data for the pressuresensor
x x GENERAL STOP x
4 Unknown Actuator Type x x x GENERAL STOP x
5 Actuator Card not Detected x x x GENERAL STOP x
6 Incorrect Power for Actuator x x x x SECURITY x
7 Pressure sensor not Detected x x SECURITY x
8Incorrect Pressure Signal (negativepressure)
x x SECURITY x
9
Pressure sensor signal > 120% of fullscale
- if the pressure sensor isconfigured in voltage mode theinput signal was higher than 6V(full scale is 5V)
- if the pressure sensor isconfigured in current mode theinput signal was higher than
38.4mA (full scale is 32mA)
x x SECURITY x
10Regulation out of order : too manyoscillations
x SECURITY x
11Regulation out of order : pressure outof tolerance 2
x SECURITY x
12Regulation out of order : pressure outof tolerance 4
x SECURITY x
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EFS
DEFAUT DESCRIPTION
ARRETGENERAL
TESTACTUATEUR
SECURITE
REGULATIONACTIVE
BOUCLEOUVERTE
RUNNING MODEafter fault
acknowledge
ARRETDURGENCE
50 Card 1: Differential leakage current x x x x GENERAL STOP x
51Card 1: Actuator A :over-current protection
x x x SECURITY x
52Card 1: Actuator A :maximum current reached in theactuator
x x x GENERAL STOP x
53Card 1: Actuator A :impedance too high
x GENERAL STOP
54Card 1: Actuator A :impedance too low
x GENERAL STOP
55 Card 1: Actuator B :over-current protection
x x x SECURITY x
56Card 1: Actuator B :maximum current reached in theactuator
x x x GENERAL STOP x
57Card 1: Actuator B :impedance too high
x GENERAL STOP
58Card 1: Actuator B :impedance too low
x GENERAL STOP
59 Card 1: Fuse error.X x x x GENERAL STOP x
70 Card 2 : Differential leakage current x x x x GENERAL STOP x
71Card 2: Actuator A :over-current protection
x x x SECURITY x
72Card 2: Actuator A :maximum current reached in theactuator
x x x GENERAL STOP x
73Card 2: Actuator A :
impedance too high
x GENERAL STOP
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EFS
74Card 2: Actuator A :
impedance too low
x GENERAL STOP
75Card 2: Actuator B :over-current protection
x x x SECURITY x
76
Card 2: Actuator B :maximum current reached in theactuator
x x x GENERAL STOP x
77Card 2: Actuator B :impedance too high
x GENERAL STOP
78Card 2: Actuator B :
impedance too low
x GENERAL STOP
79 Card 2: Fuse error. X x x x GENERAL STOP x
90 Card 3: Differential leakage current x x x x GENERAL STOP x
91Card 3: Actuator A :over-current protection
x x x SECURITY x
92
Card 3: Actuator A :maximum current reached in theactuator
x x x GENERAL STOP x
93 Card 3: Actuator A :impedance too high
x GENERAL STOP
94Card 3: Actuator A :impedance too low
x GENERAL STOP
95Card 3: Actuator B :over-current protection
x x x SECURITY x
96Card 3: Actuator B :maximum current reached in theactuator
x x x GENERAL STOP x
97Card 3: Actuator B :impedance too high
x GENERAL STOP
98Card 3: Actuator B :impedance too low
x GENERAL STOP
99 Card 3: Fuse error. X x x x GENERAL STOP x
110 Card 4: Differential leakage current x x x x GENERAL STOP x
111Card 4: Actuator A :over-current protection
x x x SECURITY x
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112
Card 4: Actuator A :
maximum current reached in theactuator
x x x GENERAL STOP x
113Card 4: Actuator A :impedance too high
x GENERAL STOP
114Card 4: Actuator A :impedance too low
x GENERAL STOP
115Card 4: Actuator B :over-current protection
x x x SECURITY x
116
Card 4: Actuator B :
maximum current reached in theactuator
x x x GENERAL STOP x
117Card 4: Actuator B :impedance too high
x GENERAL STOP
118Card 4: Actuator B :impedance too low
x GENERAL STOP
119 Card 4: Fuse error. X x x x GENERAL STOP x
*****