EDC-Installation Manual

Installation Manual

for EDC-controlled

Testing Machines

Project Leader : Michael Grupp

Edition Changes Date Name

1 First edition (not complete) 10.4.97 J. Broszeit
2 in Arbeit April 97 J. Broszeit
3 Überarbeitung 20.11.97 M. Grupp
4 Minor changes (new address etc.) 21.10.98 H.Schabel
5 New EDC-Set-up, controller set-up 18.10.99 H.Schabel
6 RDPH 10.02.00 N.Metcalfe

Doli Elektronik GmbH Fraunhoferstr. 23h D-80469 Munich

Telephone: +49 89 20 24 30 eMail: info@doli.de
Telefax: +49 89 20 24 32 43 homepage: www.doli.de

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Contents
1 SAFETY HINTS.......................................................................................................................................................... 6

2 INSTALLATION MANUAL...................................................................................................................................... 8
2.1 INSTALLATION REQUIREMENTS ................................................................................................................................. 8
3 MANUAL USER SET-UP MENU ............................................................................................................................. 9
3.1 SET-UP MENU STRUCTURE ...................................................................................................................................... 10
3.2 MACHINE DATA ....................................................................................................................................................... 11
3.3 SENSOR DATA 1 TO 4 ............................................................................................................................................... 11
3.4 CLOSED LOOP CONTROL .......................................................................................................................................... 12
3.5 OUTPUT CHANNEL ................................................................................................................................................... 12
3.6 BIT-INPUT ................................................................................................................................................................ 12
3.7 BIT-OUTPUT............................................................................................................................................................. 12
3.8 GENERAL DATA ....................................................................................................................................................... 12
3.9 ADMINISTRATION .................................................................................................................................................... 12
3.10 SENSOR DATA 5 TO 16 ........................................................................................................................................ 13
3.11 EDC-CONNECTOR DESCRIPTION ........................................................................................................................ 14
3.12 LINEARISATION MENU........................................................................................................................................ 15
3.13 EXAMPLES OF DIFFERENT SENSOR TYPES:.......................................................................................................... 17
3.13.1 Incremental Transducer as Position Transducer .......................................................................................... 17
3.13.2 Draw Wire Position Transducer ................................................................................................................... 18
3.13.3 Analogue Position Transducer...................................................................................................................... 19
3.13.4 Analogue Load Transducer........................................................................................................................... 20
3.13.5 Analogue Pressure Transducer..................................................................................................................... 21
3.13.6 Analogue Tension Transducer ...................................................................................................................... 22
3.13.7 Linear incremental Tension Transducer ....................................................................................................... 23
3.13.8 Example for the connection of an external keyboard .................................................................................... 24
3.14 SET-UP INSTALLATION AID ................................................................................................................................. 25
3.14.1 Machine Data................................................................................................................................................ 25
3.14.2 Sensors .......................................................................................................................................................... 28
3.14.3 Closed loop control....................................................................................................................................... 31
3.14.3.1 General Parameters ............................................................................................................................................... 31
3.14.3.2 Closed loop control Parameter .............................................................................................................................. 32
3.14.4 Output Channels ........................................................................................................................................... 34
3.14.5 Bit-Input ........................................................................................................................................................ 34
3.14.6 Bit-Output ..................................................................................................................................................... 34
3.14.7 General Data................................................................................................................................................. 35
3.14.8 Management.................................................................................................................................................. 35
4 MAKING THE MACHINE LIVE ........................................................................................................................... 36

5 CLOSED LOOP CONTROLLER ADJUSTMENT............................................................................................... 38

5.1 STEPS TO ADJUST CLOSED LOOP PARAMETER .......................................................................................................... 38
5.2 GENERAL HINTS FOR USING THE CLOSED LOOP CONTROLLER ADJUSTMENT FUNCTIONS.......................................... 39
5.2.1 Explanation of terminology used................................................................................................................... 39
5.2.2 Zooming the Graphics................................................................................................................................... 42
5.3 OPTIMISING SPEED CONTROL LOOP. ....................................................................................................................... 43
5.3.1 Typical Speed Controller Responses to step-function ................................................................................... 45
5.4 OPTIMISING POSITION CONTROL LOOP.................................................................................................................... 46
5.4.1 Typical Position Controller Responses to step-function ............................................................................... 47
5.5 OPTIMISING POSITION ACCELERATION .................................................................................................................... 48
5.6 OPTIMISING THE CLOSED LOOP CONTROLLER DIFFERENTIAL PART .......................................................................... 49
5.6.1 Adjusting the differential part with rectangular cycles ................................................................................. 49
5.6.2 Adjusting the differential part with cosinusoidal cycles................................................................................ 50
5.7 GENERAL HINTS FOR ADJUSTMENT OF THE CLOSED LOOP CONTROLLER .................................................................. 51
5.8 TYPICAL CONTROLLER SETTINGS FOR DIFFERENT SYSTEMS ................................................................................... 52

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5.9 CLOSED-LOOP SET-UP PROGRAM PARAMETERS ...................................................................................................... 53

5.9.1 Closed-loop Speed Controller Parameters ................................................................................................... 53
5.9.2 Closed-loop Position Controller Parameters................................................................................................ 54
5.9.3 Acceleration setting Parameters ................................................................................................................... 54
5.9.4 Rectangular Cycles Parameters.................................................................................................................... 55
5.9.5 Cosine Cycles Test Parameters..................................................................................................................... 56
5.9.6 Set-up Parameters......................................................................................................................................... 57
6 HW-DESCRIPTIONS............................................................................................................................................... 58
6.1.1 EDC5/25 Front view ..................................................................................................................................... 58
6.1.2 EDC5/25 Rear view....................................................................................................................................... 58
6.1.3 Pin Description ............................................................................................................................................. 59
6.1.3.1 PC/Printer-Interface.................................................................................................................................................... 59
6.1.3.2 Load measurement ..................................................................................................................................................... 60
6.1.3.3 Drive Control Signals................................................................................................................................................. 62
6.1.3.4 Incremental Input for X-Head Position ...................................................................................................................... 63
6.1.3.5 Calibration Contact..................................................................................................................................................... 63
6.1.3.6 External keyboard....................................................................................................................................................... 64
6.1.3.7 Motor/Valve ............................................................................................................................................................... 65
6.1.4 Triggering Components ................................................................................................................................ 65
6.2 EDC100 .................................................................................................................................................................. 66
6.2.1 System Overview ........................................................................................................................................... 66
6.2.2 EDC100 Features ......................................................................................................................................... 67
6.2.3 EDC100 Front view ...................................................................................................................................... 68
6.2.4 EDC100 Rear view........................................................................................................................................ 68
6.2.5 Pin Description ............................................................................................................................................. 69
6.2.5.1 PC/Printer-Interface.................................................................................................................................................... 69
6.2.5.2 I4-Bus Option-slots .................................................................................................................................................... 69
6.2.5.3 Drive Interface............................................................................................................................................................ 70
6.2.5.3.1 Drive Variants.................................................................................................................................................. 71
6.2.5.3.2 Incremental Input for X-Head Position on the EHC2 (No 0834)..................................................................... 71
6.2.5.3.3 Safety related signals ....................................................................................................................................... 72
6.2.5.3.4 External Drive Control Signal Connector ........................................................................................................ 74
6.2.5.3.5 Drive Interface Safety Consideration............................................................................................................... 75
6.2.5.4 Calibration Contact..................................................................................................................................................... 78
6.2.5.5 Universal-I/O.............................................................................................................................................................. 78
6.2.6 Addressing hardware .................................................................................................................................... 78
6.3 DIFFERENCES BETWEEN EDC5/25 AND EDC100 ................................................................................................... 79
6.4 I4-BOARDS .............................................................................................................................................................. 80
6.4.1 4ETF ............................................................................................................................................................. 80
6.4.1.1 System Overview ....................................................................................................................................................... 80
6.4.1.2 Pin Description........................................................................................................................................................... 82
6.4.1.3 Analogue Output (Option).......................................................................................................................................... 83
6.4.1.4 Triggering Components.............................................................................................................................................. 84
6.4.2 INC................................................................................................................................................................ 85
6.4.2.1 System Overview ....................................................................................................................................................... 85
6.4.2.2 Pin Description........................................................................................................................................................... 87
6.4.2.3 Triggering the Components........................................................................................................................................ 88
6.4.3 4IO ................................................................................................................................................................ 89
6.4.3.1 System Overview ....................................................................................................................................................... 89
6.4.3.2 Pin Description........................................................................................................................................................... 91
6.4.3.3 Triggering the Components........................................................................................................................................ 91

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TABLES
TABLE 1 LINEARISATION MENU PARAMETERS ...................................................................................................................16
TABLE 2 4ETF ADJUSTMENT VALUES FOR MEASURING BRIDGES WITH ALTERNATING VOLTAGE SUPPLY ..........................30
TABLE 3 4ETF ADJUSTMENT VALUES FOR DIRECT VOLTAGE MEASURING SENSORS ...........................................................30
TABLE 4 CLOSED LOOP CONTROL PARAMETERS .................................................................................................................32
TABLE 5 DESCRIPTION OF POSITION MODE GAIN SETTINGS ..............................................................................................39
TABLE 6 DESCRIPTION OF LOAD MODE GAIN SETTINGS ....................................................................................................40
TABLE 7 DESCRIPTION OF POSITION MODE GAIN SETTINGS ..............................................................................................40
TABLE 8 SPEED CONTROLLER PARAMETERS.......................................................................................................................53
TABLE 9 POSITION CONTROLLER PARAMETERS ..................................................................................................................54
TABLE 10 ACCELERATION SETTING PARAMETERS ................................................................................................................54
TABLE 11 RECTANGULAR CYCLE TEST PARAMETERS ..........................................................................................................55
TABLE 12 COSINE CYCLES TEST PARAMETERS .....................................................................................................................56
TABLE 13 SET-UP PARAMETERS............................................................................................................................................57
TABLE 14 PC/PRINTER INTERFACE CONNECTOR PIN CONNECTIONS .....................................................................................59
TABLE 15 LOAD CONNECTOR PIN LAYOUT............................................................................................................................61
TABLE 16 DRIVE CONTROL CONNECTOR PIN LAYOUT ..........................................................................................................62
TABLE 17 INCREMENTAL TRANSMITTER CONNECTOR PIN LAYOUT .....................................................................................63
TABLE 18 CALIBRATION CONNECTOR PIN LAYOUT ..............................................................................................................63
TABLE 19 EXTERNAL KEYBOARD CONNECTOR PIN DESCRIPTION AT THE EDC-CASE ...........................................................64
TABLE 20 PIN DESCRIPTION FOR MOTOR/VALVE CONNECTION ..............................................................................................65
TABLE 21 PC/PRINTER INTERFACE PIN DESCRIPTION ...........................................................................................................69
TABLE 22 EDC100 EXTERNAL INCREMENTAL CONNECTOR PIN DESCRIPTION .....................................................................71
TABLE 23 POWER AMPLIFIER SAFETY SIGNALS CONNECTOR PIN DESCRIPTION ...................................................................73
TABLE 24 FRONT PANEL SAFETY SIGNAL CONNECTOR PIN DESCRIPTION ............................................................................73
TABLE 25 EHC2 DRIVE CONTROL SIGNAL CONNECTOR PIN DESCRIPTION ..........................................................................74
TABLE 26 UNIVERSAL-I/O CONNECTOR PIN DESCRIPTION ...................................................................................................78
TABLE 27 LOAD PLUG PIN DESCRIPTION ..............................................................................................................................82
TABLE 28 4ETF BRIDGE LINK CONNECTIONS ......................................................................................................................82
TABLE 29 ANALOGUE OUTPUT TECHNICAL DATA ................................................................................................................83
TABLE 30 4INC- CONNECTOR PIN DESCRIPTION ..................................................................................................................87
TABLE 31 INCREMENTAL TRANSDUCERS ADAPTATION MODULES .......................................................................................88
TABLE 32 4IO CONNECTOR PIN DESCRIPTION ......................................................................................................................91

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FIGURES
FIGURE 1 EDC25 REAR VIEW ...........................................................................................................................................14
FIGURE 2 EDC100 REAR VIEW ............................................................................................................................................14
FIGURE 3 CONNECTORS ON I4 INTERFACES..........................................................................................................................14
FIGURE 4 CORRECT SELECTION OF LINEARISATION STEPS....................................................................................................15
FIGURE 5 INCORRECT SELECTION OF LINEARISATION STEPS................................................................................................15
FIGURE 6 EDC DISPLAY WHILST IN ZOOM MODE.................................................................................................................42
FIGURE 7 STEP-INPUT SIGNAL TO STIMULATE SPEED CONTROLLER ......................................................................................44
FIGURE 8 TYPICAL RESPONSES OF THE SPEED CONTROLLER TO STEP-FUNCTION .................................................................45
FIGURE 9 STEP INPUT SIGNAL TO STIMULATE POSITION CONTROLLER ................................................................................46
FIGURE 10 TYPICAL POSITION CONTROLLER RESPONSES TO A STEP-FUNCTION .................................................................47
FIGURE 11 STEP INPUT TO STIMULATE ACCELERATION CONTROLLER .................................................................................48
FIGURE 12 RECTANGULAR COMMAND CYCLE WAVEFORM .................................................................................................49
FIGURE 13 COSINE COMMAND CYCLE GENERATION WITH AND WITHOUT A WAIT-TIME......................................................50
FIGURE 14 FRONT VIEW OF THE EDC5/25 ..........................................................................................................................58
FIGURE 15 REAR VIEW OF THE EDC5/25 ............................................................................................................................58
FIGURE 16 GENERAL DIAGRAM SHOWING ELECTRONIC STRUCTURE .................................................................................66
FIGURE 17 EDC100FRONT VIEW ........................................................................................................................................68
FIGURE 18 EDC100 REAR VIEW .........................................................................................................................................68
FIGURE 19 DIAGRAMMATIC LAYOUT OF DRIVE INTERFACE................................................................................................70
FIGURE 20 SAFETY RELATED SIGNALS CONNECTIONS FROM THE POWER AMPLIFIER TO THE FRONT PANEL.....................72
FIGURE 21 DIAGRAMMATIC LAYOUT OF RELAYS, EMERGENCY STOP, LIMIT SWITCH AND ON-KEY..................................76
FIGURE 22 VIEW OF 4ETF COMPONENTS ...........................................................................................................................81
FIGURE 23 VIEW OF ANALOGUE OUTPUT COMPONENTS ....................................................................................................84
FIGURE 24 4INC BLOCK DIAGRAM ....................................................................................................................................85
FIGURE 25 DUAL AND SINGLE ADAPTATION MODULES......................................................................................................88
FIGURE 26 4IO BLOCK DIAGRAM .......................................................................................................................................89

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1 Safety Hints
Warning Signs: Always heed notices associated with the following warning signs:

Danger by Electricity General Warning

and its effects General Hint

♦ Only Qualified personnel should perform transport, installation, commissioning and maintenance
operations. They must be well acquainted with all aspects of the equipment and qualified to carry
out the relevant operation.

♦ All qualified personnel must be acquainted with and adhere to the following standards and
directives:

IEC 364 or CENELEC HD 384 or DIN VDE 0100

national rules for prevention of accidents or VBG 4

Consult this documentation during installing and starting of the appliance. Wrong handling can
cause damage to property or persons. Always check system specification and installation
conditions (referring to unit type label and associated documentation).

♦ The instrumentation contains components that can be damaged by electrostatic discharges during
handling. Always wear an earth strap to dissipate any electrostatic body charge by before handling
any instrumentation. Avoid contact with highly static materials (synthetic fibres or plastic sheets
etc.) when handling instruments and place all units on a conductive base mat.

Do not open the instrument casing and keep covers fitted during operation. Failure to follow
this procedure can result in death, personal injury and property damage.

Remove mains plug before opening the instrument casing. Failure to follow this procedure
can result in death, personal injury and property damage.

Never insert or remove any electrical connector in the servo amplifier whilst the mains
power is switched on as permanent damage can be caused to both the system and person.

Always wait 2 minutes after disconnecting the mains electrical supply from the servo
amplifier before touching or removing boards or connectors as a charged voltage may still
retain a charged voltage. Some internal capacitors can remain charged with dangerous
voltages for up to two minutes after switching off the supply voltage. For safety reasons,
measure the intermediate circuit voltage and wait until this has reduced to less than 40V.

-Conformity, Directives and Standards

Doli instrumentation is suitable for use with electrical systems or testing machines.

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After installation with a testing machine, the system must not be used until compliance with the
EU Testing Machine Directive 89/392/EWG has been confirmed. EN 60204 and EN 292-2 standards
must also be adhered to.

Doli instrumentation is manufactured in accordance with the Low Voltage Directive 73/23/EWG, and
the co-ordinated standards EN 50178 in connection with EN 60204.

Provided the components and procedures detailed in this installation manual and associated
documentation have been followed, then the protection objectives of EMV regulation (EMVG) for
testing machines and systems are met in accordance with the following standards (correspondence
with the EMV-Directive 89/336/EWG):

♦ EN 50082 generic specification interference immunity, industry

♦ EN 50081 generic specification emission, industry

Hints on installations to meet EMV requirements, e.g. screening, earthing, handling of plugs and
installation of wires etc. are located in this documentation.

The instrument manufacturer, testing machine manufacturer/modifier and commissioning engineer are
responsible for ensuring their content conforms with all relevant electrical and safety standards.

The following qualifications are required to handle, install or commission this

equipment
Transportation: only persons knowledgeable in the handling of electrostatic
critical components

Installation: only persons having electro-technical training

Commissioning: only persons having a wide electrical engineering/motive power

engineering knowledge

Legal Use of the Instruments

The instrument must only be used with a 230/115 V, 50/60 Hz. single-phase mains supply

Instrumentation must only be used in accordance with the environmental conditions defined in this
manual.

The instrumentation is designed for use with testing machine systems and must only to be operated as
an integrated component.

EMV-Directive (89/336/EWG) and EG-Low Voltage Directive 73/23/EWG must have

been fully conformed with before a system is handed to a client after commissioning.

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2 Installation Manual
Before commencing any installation or commissioning it is essential all personnel are familiar and
follow all requirements described in the Safety Hints on pages Chapter 1 of this manual
This manual has been written in the form of a checklist and provides guidance on how to set-up a
testing machine correctly.

2.1 Installation Requirements

PC
MKEEP-Program
Serial cable PC–EDC
Debug cable

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3 Manual User set-up menu

Switch on the unit using the On/Off switch located on the EDC rear panel.
The front panel ON lamp should not be illuminated, (ON lamp indicates the system is controlling and
is not a mains-on indicator).
If the ON lamp is illuminated, then it is necessary to perform one of the following functions :
Press and release the front panel Emergency stop button
Press function key "F2" and depress Digipoti knob at the same time
Switch the EDC off and on again on using the mains On/Off-Switch.
The "system check" message is shown on the front panel display whilst an internal check sequence is
performed, it is only possible to enter the set-up menu after this the message disappears
Open the set-up menu by pressing the "F1", ∆(Up), ∇(Down) keys at the same time.
Turn the Digipoti knob (or press "F2"function key) to move the cursor to the required menu item.
Pressing either the Digipoti knob or function key "F3" selects the marked menu item and calls up the
associated submenu.
Move the cursor to the required parameter by turning the Digipoti knob or pressing "F2" key.
Press the Digipoti knob or "F3" key and enter the required value using the numeric keypad or select
parameter entry and then store it by pressing the Digipoti knob or "F3" key.
After entry the cursor automatically moves to the next parameter.
To modify an input, select the parameter and press Digipoti knob or "F3" key, then press "F1"
(CLEAR KEY) key to erase the value. A new value can now be entered.
To leave a submenu or the main menu, press "F1" (ESC) key.
Attention: The machine data must be entered before attempting to enter additional
parameters. The most important data is described below.
SpeeT: Speed controller cycle time.
The value must be set between 0.5 ms and 2.5 ms. (for the EDC5/25 it is fixed at 2.5 ms).
PosT: Position controller cycle time.
The value must be set between 1 ms and 10 ms.
(PosT must be an integral multiple of SpeeT value).
Standard values are 2.5 ms for SpeeT and 10 ms for PosT

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3.1 Set-up Menu Structure

Key Inscription Resulting Action
F1 ESC Back to the previous menu
F2 ∇ Moves the arrow cursor “⇒“ down (in the parameter menu)
F3 ↵ Starts the editing process for the marked parameter
Digipoti Moves the arrow cursor “⇒“up and down (in the parameter menu)
Digipoti key Starts the editing process for the marked parameter

Setup machine 1 Machine data Linearisation

Setup machine 2 Sensors X-head

Setup machine 3 Load

Setup machine 4 Extension

Digipoti

Sensor 5

Sensor 16

Closed loop control X-head

EDC-Setup Menu Load

by pressing the
keys
UP/DOWN/F1 Extension
at the same time.

ON lamp must not Output channel Command output

be illuminated

Output channel 2

Output channel 16

Bit input Bit input 1

Bit input 10

Bit output Bit output 1

General data

Administration Bit output 10

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3.2 Machine data

For DoPE Version 2.00 (for PE-Version 2.00 look at EDC-Display F1-INFO)
Name (old) Comment Value / Choice Unit Page
SpeeT Speed controller cycle time s
Pos T (Rgzyk) Position controller cycle time s
CtrlS (Rgstr) Controller type selection SPINDLE_SP ! none
SPINDLE !
HYDRAULIC !
PNEUMATIC !
DataT (Mwref) Data acquisition refresh rate s
TMode (Tmode) Machine is controlled CTRL ! none
Only measured values are detected. NO CTRL !
Bypas (Bypas) Bypass or drain valve fitted on hydraulic systems YES ! none
NO !
XhDir (Dir) Controller output positive movement upwards UP=POSITIV ! none
Controller output positive movement downwards DOWN=POSITIV !
MoEnc (1.0) Transmission ratio ~ drive to encoder none
EncXh (Scale) Transmission ratio ~ encoder to X-head travel U/mm
Bopen (Bopen) Brake opening time s
Bclos (Bclos) Brake closing time s
PArea (KolbF) Piston area of hydraulic machine mm2, cm2, dm2,
Fmax (Fmax) Maximum machine load capacity N, kN
F100%(F100%) Nominal machine load N, kN
Stiff Machine stiffness (currently not used) kN/mm
ClCon Clamp lock connector number (X1, ...)
ClLim Clamp lock output signal HIGH ACTIVE ! none
LOW ACTIVE !
ClCha Clamp lock channel
ShCon Shield/Safety screen connector number (X1, ..)
ShTyp Shield/Safety screen type SIMPLE ! none
LOCKED !
ShTim Shield/safety screen locking time (0 to 2 s) s
Linearization Linearisation menu on separate sheet

3.3 Sensor data 1 to 4

Name (old) Comment S1 X-head S2 Load S3 Extension S4 Digipoti Page
Conne Connector No (X1,X2, ...)
Sign Sign INV ! INV ! INV ! INV (ExVor) !
N-INV ! N-INV ! N-INV ! N-INV !
Ctrl Control active YES ! YES ! YES ! Not applicable
NO ! NO ! NO !
LimCt Reaction on range limit STOP ! STOP ! STOP ! Not applicable
detection STATE ! STATE ! STATE !
ConCt Reaction on disconnection of STOP ! STOP ! STOP ! Not applicable
connector STATE ! STATE ! STATE !
Integ Integration time (analogue Ch.) s s s Not applicable
EEPRO E2PROM active YES ! YES ! YES ! Not applicable
NO ! NO ! NO !
Not applicable in case of E2PROM being active
Init Initialisation (Sinit) (Finit) (Dinit) Not applicable
Nomin Nominal value Not applicable
Unit Dimension (unit) Not applicable
Offse Offset
ULimi(Pomax) Upper range limit in % Not applicable
LLimi(Pomin) Lower range limit in % Not applicable
Scale Signal period (Skali/4)
Corre Correction value Not applicable

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3.4 Closed loop control

Name (old) Comment Ctrl x-head Ctrl load Extension Page
Accel Acceleration mm/s² (Xppne) N/s² mm/s²
Speed Speed mm/s (Xpnen) N/s mm/s
WndSi Target window size mm (TWinx) N mm
WndTi Target window time s (TWinT) s s
Devia Control deviation mm (Devia) N mm
DevRe Control detection reaction STOP ! STOP ! STOP !
STATE ! STATE ! STATE !
PosK P-part, position controller (Rgp k) (FRgp k) (Drgp k)
PosTi I- part, position controller (Rgp ti)
Normally set to zero.
PoGTd D- part, for position generator
SpeK P- part for speed controller. (Rgpxp k) (Frgpxp k) (Drgpxp k)
SpeTi I- part for speed controller. (Rgpxp ti) (Frgpxp ti) (Drgpxp ti)
AccK P- part for acceleration controller
(only for pneumatic systems)
Integ Data-integration time for s s (Fintg) s
controller (only analogue Channels)

3.5 Output channel

Name (old) Comment Value / Choice Unit Page
Conne Connector No (X1,X2, ...) none
Sign (Stgsi) Sign INV none
N-INV
Max (Stg+) Maximum set value (–100% to +100%) %
Min (Stg-) Minimum set value (–100% to +100%) %
Init Initialisation value (offset)(–100% to +100%) %
Volta (Volta) Max voltage for DDA04-06 Volt [V]
Curre (Curre) Max current for DDA04-06 Ampere [A]

3.6 Bit-input
Name (old) Comment Value / Choice Unit Page
Conne Connector No (X1,X2, ...)
StMsk Stop mask (I/O Bit for stop action like Stop-key)
StLev Stop level (active high/low)

3.7 Bit-output
Name (old) Comment Value / Choice Unit Page
Conne Connector No (X1,X2, ...)
Init Initial value

3.8 General data

Name (old) Comment Value / Choice Unit Page
MaCnt (MaCnt) Number of machines connected 1-4
MaIo (MaIo) Machine set-up changed via external hardware YES
NO
Super Supervisor mode YES
NO
SPass Supervisor password (0 selects no password) 0 to 65535
Logo DOLI-Logo appears on the EDC Display when YES
switched on NO

3.9 Administration
Copy SETUP Copy actual set-up to another EDC (currently not implemented) Page
Erase SYSEEPROM Erase SYSEEPROM data
Erase NOVRAM Erase actual X-head position in the NOVRAM

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3.10 Sensor data 5 to 16

Name Comment Sensor 5 Sensor 6 Sensor 7 Sensor 8
Conne Connector No (X1,X2, ...)
Sign Sign INV ! INV ! INV ! INV !
N-INV ! N-INV ! N-INV ! N-INV !
LimCt Reaction on range limit detection STOP ! STOP ! STOP ! STOP !
STATE ! STATE ! STATE ! STATE !
Integ Integration time s s s s
(only analogue Channels)
EEPRO EEPROM active YES ! YES ! YES ! YES !
NO ! NO ! NO ! NO !
Not applicable if EEPROM selected active
Init Initialisation
Nomin Nominal value
Unit Dimension (unit)
Offse Offset
ULimi Upper range limit in %
LLimi Lower range limit in %
Scale Signal period
Corre Correction value

Name Comment Sensor 9 Sensor 10 Sensor 11 Sensor 12

Conne Connector No (X1,X2, ...)
Sign Sign INV ! INV ! INV ! INV !
N-INV ! N-INV ! N-INV ! N-INV !
LimCt Reaction on range limit detection STOP ! STOP ! STOP ! STOP !
STATE ! STATE ! STATE ! STATE !
Integ Integration time s s s s
(only analogue Channels)
EEPRO E2PROM active YES ! YES ! YES ! YES !
NO ! NO ! NO ! NO !
Not applicable if EEPROM selected active
Init Initialisation
Nomin Nominal value
Unit Dimension (unit)
Offse Offset
ULimi Upper range limit in %
LLimi Lower range limit in %
Scale Signal period
Corre Correction value

Name Comment Sensor 13 Sensor 14 Sensor 15 Sensor 16

Conne Connector No (X1,X2, ...)
Sign Sign INV ! INV ! INV ! INV !
N-INV ! N-INV ! N-INV ! N-INV !
LimCt Reaction on range limit detection STOP ! STOP ! STOP ! STOP !
STATE ! STATE ! STATE ! STATE !
Integ Integration time s s s s
(only analogue Channels)
EEPRO E2PROM active YES ! YES ! YES ! YES !
NO ! NO ! NO ! NO !
Not applicable if E2PROM selected active
Init Initialisation
Nomin Nominal value
Unit Dimension (unit)
Offse Offset
ULimi Upper range limit in %
LLimi Lower range limit in %
Scale Signal period
Corre Correction value

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3.11 EDC-Connector Description

Rear View
OUT CAL. GND
EDC 5/25
Keyboard 1
Fuses 220V/110V
0

A B C
X22 Option
Motor/Valve
The front panel
Digipoti control is
A B C
X21 Option No X63A

X4 X1 X7 X14
Motion Control PC/Printer Crosshead Travel Load

Figure 1 EDC25 rear view

Rear View
A
X5 EDC 100
X6 X3 Keyboard
B

C The front panel

Digipoti control is
0 No X63A
X28 X27 X26 X25 X24 X23 X22 X21
1

X4 X2 X7 X1
Motion Control I/O Crosshead Travel PC/Printer

Figure 2 EDC100 Rear View

Connectors fitted to various I4-Boards

4ETF 4TAST 4INC 4I/O

A analogue A Digipoti A INC-Sensor 0

output keys
LED`s

Bit-input 0 Bit-input 0
B CF-Sensor 0 B Bit-output 0 B
Bit-input 0 Bit-output 0

Bit-input 1
C Bit-output 1 C INC-Sensor 1

Figure 3 Connectors on I4 Interfaces

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3.12 Linearisation Menu

“Protected“ machine data can be entered whilst in the Linearization submenu.
After leaving the submenu, this data is only transferred to the E2PROM when the write sequence is
initiated and the sensor plug setting button activated.
If the sensor plug button is not activated, the data remains unchanged in the E2PROM and the EDC
utilises the ‘old’ data upon leaving the set-up menu.
Linearisation can compensate for a non-linear load channel. Up to 10 sets of correction data can be
entered and each data set contains the indicated value (Mv i , the load value indicated on EDC) and
true value (Ref. i, the true load value from a reference device).
Parameter No. contains the number of valid steps. If No. = 0 or 1, then Linearisation is not activated.

Correct !

Not linearized Mv 1 = Ref. 1

Linearized Mv 2 ≠ Ref. 2
Mv 3 ≠ Ref. 3
Mv 4 = Ref. 4
e.g.
0,00 kN, 0,00 kN
2,00 kN, 2,02 kN
8,00 kN, 8,02 kN
10,00 kN, 10,00 kN

Mv 1 Mv 2 Mv 3 Mv 4

Figure 4 Correct selection of Linearisation steps

Incorrect !

Not linearized Mv 1 ≠ Ref. 1

Linearized Mv 2 ≠ Ref. 2
Wrong Mv 3 ≠ Ref. 3
Mv 4 ≠ Ref. 4
e.g.
1,00 kN, 1,01 kN
2,00 kN, 2,02 kN
8,00 kN, 8,02 kN
10,00 kN, 10,01 kN

Mv 1 Mv 2 Mv 3 Mv 4

Figure 5 Incorrect selection of Linearisation steps

The Linearisation steps must be carefully selected in order to achieve the best result. If the measured
value and the reference value are identical for the first step then values below this step are not
linearised. Also if the measured value and the reference value are identical for the last step then
values above this step are not linearised (see. Figure 4).
If values are entered as in Figure 5, i.e. with the non-linearised output not passing through zero then
this results in offset errors.

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Linearization menu Parameters.

Machine Parameter Choice Remark
Number No. of valid Linearisation steps.
No.= 0 Linearisation not active.
No.= 1 Not allowed, resets to 0.
Mv 1 N, kN Measured value Linearisation step 1
Ref. 1 N, kN True value for Mv 1 (unit as Mv 1)
Mv 2 N, kN Measured value Linearisation step 2
Ref. 2 N, kN True value for Mv 2
Mv 3 N, kN Measured value Linearisation step 3
Ref. 3 N, kN True value for Mv 3
Mv 4 N, kN Measured value Linearisation step 4
Ref. 4 N, kN True value for Mv 4
Mv 5 N, kN Measured value Linearisation step 5
Ref. 5 N, kN True value for Mv 5
Mv 6 N, kN Measured value Linearisation step 6
Ref. 6 N, kN True value for Mv6
Mv 7 N, kN Measured value Linearisation step 7
Ref. 7 N, kN True value for Mv 7
Mv 8 N, kN Measured value Linearisation step 8
Ref. 8 N, kN True value for Mv 8
Mv 9 N, kN Measured value Linearisation step 9
Ref. 9 N, kN True value for Mv 9
Mv 10 N, kN Measured value Linearisation step 10
Ref. 10 N, kN True value for 10

Table 1 Linearisation menu Parameters

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3.13 Examples of different Sensor Types:

3.13.1 Incremental Transducer as Position Transducer
Position transducer: (e.g.: Connector number X7)
Incremental transducer (e.g. 2500 increments per revolution)
E2PROM (readable and writeable with the MKEEPROM-program)
[Header data]
Transducer code : 8000 (customer specific)
Output channel code :0
STE/STA-Code :0
Identity number : 784 (Doli specific)
- Index : - (1. Layout)
- SerNo :0
Transducer class : Incremental
Data version : (Doli specific)
Sensor Connector data Sensor data
Supply voltage 1 :5V Transducer type : Incremental transducer
Supply voltage 2 :0 Transducer nom. value unit : Inc/Rev
Supply voltage 3 :0 Signal period : 2500
Current for supply voltage 1 : 0.02 A Correction factor :1
Current for supply voltage 2 :0 Meas. position :0
Current for supply voltage 3 :0 Transducer signal type : TTL
Signal type at input :TTL Reference mark : none
Signal type at output :TTL Reference first distance :0
Factor of Interpolation :1 Reference Nominal distance :0
Maximum input frequency : 5000 kHz Dislocation of the mean reference :0
Maximum output frequency : 5000 kHz Transducer frequency limit :0
Polarity : positive
Meas. Range limit - negative :
- positive :
The data entered into the Sensor E2PROM is similar to that entered in the set-up as sensor data,
Attention: EDC 5/25 can NOT read connector- E2PROM at connector X7, set the parameter EEPRO to NO.
Sensor adjustment parameters in the set-up menu
Name (old) Comment S1 X-head
Conne Connector number (X1,X2, ...) X7
Sign Sign INV !
N-INV ⌧
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0 s
(only analogue Channels)
EEPRO E2PROM active YES !
NO ⌧
Not applicable, if E2PROM is active
Init Initialisation 0
Nomin Nominal value 0
Unit Dimension (unit) Inc/U
Offse Offset 0
ULimi (Pomax) Upper range limit in % 100
LLimi (Pomin) Lower range limit in % 100
Scale Signal period 2500
Corr Correction value 0

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3.13.2 Draw Wire Position Transducer

Position transducer: (e.g.: Connector number X7)
Draw Wire transducer 9IS, linear incremental transducer (e.g.: 5000 increments per revolution)

E2PROM (readable and writeable with the MKEEPROM-program)

[Header data]
Transducer code : 8000 (customer specific)
Output channel code :0
STE/STA-Code :0
Identity number : 922 (Doli specific)
- Index : a (2. Layout)
- SerNo :0
Transducer class : Incremental
Data version : (Doli specific)
Sensor Connector data Sensor data
Supply voltage 1 :5V Transducer type : Linear transducer
Supply voltage 2 :0 Transducer nom. value unit :m
Supply voltage 3 :0 Signal period : 0.000032768 m/Inc
Current for supply voltage 1 : 0.085 A Correction factor :1
Current for supply voltage 2 :0 Meas. position :2
Current for supply voltage 3 :0 Transducer signal type : Sinusoidal 11µA
Signal type at input : Sinusoidal 11µA Reference mark : none
Signal type at output :TTL Reference first distance :0
Factor of Interpolation : 10 Reference Nominal distance :0
Maximum input frequency : 250 kHz Dislocation of the mean reference :0
Maximum output frequency : 2500 kHz Transducer Limit frequency : 250 kHz
Polarity : positive
Meas. Range limit - negative : 100 % (of measuring range)
- positive : 100 % (of measuring range)
The data entered into the Sensor-E2PROM is similar to that entered in the set-up as sensor data.
Attention: EDC 5/25 can NOT read connector-E2PROM at connector X7, set the parameter EEPRO to NO.
Sensor adjustment parameters in the set-up menu
Name (old) Comment S1 X-head As the sensor is handled like a linear transducer, the
Conne Connector number (X1,X2, ...) X7 signal period must be recalculated.
Sign Sign INV !
N-INV ⌧ Signal period = Circumference of the pulley block /
Ctrl Control active YES ⌧ Increments per revolution.
NO ! (e.g.. 0.000032768 = 0.16384 m/5000 Inc/rev)
LimCt Reaction on range limit STOP ⌧
detection STATE ! In order to get the value of the signal period for the
ConCt Reaction on disconnect STOP ⌧ set-up adjustment, the interpolation factor must be
Connector detection STATE ! referred to.
Integ Integration time 0 s (e.g. 0.0000032768 = 0.16384m / 5000 Inc/rev * 10)
(only analogue Channels)
EEPRO E2PROM active YES !
NO ⌧
Not applicable, if E2PROM is active
Init Initialisation 0
Nomin Nominal value 2
Unit Dimension (unit) m
Offse Offset 0
ULimi (Pomax) Upper range limit in % 100
LLimi (Pomin) Lower range limit in % 100
SigPe Signal period 3.2768 E -6
Corr Correction value 1

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3.13.3 Analogue Position Transducer

Position transducer (z. B.: Connector number X22B for EDC100 or X21B for EDC5/25)
Analogue position transducer: (e.g.: position sensor with 0.3 m nominal value and 10 mV/V)

E2PROM (readable and writeable with the MKEEPROM-program)

Transducer code : 000f (customer specific)
Output channel code :0
STE/STA-Code :0
Identity number : 747 (Doli specific)
Index : a (1. Layout)
SerNo :0
Transducer class : with measuring bridge
Data version : (Doli specific)
Operation data
Strain gauge reference : No
Transducer has own supply : No
Operation frequency-Min : 0 Hz
-Max : 5000 Hz
Maximum supply voltage : 10 V
Maximum output signal : --- (value is not used)
Minimum Impedance : 360 Ω
Transducer nominal value unit :m
Transducer nominal value : 0.3
Transducer Offset :0
Meas. Range limit - negative : 130 % (100% = Nominal value of the transducer)
- positive : 130 % (100% = Nominal value of the transducer)
Reference nominal value : 10 mV/V
Reference Tolerance - upper : 0.5 %
- lower : 0.5 %
Correction value : 1 ( = Sensitivity of transducer at nominal value / Nominal value of the reference inside sensorplug)
The data entered into the Sensor- E2PROM is similar to that entered in the set-up as sensor data. The initialisation value
can be calculated by using list 47 the of the driver documentation. Reference nominal value * correction value * largest
meas. range limit (e.g. 10 mV/V * 130 % * 1 = 13 mV/V, this results in an Init-value of 108)
Sensor adjustment parameters in the set-up menu
Name (old) Comment S1 X-head
Conne Connector number (X1,X2, ...) X22B
Sign Sign INV !
N-INV ⌧
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0.02 s
(only analogue Channels)
EEPRO E2PROM active YES !
NO ⌧
Not applicable, if E2PROM is active
Init Initialisation 108
Nomin Nominal value 0.3
Unit Dimension (unit) m
Offse Offset 0
ULimi (Pomax) Upper range limit in % 130
LLimi (Pomin) Lower range limit in % 130
Scale Signal period 0
Corr Correction value 1

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3.13.4 Analogue Load Transducer

Load transducer (e.g. 2mV/V, 10 kN, Connector number X21B for EDC100 or X14 for EDC5/25)
Analogue load transducer (e.g.: load cell with 10 kN nominal value and 2 mV/V)

E2PROM (readable and writeable with the MKEEPROM-program)

Transducer code : 8000 (customer specific)
Output channel code :
STE/STA-Code :
Identity number : 580 (Doli specific)
Index : - (1. Layout)
SerNo :
Transducer class : with measuring bridge
Data version : (Doli specific)
Operation data
Strain gauge reference : No
Transducer has own supply : No
Operation frequency-Min : 0 Hz
-Max : 5000 Hz
Maximum supply voltage : 10 V
Maximum output signal : --- (value is not used)
Minimum Impedance : 380 Ω
Transducer nominal value Unit : Newton
Transducer Nominal value : 10000
Transducer Offset :0
Meas. Range limit - negative : 130 % (100% = Nominal value of the transducer)
- positive : 130 % (100% = Nominal value of the transducer)
Reference nominal value of the : 2 mV/V
Reference tolerance - upper : 0.5 %
- lower : 0.5 %
Correction value : 1 ( = Sensitivity of transducer at nominal value / Nominal value of the reference inside sensorplug)
The data entered into the Sensor- E2PROM is similar to that entered in the set-up as sensor data. The initialisation value
can be calculated by using list 47 the of the driver documentation. Reference nominal value * correction value * largest
meas. range limit (e.g. 2 mV/V * 130 % * 1 = 2.6 mV/V, this results in an Init-value of 32)
Sensor adjustment parameters in the set-up menu
Name (old) Comment S2 Load
Conne Connector number (X1,X2, ...) X21B
Sign Sign INV ⌧
N-INV !
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0.02 s
(only analogue Channels)
EEPRO E2PROM active YES ⌧
NO !
Not applicable, if E2PROM is active
Init Initialisation 32
Nomin Nominal value 10000
Unit Dimension (unit) N
Offse Offset 0
ULimi (Pomax) Upper range limit in % 130
LLimi (Pomin) Lower range limit in % 130
Scale Signal period 0
Corr Correction value 1

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3.13.5 Analogue Pressure Transducer

Pressure transducer (e.g.: Connector number X21B for EDC100 or X14 for EDC5/25) Analogue Pressure transducer (e.g.
2mV/V for 50 MPa) 1 bar is equal to 100000 Pa.

E2PROM (readable and writeable with the MKEEPROM-program)

Transducer code : 0040 (customer specific)
Output channel code :0
STE/STA-Code :0
Identity number : 580 (Doli specific)
Index : a (1. Layout)
SerNo :0
Transducer class : with measuring bridge
Data version : (Doli specific)
Operation data
Strain gauge reference : No
Transducer has own supply : No
Operation frequency-Min : 0 Hz
-Max : 5000 Hz
Maximum supply voltage : 10 V
Maximum output signal : --- (value is not used)
Minimum Impedance : 360 Ω
Transducer nominal value unit : Pascal
Transducer Nominal value : 50,000,000
Transducer Offset :0
Meas. Range limit - negative : 130 % (100% = Nominal value of the transducer)
- positive : 130 % (100% = Nominal value of the transducer)
Reference nominal value : 2 mV/V
Reference tolerance - upper : 0.5 %
- lower : 0.5 %
Correction value : 1 ( = Sensitivity of transducer at nominal value / Nominal value of the reference inside sensorplug)
The data entered into the Sensor- E2PROM is similar to that entered in the set-up as sensor data. The initialisation value
can be calculated by using list 47 the of the driver documentation. Reference nominal value * correction value * largest
meas. range limit (e.g. 2 mV/V * 130 % * 1 = 2.6 mV/V, this results in an Init-value of 32)
Sensor adjustment parameters in the set-up menu
Name (old) Comment S2 Load
Conne Connector number (X1,X2, ...) X21B
Sign sign INV ⌧
N-INV !
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0.02 s
(only analogue Channels)
EEPRO E2PROM active YES ⌧
NO !
Not applicable, if E2PROM is active
Init Initialisation 32
Nomin Nominal value 50,000,000
Unit Dimension (unit) Pa
Offse Offset 0
ULimi (Pomax) Upper range limit in % 130
LLimi (Pomin) Lower range limit in % 130
Scale Signal period 0
Corr Correction value 1

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3.13.6 Analogue Tension Transducer

Tension transducer (z. B.: Connector number X22B for EDC100 or X21B for EDC5/25)
Analogue tension transducer (2mV/V, nominal value 2mm)

E2PROM (readable and writeable with the MKEEPROM-program)

Transducer code :0
Output channel code :0
STE/STA-Code :0
Identity number :0
Index : - (1. Layout)
SerNo :0
Transducer class : with measuring bridge
Data version : (Doli specific)
Operation data
Strain gauge reference : No
Transducer has own supply : No
Operation frequency-Min : 0 Hz
-Max : 5000 Hz
Maximum supply voltage : 10 V
Maximum output signal : --- (value is not used)
Minimum Impedance : 360 Ω
Transducer nominal value unit :m
Transducer nominal value : 50,000,000
Transducer offset :0
Meas. Range limit - negative : 130 % (100% = Nominal value of the transducer)
- positive : 130 % (100% = Nominal value of the transducer)
Reference nominal value : 2 mV/V
Reference Tolerance - upper : 0.5
- lower : 0.5
Correction value : 1 ( = Sensitivity of transducer at nominal value / Nominal value of The initialisation value can
be calculated by using list 47 the of the driver documentation. Reference nominal value * correction value * largest meas.
range limit (e.g. 2 mV/V * 130 % * 1 = 2.6 mV/V, this results in an Init-value of 32)
Sensor adjustment parameters in the set-up menu
Name (old) Comment S3 Tension
Conne Connector number (X1,X2, ...) X21B
Sign sign INV ⌧
N-INV !
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0.02 s
(only analogue Channels)
EEPRO E2PROM active YES ⌧
NO !
Not applicable, if E2PROM is active
Init Initialisation 32
Nomin Nominal value 0.002
Unit Dimension (unit) m
Offse Offset 0
ULimi (Pomax) Upper range limit in % 130
LLimi (Pomin) Lower range limit in % 130
Scale Signal period 0
Corr Correction value 1

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3.13.7 Linear incremental Tension Transducer

Tension transducer (e.g.: Connector number X22A for EDC100 or X21A for EDC 5/25)
Linear incremental tension transducer (e.g.: resolution 0.1µm, Meas. position 35mm)

E2PROM (readable and writeable with the MKEEPROM-program)

[Header data]
Transducer code : 8000 (customer specific)
Output channel code :0
STE/STA-Code :0
Identity number : (Doli specific)
- Index : b (3. Layout)
- SerNo :0
Transducer class : Incremental
Data version : (Doli specific)
Sensor Connector data Sensor data
Supply voltage 1 :5V Transducer type : Linear transducer
Supply voltage 2 :0 Transducer nom. value unit :m
Supply voltage 3 :0 Signal period : 0.0000001 m/Inc
Current for supply voltage 1 : 0.000011 A Correction factor :1
Current for supply voltage 2 :0 Meas. position : 0,035
Current for supply voltage 3 :0 Transducer signal type : TTL
Signal type at input : TTL Reference mark : none
Signal type at output : TTL Reference first distance :0
Factor of Interpolation : 10 Reference nominal distance :0
Maximum input frequency : 250 kHz Dislocation of the mean reference :0
Maximum output frequency : 2500 kHz Transducer frequency limit : 250 kHz
Polarity : positive
Meas. Range limit - negative : 100 %
- positive : 100 %

The data entered into the Sensor E2PROM is similar to tat entered in the set-up as sensor data

Sensor adjustment parameters in the set-up menu

Name (old) Comment S3 Tension
Conne Connector number (X1,X2, ...) X7
Sign sign INV !
N-INV ⌧
Ctrl Control active YES ⌧
NO !
LimCt Reaction on range limit STOP ⌧
detection STATE !
ConCt Reaction on disconnect STOP ⌧
Connector detection STATE !
Integ Integration time 0 s
(only analogue Channels)
EEPRO E2PROM active YES !
NO ⌧
Not applicable, if E2PROM is active
Init Initialisation 0
Nomin Nominal value 0.035
Unit Dimension (unit) m
Offse Offset 0
ULimi (Pomax) Upper range limit in % 100
LLimi (Pomin) Lower range limit in % 100
Scale Signal period 0.0000001
Corr Correction value 1

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3.13.8 Example for the connection of an external keyboard

For safety reasons, the external keyboard HALT key directly controls the EDC (i.e. not via the PC).
The stop function can be assigned to any key by setting the appropriate bit number as detailed. It is
possible to assign the stop function to multiple keys by summing the Set-up input numbers.
Bit-Input: The keys to initiate the stop function can be defined with the Stop-Mask (StMsk). Enter the
value of the key in the set-up menu. If 0 is entered, no key is allocated to stop.
The Stop-Level (StLev) determines, whether the stop function is controlled high active (set BIT) or
low active.
Bit-Output: Allows definition of which LED's illuminate on the keyboard. Enter the value of the key
in the set-up menu. The default adjustment is 0, i.e. no LED lights.
Key Bit Set-up
1 2 3 No No Input
number
1 0 1
4 5 6 2 1 2
3 2 4
7 8 9 4 3 8
5 4 16
6 5 32
10 11 12 7 6 64
8 7 128
9 8 256
13 14 15 10 9 512
11 10 1024
12 11 2048
16 13 12 4096
Digipoti 14 13 8192
15 14 16384
16 15 32768
Bit-Input
Name (old) Comment Value/Choice Unit Page
Conne Connector number (X1,X2, ...) X25A
StMsk Stop mask (0-32767) 16512
StLev Stop level (0-32767) 16512

Bit-Output
Name (old) Comment Value/Choice Unit Page
Conne Connector number (X1,X2, ...) X25A
Init Initial value (0-32767) 0

In the above example, the external keyboard is connected to a 4TAST-Card at Connector number
X25A. Keys 8 and 15 are assigned with the stop function as the two bits associated with these keys
have been set (i.e. StLev = 128+16384=16512).
The stop function can be initiated by pressing both or either one of these keys (high active) The
Init-value for the Bit-output has been set to 0 in order to have no LED illumination as this depends
upon the connected software.

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3.14 Set-up Installation Aid

This chapter describes how to adjust the set-up of EDC 5/25 and EDC 100 instruments.
The machine data section must be completed first before entering other parameters.

3.14.1 Machine Data

SpeeT: This parameter defines the basic system clock signal that is used to synchronise the
processing of all sensor data and the transmitting of signals to the controller thus
ensuring all data is sampled at exactly the same time.
The SpeeT parameter values must be between 0.0005s and 0.0025s for the EDC 100.
The EDC 5/25 has a 0.0025s fixed value.
Attention: All other time bases are derived from the SpeeT time base and must be
selected as an integral multiple of the SpeeT value.
PosT: Position controller time base
The built-in position generator and position controller are controlled by this time base.
The value for PosT must be an integral multiple of SpeeT and be selected between 1 ms
and 0.01 s. A common value is 0.01 s for EDC 5/25 and EDC 100.
CtrlS: Controller structure mode. The following modes can be selected :
SPINDEL_SP (speed controller, internal, integrated in the software)
SPINDEL (speed controller, external)
HYDRAULICS (Hydraulic system)
PNEUMATICS (Pneumatic System).
DataT: Time base used for evaluation of the measured data (other than control loop).
With "standalone" appliances, data is evaluated by the application program
(e.g. tensile/compression test).
For PC-controlled systems, this time base controls data transmission to the PC.
The value for DataT must be an integral multiple of SpeeT. The value normally is
selected between 0.01 s and 0.1 s. (0.02 s. is a common value)
TMode: Selects whether EDC controls the machine. The following modes can be selected :
CTRL - EDC controls the machine and processes the data values.
NO CTRL - EDC does NOT control machine or influence operation and only
processes data values.
Bypas: This parameter is only relevant for hydraulic systems having a controlled dump valve.
XhDir: This parameter determines whether a positive crosshead speed signal corresponds to an
upward or a downward crosshead movement.
This information is required for the correct interpretation by the "UP" and "DOWN",
key's as well as the associated lamps.

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MoEnc: Transmission ratio between motor and encoder.

Ratio of any transmission gearing fitted between the motor shaft and encoder.
Set to 1 if encoder directly driven and for hydraulic machines.
EncXh: Transmission ratio between encoder and crosshead in turns at the encoder per mm
crosshead movement.
Normally gearbox transmission ratio divided by the pitch of the screw.
For hydraulic testing machines this parameter must be set to 1.0
Bopen: Delay time after activating control and releasing a machine brake or stop valve.
This ensures a smooth transition between braked and controlled states.
Standard value is 0.2 s.
Bclos: Delay time after activating the brake or stop valve and releasing control.
This ensures a smooth transition between controlled and braked states.
Standard value is 0.2 s.
PArea: The piston thrust area and is only relevant for hydraulic testing machines using a
pressure transducer to calculate applied load (i.e. pressure ξ piston area).
If an incorrect piston area is entered then the resulting displayed load value will also be
incorrect.
The piston area can be entered in mm², cm² or dm² units.
Fmax: Maximum machine load capacity and is used to calculate the load limit.
Normally this value is set 5-10% higher than F100%.
In practice the lowest value set by Fmax, F100% or Load Sensor maximum is used.
Example 100 kN machine with a 2 kN load cell:
Fmax: 110 kN
F100%: 100 kN
calculated load limit: 2 kN (+defined range limit)
F100%: Nominal machine load rating and is used to calculate the load display limit.
Example 100 kN machine with a 2 kN load cell:
Fmax: 110 kN
F100%: 100 kN
calculated load limit: 2 kN (+defined range limit)
Stiff: Mechanical stiffness value for the machine i.e. kN/mm deformation.
The next three parameters relate to EDC controlled gripping/clamping devices.
ClCon: Connector identification number for clamp lock mechanism.
Only EDC100 universal I/O, 4INC- or 4IO-Interfaces are supported (ref. Para. 3.11).
Select "---"when no load controlled grips are fitted.
ClLim: Active level selection for "lock clamp" output signal. (High or low)
ClCha: Select grip control channel (Position, load, extension, Channel 4 to 16).
The active limits are defined in the application program, "User set-up" menu for standalone
appliances, or as parameter value in the PC-Program.

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The next three parameters relate to EDC controlled security shield/safety screens.
ShCon: Connector identity number for shield.
Only EDC100 universal I/O, 4INC- or 4IO-Interfaces are supported (ref. Para. 3.11).
Select "---" When no shield is fitted.
ShTyp: Shield/Safety Screen type
SIMPLE - the shield must be closed before defined load limits can be exceeded.
LOCKED - the shield must be closed and locked before defined load limits can be
exceeded.
ShTim: Time period allowed for the shield to report locked after a lock command sent.
(0 to max. 2 seconds).
Further parameters are defined in application programs, "User set-up" menu for standalone
appliances, or as parameter value in the PC-Program).
Linearisation: Selects the Linearisation menu (ref. Para. 3.12 ).

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3.14.2 Sensors
Conne: Connector Number where the sensor is attached (ref. Para. 3.11).
Sign: Parameter to select the sensor polarity.
INV Inverts transducer signal polarity
N-INV Retains transducer default polarity
The polarity of all control sensors must be identical under the same conditions.
E.g. An increase of a crosshead position value must result in an increase in both load
and extension values from the transducers as fitted.
Ctrl: Parameter to enable/disable the sensor from being used for control purposes.
YES Sensor can be selected as a control parameter
NO Sensor only used for measuring purposes.
(Only selectable for position, load and extension sensors).
LimCt: Reaction to activating a range limit.
STOP machine stopped
STATUS no action. If STATUS selected for a load sensor this can result in damage
to both the sensor and machine.
ConCt: Reaction to sensor disconnection
STOP machine stopped
STATUS no action. If STATUS selected for a load sensor this can result in damage
to both the sensor and machine.
(Only selectable for position, load and extension sensors)
Integ: Sensor integration time for data acquisition.
(Only selectable for analogue channels)
With a long integration time, data is very stable but peak values may not always be
correctly detected.
With a short integration time, the indicated values are less stable but the peak values
are correctly detected.
Common values lie between 0.02 and 0.2 seconds.
Integration time must be an integral multiple of SpeeT up to a maximum of
100 * SpeeT.
EEPRO: Selection of sensor data source
YES Sensor- E2PROM is utilised.
NO Data from an alternative source utilised.
As EDC5/25 appliances cannot read a E2PROM at connector X7 (X-head), enter NO.

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Init: Defines a 4ETF interface measuring range for, Enter 0 for all other interfaces.
This parameter is evaluated from the reference nominal value, range limit and
correction value.
E.g.:
Nominal value of the reference: 2 mV/V
Range limit: 130 %
Correction value: 0,9978
The maximum output signal of the sensor may be calculated as follows:
2 mV/V * 130 % * 0,9978 = 2,59428 mV/V
Refer to the tables on Page 30 and select the nearest higher input range for the 4ETF
amplifier i.e. 2.6 mV/V which indicates an init value of 32.
Nomin Defines the sensor nominal value
E.g. 10000 for a load cell with a nominal value of 10 kN and Unit set to N.
Unit Defines physical SI-unit for sensor.
E.g. Units available depend upon sensor type selected (e.g. N, m ..).
Offse Sensor offset value.
This value is subtracted from the measured value and compensates for a sensor offset.
(Currently the offset value is only used in PC-Control).
Ulimi Sensor upper range limit as % of nominal value. This limit must not exceed the sensor
maximum travel range and must be a positive value.
Llimi Sensor lower range limit as % of nominal value. This limit must not exceed the sensor
minimum travel range and must be a negative value.
Scale Parameter to select scaling of linear or rotary transducer.
For linear transducers, the unit is normally m/Inc, i.e. values within the µm-range.
For rotary transducers, the unit is Inc/rev, i.e. values within a range of 500 to 100000.
This parameter is not applicable for analogue sensors.
Corr Correction value, derived from adjusting (scaling) function.
Correction value = sensor nominal output/sensorplug reference bridge nominal value.

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Maximum Init Excitation voltage Amplification at Amplification

input range value Demodulator at Input
1,16 mV/V 44 5,5 V 2,236 387
1,50 mV/V 40 5,5 V 1,710 387
2,00 mV/V 36 5,5 V 1,307 387
2,60 mV/V 32 5,5 V 1,000 387
3,40 mV/V 24 2,5 V 1,710 387
4,45 mV/V 20 2,5 V 1,307 387
5,80 mV/V 16 2,5 V 1,000 387
7,60 mV/V 8 1,1 V 1,710 387
10 mV/V 4 1,1 V 1,307 387
13 mV/V 108 5,5 V 2,236 34,6
17 mV/V 104 5,5 V 1,710 34,6
22 mV/V 100 5,5 V 1,307 34,6
29 mV/V 96 5,5 V 1,000 34,6
38 mV/V 88 2,5 V 1,710 34,6
50 mV/V 84 2,5 V 1,307 34,6
65 mV/V 80 2,5 V 1,000 34,6
85 mV/V 72 1,1 V 1,710 34,6
111 mV/V 68 1,1 V 1,307 34,6
145 mV/V 172 5,5 V 2,236 3,1
190 mV/V 168 5,5 V 1,710 3,1
249 mV/V 164 5,5 V 1,307 3,1
325 mV/V 160 5,5 V 1,000 3,1
425 mV/V 152 2,5 V 1,710 3,1
556 mV/V 148 2,5 V 1,307 3,1
727 mV/V 144 2,5 V 1,000 3,1
950 mV/V 136 1,1 V 1,710 3,1
1243 mV/V 132 1,1 V 1,307 3,1
1625 mV/V 128 1,1 V 1,000 3,1

Table 2 4ETF Adjustment values for measuring bridges with alternating voltage supply

Maximum Init Excitation voltage Amplification at Amplification

input range value Demodulator at Input
727 mV 142 1,1 V 2,236 3,1
950 mV 138 1,1 V 1,710 3,1
1243 mV 134 1,1 V 1,307 3,1
1625 mV 130 1,1 V 1,000 3,1

Table 3 4ETF Adjustment values for direct voltage measuring sensors

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3.14.3 Closed loop control

3.14.3.1 General Parameters

Accel: The maximum allowable acceleration/deceleration value [mm/s² or N/s²] of the
machine under nominal load.
The maximum acceleration is calculated from the maximum speed and the time needed
to reach this speed.
All driven accelerations are restricted to this limit in order to avoid saturating the drive
signal.
Speed: The maximum allowable machine driven speed [mm/s or N/s] under nominal load.
For screw driven machines this value is calculated from the maximum motor speed, the
screw pitch and (if existing) the transmission ratio between motor and screw.
Nominal speed (screw machines) = max. motor speed * screw pitch * transmission
ratio.
For hydraulic machines, the piston area, hydraulic power pack and control valve flow
rate are used to calculate the speed.
All driven velocities are restricted to this limit in order to avoid saturating the drive
signal.
Nominal Speed (hydraulic machines) = max. flow rate(valve or power pack) / piston
area
WndSi & Parameters to set width and time of an input target window.
WndTi When a command signal reaches the final position a target window is generated about
this point and the actual value must achieve this level within the WndSi tolerance band
value in a shorter time than that set by the WndTi value
If the signal does not reach this window in the specified time, a signal is produced
which can be utilised to initialise an alternative procedure (normally in association with
external control programs). The signal does not influence the EDC test application and
this continues to the next stage.
WndTi value selected between 0,2 and 0,5 s and depends on adjusted gain settings.
WndSi value for x-head position control selected between 0.1 and 1 mm, and depends
on the system controller accuracy.
Devia: Maximum difference value allowed between command and actual values [mm or N].
DevRe: Select EDC action when the set Devia value is exceeded.
STOP Test stopped
STATE Test not stopped

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3.14.3.2 Closed loop control Parameter

Depending upon the selected control loop structure and control channel the parameters listed in
Table 4 are required :
Control loop structure SPINDEL_SP SPINDEL HYDRAULIC PNEUMATIC
Position PosK PosK PosK PosK
PosTi PosTi PosTi PosTi
PoGTd PoGTd PoGTd PoGTd
SpeK SpeK SpeK
SpeTi SpeTi SpeTi
AccK
Load PosK PosK PosK PosK
PosTi PosTi PosTi PosTi
PoGTd PoGTd PoGTd PoGTd
SpeK SpeK
SpeTi SpeTi
AccK
Extension PosK PosK PosK PosK
PosTi PosTi PosTi PosTi
PoGTd PoGTd PoGTd PoGTd
SpeK SpeK
SpeTi SpeTi
AccK
Table 4 Closed Loop Control parameters

PosK: Position (x) controller Gain (Proportional part)

Different values required for crosshead position, load or extension sensors
PosTi: Position (x) controller Integration time (Integral part)
Different values required for crosshead position, load or extension sensors.
Attention: This parameter must normally be set to zero, since the speed controller
integral part is usually active.
A control loop with different two integral parts results in instability.
PoGTd: Differential part of the control loop.
This part amplifies changes in the position command generator and compensates for the
inertia mass of the system.
Different values required for crosshead position, load or extension sensors
SpeK: Speed (dx/dt) controller Gain (Proportional part)
Different values required for crosshead position, load or extension sensors
SpeTi: Speed (dx/dt) controller Integration time (Integral part)
Different values required for crosshead position, load or extension sensors
BesK: Acceleration (dx”/dt2) controller Gain
Different values required for crosshead position, load or extension sensors
The optimum values for most of the closed loop parameters can be established from within the
controller setting program.

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Integ: Integration Time for actual value when transferring to the control loop
(only for analogue channels).
This integration time value is set independently from the sensor data acquisition
integration time value.
Typical values for integration time lie between 0.01 to 0.02 ms.
Integration Time must be an integral multiple of SpeeT up to a maximum value of
100 * SpeeT.
Attention: Changing this parameter influences all gains associated with the sensor
control loop.

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3.14.4 Output Channels

Conne: Output channel Connector No. (ref. Para. 3.11).
Sign: Output channel Polarity.
INV invert output signal polarity
N-INV retain default output polarity
The polarity must be altered if the machine starts in an uncontrollable manner after
activating RUN.
Max: Output channel % maximum value.
Value between –100% and +100%.
Min: Output channel % minimum value.
Value between –100% and +100%.
Init: Output channel % offset
Value between –100% and +100%.
For screw machines, this parameter is normally set to zero.
For hydraulic machines operated in bypass control mode, this parameter sets the servo
valve offset signal necessary to counteract the piston weight and keep the machine
piston in a steady state.
Volta: Maximum motor voltage (only for DOLI-output transformers DDA04, DDA05,
DDA06 having software adjustment feature).
Curre: Nominal motor current (only for DOLI-output transformers DDA04, DDA05, DDA06
having software adjustment feature)

3.14.5 Bit-Input
Conne: Bit-Input device Connector No. (ref. Para. 3.11).
StMsk: Input mask value to activate the stop function (identical to function activated when
front panel Stop-key pressed).
StLev: Select function activated by HIGH or LOW active state.

3.14.6 Bit-Output
Conne: Bit-Output device Connector No. (ref. Para. 3.11).
Init: Default state after initialisation.

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3.14.7 General Data

MaCnt: Number of different machines set-ups stored by the EDC.
EDC100 appliances can store a maximum of four set-ups, EDC5/25 a maximum of 2.
MaIo: Select whether software accesses the internal or external set-up
YES Changed by external set-up parameters via I/O
NO Use internal set-up parameters.
Super: Select supervisor mode or not.
YES Supervisor mode active.
Enables access to settings not available in the user mode, e.g. controller setting.
NO Supervisor mode not active.
SPass: Supervisory password value
Number between 1 and 65535.
Selecting 0 disables password protection.
Logo: Select whether DOLI-Logo with e-mail address displays for a short period at start-up.
YES Displays logo
NO No logo displayed

3.14.8 Management
SETUP copy: Creates a copy of the set-up parameters for transfer to similar machines.
This function enables other machines to be rapidly set-up, with only a few
parameters requiring modification.
SYSEEPROM erase: Erases the stored set-up, user and application program data from the
SYSEEPROM.
Attention: After erasing, all data must be re-entered.
NOVRAM erase: Erases the stored actual X-head position from a NOVRAM and resets
store to zero.

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4 Making the Machine Live

During the initial stages of commissioning and until such time as all functions of the
machine have been checked, it is essential the operator remains within easy reach of
the MAIN SYSTEM ISOLATOR as under some faulty interconnection
combinations it may be possible to start but not be stop the machine using the
EMERGENCY STOP or the MAIN SWITCH.
If the motor moves intermittently or races out of control, press the EMERGENCY
STOP

Before making the machine live, check the functioning of the EMERGENCY STOP and all connected
limit switches.
Activating each limit switch and Emergency stop button in turn whilst pressing the ON-key and these
actions must cause the EDC to display the appropriate error message (or optionally on the PC screen).
It must not be possible to switch the machine on under any of these conditions.
The following signal sequence must occur before it is possible to start the machine using the ON
button.
No limit switch activated
No EMERGENCY STOP active
TEST signal = 24 V → AON-Signal = 24 V → motor contactor is switched → TEST-Signal =
0 V → drive ready ABER1, ABER2 Signals = 24 V → drive free AFG-Signal = 24 V →
release ON button,
System changes into the ON state.
The next step is to activate the drive to the testing machine:
First note the position display reading (if existing) before pressing the ON button and activating the
drive.
When the X-head travels in a tensile loading direction the position display must indicate a more
positive value.
The position sensor signal polarity must be altered if the position display indicates a less positive
value when moving in a tensile loading direction. (see Sign parameter in Para. 3.14.2 Page 6).

The motor may possibly move or race out of control the wrong polarity selected and
can only be stopped using the EMERGENCY STOP button.
Always place a hand on EMERGENCY STOP when pressing ON button.

When the position display has the correct polarity, the controller output must be checked for the same
condition.
Activate the On button and select either the UP or DOWN key
Attempt to move the X-head by turning at the Digipoti knob clockwise.

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If the X-head races in an un-controlled manner, the output channel polarity must be changed in the
set-up menu. (see Para. 3.14.4 )
Repeat process and move the X-head in a controlled manner.
If the X-Head remains out of control irrespective of controller polarity, the problem lies elsewhere and
the cause must be investigated.
Possible causes are:
Motor incorrectly connected,
Faulty motor control amplifier
Control output is being saturated due to wrong parameter settings
Incremental transducer not firmly connected to the motor shaft
Control parameters (Gain etc.) too large
Wrong limits set
When the machine appears to be operating correctly, the EMERGENCY STOP and LIMIT
SWITCH functions must be re-checked.
The motor contactor must drop out as soon as a limit switch or emergency stop button is activated.
A shutdown message must appear on the EDC display (Standalone) or the PC.
To comply with conventional sign notation, the polarity of the position, load and extension sensors
must be set as follows :
Position Movement in the direction that would apply a tensile load must produce a more
positive value.
Load Tensile loads must produce positive values and Compressive loads negative
values.
Extension A tensile extension must produce a positive value.
When utilising pressure transducers (single and differential) or externally mounted displacement
transducers for position or extension measurement, the above conditions regarding polarity must
always be adhered to if the sensor is to be used for control purposes.
Load cells and extensometers can usually be checked by manually applying a load or extension.
Care must always be exercised when working with low capacity and delicate devices.

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5 Closed loop Controller adjustment

The Closed loop Controller adjustment program must only be used by trained
personnel and is only accessible when the supervisor option is active
(ref. Para. 3.14.7 on page 35).
This program is used to adjust position and speed closed loop control parameters in all control modes.
Before starting the closed loop control adjustment program, the nominal data for the machine must be
calculated and entered into the set-up. The following conditions are particularly important :
1. Measuring channels scaling
2. Machine nominal speed value
3. Nominal acceleration value
4. Correct polarity of measuring and output channels (positive controller output generates
positive position and load change)
5. Correct controller structure selected
6. If possible, pre-select parameters for the controller that have been determined in
previous similar configurations. (See Para. 5.8 on page 52)

5.1 Steps to adjust closed loop parameter

After having correctly entered the nominal data into the set-up, the control parameters can be
transferred into the controller adjustment program.
Select test Set-up in the parameter menu and execute menu item Read Set-up using F3 key.
This action ensures all parameters entered into the set-up are active.
Whenever any parameters are changed during optimising of the gains etc. the revised data must be
written back to the set-up memory.
Select test Set-up in the parameter menu and then execute menu item Write Set-up using F3 key.
This action ensures all adjusted data is saved and will be used when the EDC is next activated.
The following steps must be carried out in order to optimise the closed loop controller parameters :
1. Adjust speed controller for crosshead.
Not necessary for screw driven machines with external (generally analogue) speed controllers
and for machines not fitted with a position transducer.
2. Set position controller.
Not applicable for machines not fitted with a position transducer.
3. Detect position acceleration.
Not applicable for machines not fitted with a position transducer.
4. Set D-part of the position controller.
The D-part can be set via cosine or rectangle cycles.
This step is optional but it improves the system dynamic characteristics.
5. The steps 1, 2 and 4 have to be carried out for all control sensors.
6. Store the detected parameters in the set-up data (see above).

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5.2 General hints for using the closed loop controller

adjustment functions.

5.2.1 Explanation of terminology used

With most testing machines is is possible to have 3 control modes provided the sensors are fitted
(Position from X Head or piston, Load from load cell or pressure transducer and extension from an
extensometer fitted to a specimen)
When selecting a control mode, the associated transducer produces the signal used for controlling the
machine in a closed loop manner. For optimum control under each mode it is essential the system gain
settings are individually adjusted for each parameter.
When adjusting gain the control mode should be first selected and then the individual entered.
The following tables detail the parameters to be set for each control mode.

Set-up Control Mode Parameter Description

Position Speed Gain Proprtional gain setting for controlling the rate of
change of X-Head/Pisiton position. (i.e. Velocity
component)
Speed Integration Integral gain setting to control the steady speed state
of the X-Head/Piston
Position Proportional gain used for positioning of the
X-Head/Piston
Position Integration Integration gain used for positioning of the
X-Head/Piston.
Note : This value must be set to zero as best
control is achieved by having integration set in
speed parameter. A control loop with two
integration components will always be unstable.
Position Differential gain for positioning of the
Differentiation X-Head/Piston, and is used to compensate for errrors
resulting from inetia masses on dymanic systems.
Accelleration Acceleration gain to control the rate of change of
X-Head/Piston speed when positioning.

Table 5 Description of Position Mode Gain Settings

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Set-up Control Mode Parameter Description

Load Speed Gain Proprtional gain setting for controlling the rate of
change of load. (i.e. Velocity component)
Speed Integration Integral gain setting to control the steady loading
speed state.
Position Proportional gain used for loading
Position Integration Integration gain used for loading.
Note : This value must be set to zero as best
control is achieved by having integration set in
speed parameter. A control loop with two
integration components will always be unstable.
Position Differential gain for loading, and is used to
Differentiation compensate for errrors resulting from inetia masses
on dymanic systems.
Accelleration Acceleration gain to control the rate of change of
loading.

Table 6 Description of Load Mode Gain Settings

Set-up Control Mode Parameter Description

Extension Speed Gain Proprtional gain setting for controlling the rate of
specimen straining (i.e. Velocity component)
Speed Integration Integral gain setting to control the steady specimen
straining speed.
Position Proportional gain used for specimen straining.
Position Integration Integration gain used for specimen straining.
Note : This value must be set to zero as best
control is achieved by having integration set in
speed parameter. A control loop with two
integration components will always be unstable.
Position Differential gain for specimen straining, and is used
Differentiation to compensate for errrors resulting from inetia
masses on dymanic systems.
Accelleration Acceleration gain to control the rate of change of
straining speed.

Table 7 Description of Position Mode Gain Settings

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The parameters shown in this program vary depending on the selected controller structure.
Only the required parameters are displayed (see list below).

Control Structure
Sensor SPINDEL_SP SPINDEL HYDRAULIC PNEUMATIC
Position sPosK sPosK sPosK sPosK
sPoGTd sPoGTd sPoGTd sPoGTd
sSpeK sSpeK sSpeK
sSpeTi sSpeTi sSpeTi
Load FPosK FPosK FPosK FPosK
FPoGTd FPoGTd FPoGTd FPoGTd
FSpeK FSpeK
FSpeTi FSpeTi
Extension EPosK EPosK EPosK EPosK
EPoGTd EPoGTd EPoGTd EPoGTd
ESpeK ESpeK
ESpeTi ESpeTi

Depending upon the test selected, a step-function impulse (or continuous signal) is applied to the
controller input and the response of the resulting output is measured.
During the test cycle, time, speed or position values are recorded. (default time setting is 2,5 ms).
After the stimulus, the EDC graphically displays input and output signals with identical scaling.
Overshoot and undershoot is detected and numerically indicated as % of the applied step-function.
Memory is automatically allocated to store the test step-function data and released upon completion.
The allocated memory size depends on the adjusted measuring time and the controller cycle time.
Up to 8,000 values can be stored, i.e. 20 seconds measuring time with 2,5ms. controller cycle time.
For EDC100 appliances the required memory is always made available.
With EDC5/25 appliances, a "no memory" message may be displayed if long measuring times are set
and prevent the test from being started. Reduce measuring time until the test can be carried out.
During step-input tests, turning the Digipoti knob alters either the gain or integration-time.
Turning in clockwise direction increases the value of the selected parameter and an anti-clockwise
rotation reduces the value.
The actual active value is shown in the lower left portion of the ECD display.
Toggling between gain and integration-time adjustment is achieved by pressing the Digipoti knob.
Before starting a new period, the closed loop controller updates the set values.
Gain and Integration-time should be adjusted until an optimum step-function response is achieved
(ref. Figure 8)
If the T-END key is pressed during a test, the current test is stopped and the adjusted gain and
integration time values are stored in memory.
Pressing the STOP key stops the test, but does NOT store the adjusted parameters.

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5.2.2 Zooming the Graphics

The graphic display used with step-function tests can be zoomed after a single test or after stopping a
repeating test with the HALT key.
Press the "." key to enter the zoom function.
A rectangular window is highlighted in the upper left-hand area of the graphic display and indicates
the window to be zoomed.
The highlighted rectangle can be repositioned and scaled as follows :
Press the "." key to toggle between positioning and scaling mode. The active mode is indicated on the
lower right-hand section of the display.
In the positioning mode, the window is moved horizontally by turning the Digipoti knob, pressing the
Digipoti knob toggles movement into a vertical direction.
In the scaling mode, the window is scaled horizontally by turning the Digipoti knob, pressing the
Digipoti knob toggles the scaling in the vertical direction.
The selected window is zoomed and displayed when the "-/+" key is pressed.
Pressing the "-/+" key a second time switches the display back to the original scaling.

Window to
be zoomed

k: 100000 Move
STOP HALT T-END

Figure 6 EDC Display whilst in Zoom mode.

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5.3 Optimising Speed Control Loop.

In order to optimise the control loop speed settings, a single or continuous step-speed stimulus is
applied to the speed controller input.
The step-function amplitude is defined by the parameter "Speed".
The step-function time is predefined by the “measuring time” parameter.
The time period is subdivided in 40% positive speed, 40% negative speed and 20% zero speed.
(see Figure 7)
Speed and measuring time must be selected with reference to system capabilities so that it is possible
for the required speed (positive and negative) to be achieved within the selected measuring time.
During the test cycle, time and speed values are recorded. (default time setting is 2,5 ms).
After the stimulus, the EDC graphically displays input and output signals with identical scaling.
Overshoot and undershoot is detected and numerically indicated as % of the applied step-function.
For optimum adjustment the maximum overshoot value should be adjusted to approximately 104% of
the step-function.
Attention: Before starting the test, move the X-head/piston to the central position as it is
possible for the test position datum to move during speed testing. (Movement
occurs if the machine response to a step-input is asymmetric.)
To adjust gain, start step-input test in a cyclic mode and ensure display indicates gain adjustment in
lower left-hand display area.
If gain adjustment is not selected, press the Digipoti knob. (This toggles between gain and Integration
time adjustment whilst in the step-input mode)
Observing the display, slowly increase the gain by turning the Digipoti knob clockwise until the
display indicates a small overshoot.
Select Integration time adjustment by pressing the Digipoti knob.
Observing the display, slowly increase the integration time by turning the Digipoti knob clockwise
until the display indicates the best possible square response with only a small overshoot (4%).
Toggle between gain adjustment and adjust if necessary to reduce overshoot.
Repeat process until best response is achieved. (See Figure 9)
Effect of the Integration-time:
Small values -> big effect
Large values -> small effect
i.e. increasing the Integration-time value reduces its effect.
After having correctly adjusted the control loop, finish the test by pressing the T-END key as
this is the only method of storing the newly adjusted parameters.

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Speed
0

40 % 40 % 20 %

M T im e

Figure 7 Step-Input signal to stimulate speed controller

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5.3.1 Typical Speed Controller Responses to step-function

Integration-time too short or low

gain setting .

Low Gain setting

High Gain setting

Optimum combination of gain

and integration time settings for
speed controller
(positive and negative overshoot
values approx. 104% of the step-
function)

Figure 8 Typical Responses of the Speed Controller to step-function

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5.4 Optimising Position Control Loop

In order to optimise the control loop position settings a single or continuous step-position stimulus is
applied to the input of the position controller.
The step-function amplitude is defined by the parameter "Pos".
The step-function total time is defined by the parameter measuring time.
The time period is subdivided in 50% positive dislocation from the actual position and 50% return to
the starting position. (see Figure 9)
The amplitude and measuring time have to be chosen with reference to system capabilities such that it
is possible for required movement (positive and negative) to be achieved within selected measuring
time.
During the test cycle, time and position values are recorded. (default time setting is 2,5 ms).
After the stimulus, the EDC graphically displays input and output signals with identical scaling.
Overshoot and undershoot is detected and numerically indicated as % of the applied step-function.
For optimum adjustment the maximum overshoot value should be adjusted to approximately 104% of
the step-function.
Attention Under Position control it is possible to adjust both the proportional gain and the
integration time, however if an integration time has been set for the speed controller
the position integration time must be set to zero as a control loop with two integral
components is always unstable.
To adjust gain, start step-input test in a cyclic mode and ensure display indicates gain adjustment in
lower left-hand display area. If the gain adjustment is not selected, press the Digipoti knob. (This
toggles between gain and Integration time adjustment whilst in the step-input mode)
Observing the display, slowly increase the gain by turning the Digipoti knob clockwise until the
display indicates a small overshoot. (4%). See. Figure 10
After having correctly adjusted the control loop, finish the test by pressing T-END key as this is
the only way of storing the newly adjusted parameters.
Position

50 % 50 %

MTime

Figure 9 Step Input signal to Stimulate Position Controller

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5.4.1 Typical Position Controller Responses to step-function

Gain too high

Gain too low

Optimum gain for position

controller
(positive and negative overshoot
values approx. 104% of the step-
function)

Figure 10 Typical Position Controller Responses to a step-function

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5.5 Optimising Position Acceleration

In order to optimise the control loop acceleration settings a single or continuous step-acceleration
stimulus is applied to the input of the position controller.
The step-function amplitude is set to the nominal speed value.
The step-function total time is defined by the parameter measuring time. The time period is
subdivided in 40% positive speed, 40% negative speed and 20% zero speed. (see Figure 11)
The position and the measuring time have to be chosen with reference to system capabilities such that
it is possible for required acceleration (positive and negative) to be achieved within selected
measuring time.
The program uses the time needed to reach the nominal speed to calculate the acceleration.
During the test cycle, time and acceleration values are recorded. (default time setting is 2,5 ms).
After the stimulus, the EDC graphically displays input and output signals with identical scaling.
Overshoot and undershoot is detected and numerically indicated as % of the applied step-function.
For optimum adjustment the maximum overshoot value should be adjusted to approximately 104% of
the step-function.
As this test is normally carried out using an unloaded machine the resulting acceleration gain setting is
normally too high for a loaded system. In general, after establishing the unloaded gain setting, this
value should be reduced to 50% to ensure stability with a loaded system.
The acceleration gain is adjusted by turning the Digipoti knob until the measured value follows the
step-input signal.
Any overshoot or undershoot of the measured value is indicated numerically as a % of the step-
function. For optimum adjustment the maximum overshoot value should be adjusted to approximately
104% of the step-function.
After having correctly adjusted the control loop, finish the test by pressing the T-END key as
this is the only way of storing the newly adjusted acceleration parameter.
Acceleration

40 % 40 % 20 %

MTime

Figure 11 Step Input to stimulate acceleration controller

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5.6 Optimising the closed loop controller differential part

In order to achieve the best dynamic system response the closed loop controller must be compensated
for inertia changes using differential feedback. A continuous rectangular or sinusoidal waveform is
used to cycle the system whilst adjustments are carried out.

5.6.1 Adjusting the differential part with rectangular cycles

The built-in function generator produces rectangular cyclic displacements at speeds up to the system
nominal speed.
The controller generates a constant speed signal to a required position (calculated to be 33%
measuring time), holds this position for 33% measuring time and then returns to start position in 33%
measuring time. (See Figure 12)
The position and the measuring time must be selected with reference to system capabilities such that it
is possible for required stroke (positive and negative) to be achieved within selected measuring time.
During the cycle the input and measured position are recorded against the controller time base (default
2,5 ms for EDC 100 and 8 times Controller time for EDC5/25-Systems).
Whilst cycling the system the input and measured values are graphically displayed on the EDC with
identical scaling.
The Differential-part is varied during the test by turning the Digipoti knob and should be adjusted
until the phase shift (time delay) between input and measured values is reduced to a minimum without
causing the measured value to exceed the input value.
After having correctly adjusted the control loop, finish the test by pressing the T-END key as
this is the only way of storing the newly adjusted differential parameter.
Position

1/3 1/3
MTime MTime

Figure 12 Rectangular Command cycle waveform

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5.6.2 Adjusting the differential part with cosinusoidal cycles

The built-in function generator produces cosine cyclic displacements at speeds up to the system
nominal speed.
An option is available to have one waiting period at the upper and lower peak values. (See Figure 13)
The parameters for signal amplitude and frequency being manually entered.
The position and the measuring time must be selected with reference to system capabilities such that it
is possible for required stroke (positive and negative) to be achieved within selected measuring time.
During the cycle the input and measured position are recorded against the controller time base (default
2,5 ms for EDC 100 and 8 times Controller time for EDC5/25-Systems).
Whilst cycling the system the input and measured values are graphically displayed on the EDC with
identical scaling.
The Differential-part is varied during the test by turning the Digipoti knob and should be adjusted
until the phase shift (time delay) between input and measured values is reduced to a minimum without
causing the measured value to exceed the input value.
After having correctly adjusted the control loop, finish the test by pressing the T-END key as
this is the only way of storing the newly adjusted differential parameter.
Position

Position

1/f 1/f t

Figure 13 Cosine Command cycle generation with and without a wait-time

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5.7 General hints for adjustment of the closed loop controller

The following points outline some general rules regarding control loop gains adjustment:
1. The more gain that can be applied to a system control loop without causing instability, then the
better and more accurately the system responds.
2. As the Inertia mass of a screw machine or hydraulic actuator piston increases it is necessary to
reduce acceleration gain settings and increase the speed gain settings for optimum response.
3. The response of a system to an input is influenced by both proportional and acceleration gain
settings. If the measured value still overshoots despite reducing the proportional part, then the
acceleration gain must also be reduced.
4. If the integration time for an analogue channel is increased by a factor, then the associated position
controller gain must be reduced by the same factor.
5. Changes in the gain setting required for the load and extension controllers are proportional to the
reciprocal of changes in specimen stiffness. (e.g. the stiffer the specimen the less gain required and
conversely the softer the specimen the more gain required).
Compensation for specimen stiffness is made on force or extension controller gain for screw
machines and with load and extension speed gain for hydraulic systems.
If a system moving at maximum speed does not stop immediately the stop key is activated, then it is
necessary to adjust the nominal speed value.

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5.8 Typical Controller Settings for different Systems

System Controller Control Speed- Position Controller
Structure mode Controller
K Ti K Ti Td
EDC with DDA02 (90 Watt Power Amplifier)
2,5 kN screw machine with a one Spindel_sp X-head 20000 500 4500 - -
stage toothed belt gearbox Position
EDC with DDA05 (1kW Watt Power Amplifier)
10 kN screw machine with a two Spindel_sp X-head 80000 500 5000 - -
stage toothed belt gearbox Position
100 kN screw machine Spindel_sp X-head 150000 500 4000 - -
Position
EDC with DDA06 (2,2 kW Power Amplifier)
RX530 Motor with a flywheel Spindel_sp X-head 500000 500 1000 - -
Position
100 kN screw machine Spindel_sp X-head 400000 500 2000 - -
Position
EDC with an external power amplifier
5 kN screw machine with ESR Spindel X-head - -
Amplifier Position
EDC on a Hydraulic machine with servo valve
50 kN single acting cylinder with Hydraulic X-head 40000 70 250 - -
Schneider-valve in Bypass control Position
Load 2000 100 250 - -
50 kN single acting cylinder with Hydraulic X-head 2000 100 1000 - -
Schneider-valve in direct control Position
Load 1000 500 1000 - -
300 kN single acting cylinder with Hydraulic X-head 1000 100 500 - -
Moog-D633 valve in direct Position
control
Load 1500 700 380 - -
EDC on a Hydraulic machine with proportional valve
50 kN single acting cylinder with Hydraulic X-head 30000 600 300 - -
HAWE/Doli proportional valve in Position
Bypass control
Load 100000 600 770 - -

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5.9 Closed-loop Set-up Program Parameters

The first two parameters are identical for all menu's and are only explained here.

Parameter Selection Unit Comment

Contrl Position, Load, Selected control mode. All following parameters
Extension refer to this closed control loop.
Test Speed Test function Selection.
Position Not all test functions are available with all
Acceleration Controllers or Controller-structures. Non-supported
Cycles or non-valid test functions cannot be activated. The
Cosine test functions are described later. Dependent upon
Set-up the Controller, selected test function and adjusted
Controller-structure, the following parameters may
be available.

5.9.1 Closed-loop Speed Controller Parameters

Parameter Selection Unit Comment
Period. Single The selected test is executed once or repeated until
Repeat the test is manually terminated (Stop or T-End)
MTime s Time for one Test. (typically 1-3 s)
Speed

40 % 40 % 20 %

M T im e

Speed mm/min Step-function Amplitude value for speed Controller.

N/s
sSpeK Speed Controller Gain value
FSpeK
ESpeK
sSpeTi Speed Controller Integration-time
FSpeTi
ESpeTi
Table 8 Speed Controller Parameters

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5.9.2 Closed-loop Position Controller Parameters

Parameter Selection Unit Comment
Period. Single The selected test is executed once or repeated until
Repeat manually terminated (Stop or Test-End)
MTime s Time for one Test. (typically 1-3 s)

P o s iti o n
50 % 50 %

M T im e

Pos mm Step-function Amplitude for the position Controller.

N, kN
sPosK Position Controller Gain value.
FPosK
EPosK
Table 9 Position Controller Parameters

5.9.3 Acceleration setting Parameters

Parameter Selection Unit Comment
Period. Single The selected test is executed once or repeated until
Repeat manually terminated (Stop or Test-End)
MTime s Time for one Test. (typically 1-3 s)
N o m in a l sp e e d

40 % 40 % 20 %

M T im e

Table 10 Acceleration setting Parameters

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5.9.4 Rectangular Cycles Parameters

Parameter Selection Unit Comment
Period. Single The selected test is executed once or repeated until
Repeat manually terminated (Stop or Test-End)
MTime s Time for one Test.

Position

1/3 1/3
MTime MTime
Pos mm Step-function Amplitude for the position Controller.
N, kN
sPoGTd Position generator Differential part
FPoGTd
DPoGTd
Table 11 Rectangular Cycle Test Parameters

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5.9.5 Cosine Cycles Test Parameters

Parameter Selection Unit Comment
Period. Single The selected test is executed once or repeated until
Repeat manually terminated (Stop or Test-End)
Freq Hz Test Frequency
Pos mm Amplitude
N, kN
sPoGTd Control loop Differential Part
FPoGTd
DPoGTd
WTime1 s Halt time at upper peak
WTime2 s Halt time at lower peak
PeakCt Yes/No activate/deactivate peak value control
Table 12 Cosine Cycles Test Parameters

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5.9.6 Set-up Parameters

In the set-up parameter menu only control parameters used with the selected controller structure are
displayed. It is possible to edit the control parameters in this menu.

Parameter Selection Unit Comment

Read Set-up Control parameters are transferred from the set-up
data to the controller adjusting program
Write Set-up Control parameters are transferred from the
controller adjusting program to the set-up data.
sPosK Gain value of crosshead position controller
sSpeK Gain value of crosshead speed controller
sSpeTi Integration time value for crosshead speed
controller
sPoGTd D-Part value for crosshead control loop
sAcc mm/s2 Acceleration value for crosshead
FPosK Gain value for load position controller
FSpeK Gain value for load speed controller
FSpeTi Integration time value for load speed controller
FPoGTd D-Part value for extension control loop
EPosK Gain value for extension position controller
ESpeK Gain value for extension speed controller
ESpeTi Integration time value for extension speed controller
EPoGTd D-Part value for extension control loop

Table 13 Set-up Parameters

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6 HW-Descriptions
This chapter provides a short description of all modules available in the EDC range of units.
Details of connector pin layout and inter-module functions are also listed.

6.1.1 EDC5/25 Front view

7 8 9

ON
4 5 6
STOP
1 2 3

TEST
F1 F2 F3 0 , -/+

Figure 14 Front view of the EDC5/25

6.1.2 EDC5/25 Rear view

Calibrationcontact

Fuse Fuse
230V/ I
115 V

0
Keyboard Option

Motor/ Option
Valve

Drive I/O PC/Printer X-Head Load

Figure 15 Rear view of the EDC5/25

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6.1.3 Pin Description

6.1.3.1 PC/Printer-Interface
It is possible to optionally connect a PC or a printer to the serial interface using a 9 pin plug. The logic
signals are generated by a UART in the CPU-block.
Asynchronous, full duplexlevel: RS232 Configurable via software up to 115kBaud.
CTS supported

Pin Description X1:

1 2 3 4 5 SubD Plug
6 7 8 9 9-pin

Pin No Inscription Function Signal

Type
1 STOP not used RS 232
2 RX receive data (EDC) RS 232
3 TX transmit data (EDC) RS 232
4 not used
5 GND ground GND
6 GND ground GND
7 not used
8 CTS clear to send (printer) RS 232
9 5 Volts 5 Volts power supply
(short circuit resistant)
Table 14 PC/Printer Interface Connector Pin connections

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6.1.3.2 Load measurement

Load is generally measured using strain gauge load-cells. The load cell (pure resistive) is excited with
a DC voltage. Any differential output voltage being proportional to the applied load. Load-cell
impedance must lie between 200 and 1000 Ohm.
Excitation:
Voltage supply: Bridge circuit: 10 Volt
Supply type: DC
Range of bridge impedance: > 200 Ohm
Bridge circuit: 10 Volt Full bridge, supplied asymmetrically
Measurement:
Measurement range: 2 mV/V + 50 %
Polarity change: yes
Input filter: 100 Hz
Input impedance: >1 MΩ
Resolution: EDC5: > 5000 points at 20 ms integration time.
EDC25: > 25000 points at 20 ms integration time.
Max. input signal ±3mV/V + 15% = ±3,45 mV/V
Display noise: Integration time adjustable in 2,5 ms steps over a 2,5 – 250ms
range.
Maximum noise level ±0,5% of 8% nominal value from a measured
sensor in a grounded state (i.e. 2 digits for 5000 digits). Conditions:
1. UTM static, integration time 100 ms, load cell unloaded.
2. UTM driving at zero load integration time 100 ms
Linearity ±0.1 %

The power amplifier internal resolution must reach a minimum of 5000 parts per 20 ms.
For hydraulic machines fitted with a proportional valve, the internal resolution must reach a minimum
of 5000 parts per 20 ms, the optional module 4ETF is recommended for these systems.

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Pin Description X14:

1 2 3 4 5 6 7 8 SubD Plug
9 10 11 12 131415 15-pin

Pin No Inscription Function Signal Type

1 GND-ext shield (case) + DGnd
2 SDA I²C-data Open Coll.-5V
3 SCL I²C-clock Open Coll.-5V
4 KE calibration-enable-plug TTL
5 Mess-A measuring signal A
6 Mess-B measuring signal B
7 Füh-B not used
8 Spei-A supply A
9 R-Ref. B external reference B
10 CON transmitter plugged TTL
11 5V-SW 5V for I²C periphery (not switched)
12 AGND analogue ground (10 Ω)
13 R-Ref. A external reference A
14 Spei-B supply B
15 Füh-A not used

Table 15 Load connector Pin layout

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6.1.3.3 Drive Control Signals

The limit switches and drive interconnection signals are routed through this connector.

Pin Description X4:

8 7 6 5 4 3 2 1 SubD Plug
15 14 13 12 11 10 9 15-pin

Pin No Inscription Function Signal Type

1 GND-ext shield (case) + digital-ground
2 ± 10 V set point for ext. drive (16 bit) analogue voltage
3 free
4 HAFG drive release for ext. drive (hydraulics also) 24V / 100mA
5 X triggering contactor when ext. drive 24V / 200mA
6 G triggering contactor when ext. drive GND
7 HBER drive ready from ext. drive (hydraulics also) 24V / 100mA
8 free
9 DACGND Ground for 16-bit DAC
10 GND-ext shield (case) + digital-ground
11 BR Triggering brake 24V / 100mA
12 ESOU connection limit switch up/down contact 1 ∼-supply power amplifier
13 ESOU connection limit switch up/down contact 2 ∼-supply power amplifier
14 BYP Triggering bypass valve 24V / 100mA
15 free

Table 16 Drive Control Connector Pin layout

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6.1.3.4 Incremental Input for X-Head Position

Features
5V supply for an incremental transmitter 16bit Counting of up/down pulses
Signal Type: TTL, rectangle difference signals Max. entry counting frequency :500kHz
Track A, track B, no reference necessary (transmitter 1000 lines, motor 3000Upm>
50kHz)
Direction recognition and quadruplicating of
Transmitter connected control
impulse

Pin Description X7:

5 4 3 2 1 SubD Plug
9 8 7 6 9-pin

Pin No Inscription Function Signal Type

1 Shield / GND ground
2 – reserved Ref+
3 B+ pos. track B-entry diff. TTL-level
4 A+ pos. track shield ground A-entry diff. TTL-level
5 A– neg. track A-entry diff. TTL-level
6 GND external ground ground
7 – reserved Ref.-
8 B– neg. track B-entry diff. TTL-level
9 5V-ext 5V short circuit resistant +5 Volts

Table 17 Incremental Transmitter Connector Pin Layout

6.1.3.5 Calibration Contact

Open collector, NPN, low level 0,8 Volt with 100 mA, NOT short circuit proof
Pin Pin
EDC5/25 rear panel EDC5/25 controller
board
Triggering Jacket, ESD-solid, 4mm, red X1
signal
GND Jacket, ESD-solid, 4mm, black X2

Table 18 Calibration Connector Pin Layout

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6.1.3.6 External keyboard

An external keyboard with a Digipoti control can be connected via a 12-pin round DIN-socket,
type DIN45326 KFV 120.
If an additional external keyboard is not connected, a bridge connection on the
front-panel PCB internal connector must be made between pins 13 and 14,
otherwise the keyboard hardware generates a STOP-key function.

Keyboard Pin Description:

Pin No Inscription Function Description Signal Type

A GND 0V 0V - connection
B +5V supply +5V (short circuit resistant)
C /STOP entry Stop-key input 5V-pull up
D /UP entry /UP-key input 5V-pull up
E /DOWN entry /DOWN-key input 5V-pull up
F /D-key entry Digipoti key input 5V-pull up
G Ch-2A entry track A of the inc. 5V-pull up
transmitter 2
H Ch-2B entry track B of the inc. 5V-pull up
transmitter 2
J LED1 highohm. exit for. “down“ - lamp open collect.
K LED2 highohm. exit for “up“ - lamp open collect.
L TON entry ext. keyboard plugged pull down
M shield

Table 19 External keyboard Connector Pin description at the EDC-case

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6.1.3.7 Motor/Valve

Pin Description:

1 4-pin Socket
2 4
Type Hirschmann CA 3GD
3

Pin No Inscription Function

1 motor + motor drive
2 motor - motor drive
3 free free
4 case shield

Table 20 Pin description for motor/valve connection

Hirschmann type CA 3LS09ZS for 6,0-9,5 mm or CA 3LS13ZK connectors suitable for

10,0-12,0 mm diameter cable should be used for connection to the motor.

6.1.4 Triggering Components

When adjusting the EDC5/25 Set-up to control hardware modules, ensure that the drivers are correctly
addressed. Refer to the ‘Drive for Hardware Modules of the EDC Family’ documentation.

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6.2 EDC100

6.2.1 System Overview

The DOLI type EDC100 controller is a powerful and cost effective unit specifically designed for use
with testing machines. Because of its power capability and available options the EDC100 is a more
sophisticated version than the EDC5/25 controller. The EDC100 has excellent an high resolution
capability of ±100.000 steps, a bus-system for up to eight option boards and high CPU capacity for
fast Controller calculations.
The controller is suitable for :
• screw machines fitted with of 90, 500 and 1000 Watt motors when using a specially adapted
power amplifier.
• screw machines requiring more than 1000 Watt power are driven by a ±10 Volt output signals as
well as supplying the necessary control-signals for an external power amplifier.
• hydraulic machines, driven by a proportional servo-valve.
The EDC100 controller can be used as a stand-alone unit and functions without using an external PC.
The unit has an integral alphanumeric display and function keys for input and control of a testing
machine. An optional printer or PC can be connected.

D isp la y
K eys
1 2 8 x 6 4 P ix e l

E D C 100
R e c o g n itio n
o f d ire c tio n

B r a k e / S to p v a lv e
D r a in v a lv e R S 2 3 2 w it h
CPU F IF O
D r iv e fr e e
D r iv e D r iv e r e a d y DAC D a t a a c q u is i ti o n
M ± 10 P o w e r s u p p ly -
c o n tro l S p e e d c o n tr o l l e r
D r iv e / P u m p o n
P o s i t io n c o n t r o l le r
L i m i t s w itc h e s L o a d c o n t r o l le r

E m e r g e n c y S to p
12345

4 f r e e I n p u ts

4 f r e e O u tp u t s

C a li b r a ti o n c o n t a c t

O p tio n s lo ts

1 2 3 4 5 6 7 8

C ode

Load

Figure 16 General Diagram showing Electronic Structure

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6.2.2 EDC100 Features

• Voltage supply 115V/230/V, 35 W
• Processor: 80C386EX 25MHz
• Flash EPROM: 512kByte
• CMOS RAM:256kByte
• Watchdog-Timer
• Real time display
• Synchronous data acquisition of load and position at 400 Hz.
• 8kB E2PROM on the EDC100 for system and application data (for min. 4 testing machines)
• PC/printer-interface, RS232 with FIFO and CTS, configurable via software up to 115 kBaud
with break detection
• Display and keyboard similar to EDC5/25
• 4 outputs 24V / 100 mA freely available
• 4 inputs 24V freely available
• DOLI-I4-Bus with 8 slots. One slot reserved for load
• Incremental input for X-head position:
• Incremental sensor plug Support of the
• Sinusoidal or rectangular signals (RS422 / TTL) with reference signal
• Maximum input counting frequency up to 1,5 MHz
• Transducer connected detection
• Non volatile RAM for X-head position
• Different drive variants connectable:
• Power amplifier for servomotor DDA04 500 W, (105V, 11/15A)
• Power amplifier for servomotor DDA05 1000 W, (105V, 11/15A)
• Power amplifier for servomotor DDA06 2000 W, (150V, 15/20A)
• serial IO transmission to the drive
• Calibration contact

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6.2.3 EDC100 Front view

7 8 9

ON
4 5 6
STOP
1 2 3 ON

TEST
F1 F2 F3 0 , -/+

Figure 17 EDC100Front view

6.2.4 EDC100 Rear view

Drive
RMC (ext. keyboard)
230/115 V

I
0
Load

Calibration-
26 pin 15 pin 9 pin 9 pin
contact
Drive I/O X-Head PC/Printer

Figure 18 EDC100 Rear view

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6.2.5 Pin Description

6.2.5.1 PC/Printer-Interface
An optional PC or a printer can be connected to the serial interface with signals being transmitted via
a 9-pin connector.
The logic signals are generated by an UART with FIFO.
Asynchronous, full duplex. CTS supported
Level: RS232 16 Byte FIFO
Configurable via software up to 115 kBaud. Pin description: compatible with PC/AT

Pin description X1:

1 2 3 4 5 SubD Plug
6 7 8 9 9-pin

Pin-No Inscription Function Signal

type
1
2 RX Receive Data (EDC100) RS 232
3 TX Transmit Data (EDC100) RS 232
4
5 GND Ground GND
6
7
8 CTS clear to send (Printer) RS 232
9

Table 21 PC/Printer Interface Pin description

6.2.5.2 I4-Bus Option-slots

The controller board has eight I4 Slots available for 8-Bit-BUS for IO-cards
The signal definition is similar to the I³-Bus specification.
For further information refer to the I4-Bus specification.

Features
Bus driver in FCT-T-Logic 32 Byte address space reserved for I³-Module
8 Data bits compatibility.
12 Address bits (4 Kbytes address space per Generation of one select signal and interrupt
module) signal on the BUS per module slot.
E2PROM for module detection When not accessed, the bus stays in the
Master/Slave-Mode for synchronisation non-operational mode
Downloadable to intelligent I4-Modules

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6.2.5.3 Drive Interface

The drive interface has an incremental measuring channel, an output channel with 16 bit
D/A,Transducer, control input and outputs, X-head position memory as well as safety circuit
monitoring.
The following diagram provides an overview of the drive interface and the patch plugs fitted

Front Panel
Emergency
ON Stop

To the EHC2
Front Drive-I/Os 16 Bit DAC
Panel

P
1

Monitoring Processor

To the
Power P
Ampli- 7
fier

26 pole 9 pole
Drive X-Head

Figure 19 Diagrammatic layout of Drive Interface

Switch on drive: Drive free (emergency drive):

Switch on machine, no limit switch or Limit switch active.
emergency stop active. Trace program checks TEST-Bit (motor
Trace program checks TEST Bit (motor contactor dropped before switch on) and ON
contactor dropped before switch on). button released.
Deactivate emergency stop from the PC (NAR). Deactivate emergency stop from the PC (NAR).
Operator presses ON button => “AON“ active Operator keeps ON button pressed => “AON“
(drive is switched on). active and the drive free relays are picked up.
Trace program checks TEST-Bit and AON-Bit Trace program checks TEST-Bit and AON-Bit
(motor contactor closed after switch on). (motor contactor closed after switch on).
The message “AB1, AB2“ appears after end of The message “AB1, AB2“ appears after end of
the drive power up cycle. the drive power up cycle.
Set “AFG (Drive release)“ from the PC. Set “AFG (Drive release)“ from the PC.
Connect controller output to the D/A transducer. Connect controller output to the D/A transducer.

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6.2.5.3.1 Drive Variants

Three different power amplifier variants can be connected to the EDC100:

Power amplifier for servomotor DDA04 500 W (105V, 11/15A)
Power amplifier for servomotor DDA05 1000 W (105V, 11/15A)
Power amplifier for servomotor DDA06 2000 W (150V, 15/20A)

6.2.5.3.2 Incremental Input for X-Head Position on the EHC2 (No 0834)

Features:
Signal type: TTL Maximum input counting frequency : 1,5 MHz
Track A, track B, reference (transducer 1000 marks, drive 3000 rpm > 50 kHz)
Direction detection and impulse quadruplicating Transducer connected detection
16 Bit Up/down pulse counting 5V supply for an incremental transducer protected
by a 1.8A multifuse.

Pin description X7:

5 4 3 2 1 SubD Plug
9 8 7 6 9-pin

Pin-No Inscription Function Signal

Type
1 Shield / GND screen 0V
2 /CON Incr. transducer plugged TTL
3 I2C-C I²C-Bus Clock TTL
4 B Incr. transducer trace B-input TTL
5 Ref. Incr. transducer reference- TTL
input
6 /KE calibration enable TTL
7 I2C-D I²C-Bus data TTL
8 A Incr. transducer trace A-input TTL
9 5V-ext 5V short circuit resistant +5 Volt

Table 22 EDC100 External Incremental Connector Pin description

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6.2.5.3.3 Safety related signals

The following figure provides an installation overview of the safety signals leading from the power
amplifier via the controller board to the front panel via the patch plugs.

Power Amplifier EHC2 Front Panel

Cable
X2/P2 0821.04.01a X3/P7 P11
24V 5 24V 24V 1 24V NA1 1
Emergency
Emergency
Stop
Stop
6 ES 1 NA 8 NA NA2 10
ON-L1 2
ON-
Lamp
CPU ON-L2 8

7 ES 2 TNA 3 TNA ONFF1 4

Upper Soft ONFF

Limit Switch CPU ON-Key
TNA Drive Free
3 ONFF ONFF 6 ONFF ONFF2 7
Lower Soft
Limit Switch
CPU
ONFF
Drive Free
Contactor

8 ONI1 ONI1 4 ONI1 ONI1 5

ONI
ES ON-Key
Contactor Info
9 ONI2 ONI2 5 ONI2 ONI2 6
Drive
Contactor CPU
ONI
2 GND GND 2
GND

Figure 20 Safety related Signals Connections from the Power Amplifier to the Front Panel

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Pin Description P7:

1 2 3 4 5 6 7 8 Molex Plug
8-pin

Pin-No Inscription Function Signal Type

1 24V 24 Volt 24Vdc
2 GND GND for 24 Volt signals GND
3 NA From: Emerg. Stop button of the power amplifier 24V / 200mA
To: P11 and ONFF-key of the front panel
internal info signal ‘TNA’ to CPU is branched
4 ONI1 From: Power amplifier, signal behind break drive 24V / 200mA
free contactor
To P11 and ON-key of the front panel
5 ONI2 From: P11 and ON- key of the front panel 24V / 200mA
To: Power amplifier (not used)
internal info signal ‘ONI’ to CPU is branched
6 From: P11 and ONFF- key of the front panel 24V / 200mA
To: Power amplifier, bypasses the limit switches
during drive free
internal info signal ‘ONFF’ to CPU is branched
7 GND GND for 24 Volt signals GND
8 NOTAUS1 Input: Emergency Stop button of the EDC5 / 25 /100 24V / 200mA

Table 23 Power Amplifier Safety Signals Connector Pin description

Pin Description P11:

1 2 3 4 5 6 7 8 9 10 Molex Plug
10-pin

Pin-No Inscription Function Signal Type

1 NA1 Connection to the front panel E/Stop button, contact 1 24V / 200mA
2 ON-L1 Drive to the ON-Lamp contact 1 24V / 20mA
3 free
4 ONFF1 Connection to the front panel ON-drive free key, contact 1 24V / 200mA
5 ONI1 Connection to the front panel ON-key Info, contact 1 24V / 200mA
6 ONI2 Connection to the front panel ON-key Info, contact 2 24V / 200mA
7 ONFF2 Connection to the front panel ON- drive free key, contact 2 24V / 200mA
8 ON-L2 Connection to the front panel ON-Lamp, contact 2 24V / 20mA
9 free
10 NA2 Connection to the front panel E/Stop button, contact 2 24V / 200mA

Table 24 Front Panel Safety Signal Connector Pin Description

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6.2.5.3.4 External Drive Control Signal Connector

Connector for limit switches and drive signals.

Pin Description X4:

1 2 3 4 5 6 7 8 9 SubD Plug
10 11 12 13 14 15 16 17 18 26-pin
19 20 21 22 23 24 25 26

Pin-No Inscription Function Signal Type

1 GND-ext Shield (case) + digital-ground
10 /ESo Signal upper limit switch 24V
19 DACGND Ground for 16-bit DAC
2 SYNCH+ Synchronisation 200 kHz Line driver TTL
11 SYNCH- Synchronisation 200 kHz Line driver TTL
20 ±10V Set value for ext. drive (16Bit) Analogue voltage
3 ABER1 Drive 1 ready from ext. drive 24V
12 ABER2 Drive 2 ready from ext. drive 24V
21 AFG Drive release for ext. drive 24V / 100mA
4 TEST Signal, all relay are in ground state 24V
13 FF Activate emergency drive resp. drive free 24V / 100mA
22 BYP Drive on bypass valve 24V / 100mA
5 BR Drive on Brake 24V / 100mA
14 24Vint Not used
reserved for redesign EDC5
23 AON Message contactor driven ontot 24V
6 SBUS_CL Drive on ASBUS in the Drive Clk RS232-Level
15 SBUS_DI Drive on ASBUS in the Drive data IN RS232- Level
24 SBUS_DO Drive on ASBUS in the Drive data OUT RS232- Level
7 /RNA Emergency Stop PC 24V / 100mA
16 X Not used 24V / 100mA
Drive on contactor
reserved for redesign EDC5
25 TYP_SDA I²C-data to the rating plate (in the drive pin) Open Coll. 5V
8 Free
17 +5V-I²C 5V for I²C in the drive pin not switched
26 GND24V GND for 24 Volt-Signals
9 /ESu Signal lower limit switch 24V
18 TYP_SCL I²C-Clock to the rating plate(in the drive pin) Open Coll. 5V
Table 25 EHC2 Drive Control Signal Connector Pin Description

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6.2.5.3.5 Drive Interface Safety Consideration

Supervision and control of the drive are hierarchically organised.

• The highest level contains the relay functions together with emergency stop button, limit switch
and ON key.
Emergency stop button and limit switches intervene directly with the drive control and electrically
isolate the entire drive branch when activated..
• The intermediate level contains the EDC safety circuit monitoring via a fitted PLD.
The monitoring checks the relay and contactor functions before and after switching on the drive.
If a fault occurs, the drive is deactivated and any attempt to switch on again is inhibited.
• The lowest level contains the software safety monitoring.
It is possible at any time to deactivate the drive by setting a bit (NAR).
The three levels work separately when supervising errors. In the event of an error up to three sections
stop the drive.
Example: The crosshead activates a limit switch.
• The limit switch isolates the drive circuit.
• The PLD detects the open limit switch and via the emergency stop relay isolates the contactor.
• The software detects the open limit switch and sets the NAR-Bit. This action isolates the contactor
via the PLD and emergency stop relay.
Detailed error and safety functions are described ‘Safety Techniques Drives’ documentation
Figure 21 shows the relay and other safety device interconnections e.g. emergency stop key, limit
switch and On-key.

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EDC100
24Vex Sequence
+24V
0V No ES active,
GND1 24Vdc
GND No EMERG.STOP
EMERGENCY STOP key PELV active,
+24V
/ES1 Signal: TEST=24Vdc,
ES-CPU
SW/PLD-Bits & Signal: AON=24Vdc
Emerg. Run Lock
Condition: Instrument
supplies no key etc. K5a
/ES2 K4a' Contactor K1, K2 = active
TNA
upper soft lower soft
/EMERG.STOP Info
limit switch limit switch
ONI1 Signal: TEST=0V

ON-key
Signal: AB1, AB2 =
/ONI ONI2
ON key Info
Signal: AFG = 24Vdc
K4b
/ONFF ONFF
ON Free run ON-key released
Info instrument runs
Contacts restraint
ESo ESo Info /ESo
ESu ESu Info /ESu

/AON Drive ON DON

/TEST Test TEST

K4a''
24Vex
K1 K2
/AB1 Ready Drive 1 ABER1
21 5 3 1 101 21 5 3 1 101
/AB2 Ready Drive2 ABER2 Drive
supplied

22 6 4 2 102 22 6 4 2 102

FF GND GND
FFR
/NAR /ES
K5 K4
24Vdc
24Vdc - Lock realised by K5
GND GND
- The safety monitoring PLD checks the
EMERG.STOP EMERG.RUN function of the relais
CPU Free run
(Signal "TEST" and Signal "AON")
safety relais

Figure 21 Diagrammatic layout of Relays, Emergency Stop, Limit Switch and On-Key

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Possible safety circuit monitoring errors and reactions are reported in the following list

Assumed Error Effect Reaction

Emergency stop, limit switch Signals TNA, ESO, ESU Emergency stop relay (NA-relay) is not
activated. deactivated. switched.
Emergency stop by the software. NAR-Bit set. NA-relay is not switched.
Motor contactor (K1 or K2) not TEST-Bit on 0V. Fatal error
dropped before switch on. NA-relay is not switched, error
message drive defect.
New switch on not possible.
Contactor K1 or K2 does not drop TEST-Bit on 0V after drive Fatal error
Load contacts do not open. switch-off NA-relay is not switched, error
message drive defect.
New switch-on not possible.
Contactor K1 or K2 either does not TEST-Bit on 24V after drive Fatal error
pick up or picks up after a 325 ms switch-on. NA-relay is switched off, error message
delay. drive defect
New switch on not possible.
Emergency stop relay (K5) does not AON-Bit is not set. Fatal error
pick up when switched on. NA-relay is not switched, error
message drive defect
New switch-on not possible.
Emergency stop or limit switch Drive is switched off and not switched
activated and released again. on again.
Wait for On button activation.
Emergency stop or limit switch No error message.
activated and released again while Drive is switched off and not switched
On button contact is permanently on again.
closed. Wait for On button release and
(Key clamps) reactivation.
Emergency drive bit (FFR) is set Would lead to bypass of the Drive is switched off, no bypass of the
without any reason during drive limit switch limit switch.
runs. Switch on and bypass of the limit
switch only possible when On button is
activated.
Contacts of the On button do not Limit switches stay No error message.
open by the emergency run. bypassed. PLD does not recognise error,
but software detects emergency run bit
(FFR), when operator releases up/down
key.
Emergency run relay is released, limit
switches are active again.
On button contacts do not open, No error message.
then approach to limit switch. (Key Drive is not switched on, no bypass of
clamps) limit switches. Wait for On button
release and reactivation.
Electrical failure of PLD Drive is deactivated after Each PLD condition needs the
supervision logic approx. 0,7 sec. operation of a separate drive watchdog.
(separate monitoring,
contactor without current)

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6.2.5.4 Calibration Contact

Open collector, NPN, low level 0,8 Volt with 100 mA, NOT short circuit proof
Pin Pin
EDC100 back panel EDC100 controller
board
Triggering Jacket, ESD-solid, 4mm, red X1
signal
GND Jacket, ESD-solid, 4mm, silver –

6.2.5.5 Universal-I/O
Four outputs, 24 V / 100 mA and four inputs 24V can be connected to the Universal-I/O-pin. The
signals are not assigned to any function.

Pin Description X2:

8 7 6 5 4 3 2 1 SubD Plug
15 14 13 12 11 10 9 15-pin

Pin-No Inscription Function Signal Type

1 GND-ext Shield (case) + digital-ground
2 IN2 Input 2 24V
3 IN4 Input 4 24V
4 reserved for input
5 reserved for output
6 OUT4 Output 4 24V / 100mA
7 OUT2 Output 2 24V / 100mA
8 24V 24 V Voltage supply 24V / 500mA
9 IN1 Input 1 24V
10 IN3 Input 3 24V
11 reserved for input
12 GND-24V GND for 24V-supply
13 reserved for output
14 OUT3 Output 3 24V / 100mA
15 OUT1 Output 1 24V / 100mA

Table 26 Universal-I/O Connector Pin Description

6.2.6 Addressing hardware

When adjusting the EDC5/25 Set-up to control hardware modules, ensure that the drivers are correctly
addressed. Refer to the ‘Drive for Hardware Modules of the EDC Family’ documentation.

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6.3 Differences between EDC5/25 and EDC100

The following additions have been made to the EDC100:
• Faster processor and more storage
• Higher load resolution, up to ± 160.000 pixels
• Better expansion possibilities: 8 plug-ins instead of 2 (on the EDC100 one plug-in is allocated for
load detection).
• Support of the interrupt function on the expansion plug-ins.
• Realtime Clock.
• Support of the incremental sensor plug, this enables the use of different incremental transducers
with Sinusoidal or Rectangular signals (RS422 / TTL). Information on incremental transducer is
stored in the sensor plug E2PROM.
The incremental input is not compatible with EDC5/25 units.
• Increase in the maximum counting frequency at the incremental input from 0,5 MHz to 1,5 MHz.
• Drive signal connector changed from 15-pin SubD to 26-pin SubD-HD.
• Power amplifier cable connector fitted with 4x higher capacity E2PROM to enable storage of
more data.
• Improved safety functions and greater drive interface error analysis.
• The ‘Drive defective’ error checks for incorrect 24 V voltage supply, short circuit at drive outputs
or universal-I/O and activates the drive watchdog.
• Setting of drive free relays is included in the safety check.
• 4 input and 4 outputs with 24 V level, for general use.

EDC5/25 and EDC100 Incremental Input connectors are not compatible,

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6.4 I4-Boards

6.4.1 4ETF

6.4.1.1 System Overview

The 4ETF-Module is a Carrier Frequency measurement amplifier designed for Strain Gauge
Bridge and inductive transducers as well as for use with direct current signals. The A/D
transducer uses a voltage/frequency interface and is therefore an integrating unit.
Amplifier and Supply
Carrier frequency 5 kHz Sinusoidal
Supply voltage adjustable via software (in Veff) 1,1 – 2,5 – 5,5 Volt
Sensitivity of transducer adjustable via software 1,16–1625 mV/V
Internal resistance transducer ≥ 85 Ω
Source resistance signal source (CF mode) ≤ 1,1 kΩ
Source resistance external reference (CF mode) ≤ 1,1 kΩ
DC input adjustable via software ± 0,727 V – ± 1,625 V
Input resistance (DC detection) > 15 MΩ
Common mode range ±8V
Common mode suppression (input amp.: x3,1 – x34,6 – x387) ≥ 80dB, ≥ 95dB, ≥ 105dB
Filter Bessel filter 3rd order, 100 Hz

Transducer
Type U/f transducer
Resolution at 20 ms and full drive ± 140.000 pixels
250 ms integration time ± 1.770.000 pixels
± 400.000 pixels reproducible
Linearity of amplifier and transducer Typical 0,01 % (0,025 % max.)
Linearity at 20 % max. overload Approx. 2 %
Temperature influence per ° Kelvin (CF detection) Offset 0,001 %/°K
Amplification 0,01 %/°K

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Display Noise Level:

The displayed value of a connected sensor must not deviate by more than ± 0,5 % of 0,4 % nominal
rating (i.e. 2 digits per 100.000 digits) under the following conditions:
1. Testing machine switched off, integration time 100 ms, load cell unloaded.
2. Testing machine switched on and driving, integration time 100 ms, no load being transmitted
to load cell.
Transducer Coding
The sensor plug E2PROM is used to store information regarding the connected transducer
The data is automatically read into the EDC when switching on or by request.

Sensor Plug
Testing machines are normally configured prior to delivery to a customer.
As the calibration data for each transducer is stored in the sensor plug E2PROM together with other
relevant data during a calibration procedure, it is essential the transducer and associated cable with
sensor plug always remain together. As all characteristics are stored in the sensor plug a further
calibration is not strictly necessary when transferring transducers between systems or when
connecting new factory supplied transducers. (It should be noted that some Calibration Procedures
related to Testing machines may require transducer calibration carried out with each machine
i.e. BS EN 10002)
The EDC automatically reads in the sensor plug calibration information after switching on. The sensor
plug contains:
• Reference attenuator for allow use with a wide range of transducer sensitivities.
• E2PROM to store transducer data.
The transducer cable is directly soldered to the circuit board fitted in the connector shell. Software for
programming the E2PROM is provided.

Mechanical Layout and Bridge Description

Option
Analogue Output

BR2 BR1
1 1
2 2
3 3

Figure 22 View of 4ETF Components

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6.4.1.2 Pin Description

Sensor Input
It is important to always switch off the electrical supply to the EDC before attempting to removing
any 4ETF connector in order to prevent possible damage caused by high voltages which can be
generated when an energised inductive transducers is disconnected.

1 2 3 4 5 6 7 8 SubD Plug
9 10 11 12 13 14 15 15-pin

Pin-No Inscription Function Signal Type

1 GND-ext shield (case) + DGnd
2 SDA I²C-data Open Coll.-5V
3 SCL I²C-clock Open Coll.-5V
4 KE calibration-enable-plug TTL
5 Mess-A measuring signal A
6 Mess-B measuring signal B
7 Füh-B probe B
8 Spei-A supply A
9 R-Ref. B external reference B
10 CON cell plugged TTL
11 5V-SW 5V for I²C periphery, Imax = 0,25 A
12 AGND analogue ground (10 Ω)
13 R-Ref. A external reference A
14 Spei-B supply B
15 Füh-A probe A

Table 27 Load Plug Pin Description

BR1 and BR2 links change the measuring input from the sensor plug to the I4-Bus. The following
sensor plug bridge configuration is required for normal operation (factory default setting).

BR2 BR1
2 -3 2 -3

Table 28 4ETF Bridge Link Connections

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6.4.1.3 Analogue Output (Option)

Brief Description
After passing the rectifier and 3rd order Bessel filter, the analogue signal is de-coupled at fg = 100 Hz
and connected to an amplifier for signal division.
The resulting analogue signal represents a raw value, the scaling is such that the end scale value (e.g.
largest processed load signal including 20% overload range) produces a voltage range of approx.
± 12 V.
A nominal amplifier signal produces approximately ± 10 V output signal.
No output scaling or offset options are provided and the output appears at a HF socket, series SMA
with an output resistance of 50 Ω. An optional HF to BNC adapter is available.
Technical Data
Amplifier and Supply Option Analogue Output
Output voltage for nominal input signal (incl. 20% Approximately ± 10 V (± 12 V)
overload); output load more than 2 kΩ.
Signal Source resistance 50 Ω
Filter Bessel Filter 3rd order, 100 Hz
Deceleration time (due to filter) 2,7 ms
Damping of the 5 kHz carrier frequency 90 dB
Linearity typically 0,01 % (0,025%max)
Linearity at overload of max. 20 % Approx. 2 %
Temperature influence per ° Kelvin (CF detection)
Offset 0,005 %/°K

Amplification 0,02 %/°K

Temperature influence per ° Kelvin(DC detection)
Offset 0,05 % /°K

Amplification 0,02 %/°K

Table 29 Analogue Output Technical Data

Connection Plug
The analogue output signal is available via a HF socket, series SMA.
The shield connection (outer screw thread of the socket) has a conductive contact to the front panel
and therefore to the system reference potential.
In order to get a good signal, the front panel must be directly screwed into the fixing device.

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Mechanical layout

Figure 23 View of Analogue Output Components

6.4.1.4 Triggering Components

When adjusting the EDC5/25 Set-up to control hardware modules, ensure that the drivers are correctly
addressed. Refer to the ‘Drive for Hardware Modules of the EDC Family’ documentation.

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6.4.2 INC

6.4.2.1 System Overview

The 4INC-Module provides EDC5/25 and EDC100 units with the following functions:
Two 'incremental sensor inputs' for direct connection of incremental revolving transducers with digital
quadruplicating resolution.
For each channel, the level of the incremental transducer is adapted by superimposing a 'sensor plug',
and the transducer coding is obtained from an external E2PROM in the sensor plug.
6 outputs, level 24V/100mA
1 output, relay with a change-over contact
5 inputs, 24V-level

Block Diagram 4INC

24V I/O

Incremental Square I4-Bus

Sensor x4 Interface

Incremental Square.
Sensor x4

I4-Bus

Figure 24 4INC Block Diagram

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Incremental Inputs
The interface card has two incremental inputs each having the following specification:
Transducer supply: +5V (max. 250mA)
Input level: Rectangle / TTL,
Connecting a sensor plug per channel adapts the incremental
transducer level (e.g. 7IS2-0800: Sensor plug for two sine
transducers with tenfold analogue resolution).
Analysis: Using the trace signals A and B, the resolution is digitally increased
by factor 4 and the counting direction (up/down) detected.
Transducer ID: One I²C-Bus per channel, connected to an EEPROM 24C04 inside the
sensor plug

Example: To adapt the level of the sine transducer, type “Heidenhain Minirod 450“, the
sensor plug “7IS1-0799“ can be used.
Digital Inputs
Five separate digital inputs are fitted on the interface card, each having the following specification:
Low level: < +1,8V
High level: +9V to +30V
Digital Outputs
All digital outputs (incl. the relay) are derived from an externally connected supply voltage (+24V).
Six digital outputs are fitted on the interface card, each having the following specification:
Driver components: with automatic shutoff with a short circuit
Type open emitter, +24V (external voltage supply)
Low level open output
High level +10 to +30V/100mA (external voltage supply)

One relay output is fitted on the interface card, having the following specification:
Relay, type: Siemens V23042
Kind: change-over contact rating (150V, 2A)

Attention To guarantee correct relay functioning, the externally connected +24V

voltage supply MUST be grater than +20V at all times.

A Hardware reset erases the output registers and sets all outputs (incl. the relay) to the passive state.

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6.4.2.2 Pin Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 SubD Plug
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37-pin

Pin-No Inscription Function Signal Type

19 GND-ext Shield (case)
37 /KE1 Calibration data can be written into the 2nd IN TTL
E2PROM
18 /CON1 Transducer 2 plugged IN TTL
36 SDA I²C- E2PROM Data IO OC/TTL
17 SCL1 I²C- E2PROM 2Clock OUT-OC/TTL
35 A1 Incremental measuring signal IN TTL
16 B1 Incremental measuring signal IN TTL
34 +5V Supply voltage
15 R1 Incremental measuring signal IN TTL
33
14
32 O0 Digital output OUT +24V
13 O1 Digital output OUT +24V
31 O2 Digital output OUT +24V
12 O3 Digital output OUT +24V
30 O4 Digital output OUT +24V
11 O5 Digital output OUT +24V
29 COM Relays contact middle
10 NC Relays contact break
28 NO Relays contact make
9 +24V External voltage IN +24V
27 I0 Digital input IN +24V
8 I1 Digital input IN +24V
26 I2 Digital input IN +24V
7 I3 Digital input IN +24V
25 I4 Digital input IN +24V
6 GND-ext Shield (case) IN +24V
24
5 GND-ext Shield (case)GND
23 /KE0 Calibration data can be written into the 1st IN TTL
EEPROM
4 /CON0 Transducer 1 plugged IN TTL
22 SDA I²C- E2PROM data IO OC/TTL
3 SCL0 I²C- E2PROM 1 Clock OUT OC/TTL
21 A0 Incremental measuring signal IN TTL
2 B0 Incremental measuring signal IN TTL
20 +5V Supply voltage
1 R0 Incremental measuring signal IN TTL

Table 30 4INC- Connector Pin Description

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Connection of Incremental Sensors

Adaptation modules (sensor plugs) are available for one or two channels and three different signal
types (TTL, RS422-Line receiver, 11µA-Sine).
The incremental sensor is connected to the 4INC components via a 37pin sensor plug, selected from
the following Table.
Component Channel 0 Channel 1
Number
7IS1 0799 sin –
7IL1 0795 re-line –
7IT1 0797 re-TTL –
7IS2 0800 sin sin
7IL2 0796 re-line re-line
7IT2 0798 re-TTL re-TTL

Table 31 Incremental Transducers Adaptation Modules

Sensor Plug for 1 Incremental Channel Sensor Plug for two Incremental Channels

K1 K9

INCR.
TOP Adjustm.- Chan. 1
Key

K1 K9 K1 K9

INCR. INCR.
TOP Adjustm. Chan. 0 TOP Adjustm.- Chan. 0
Key Key
1 1

Figure 25 Dual and Single Adaptation Modules

The connection cable for a sensor with a differential signal (RS422 or sine) is soldered to K1 to K9
connection points.
The connection cable for a sensor with single TTL signal is soldered partially to K1 to K9 connection
points and partially to the SUBD socket.
Further information on sensor plugs can be found in the “Incremental Sensor Plug” documentation.

6.4.2.3 Triggering the Components

When adjusting the EDC5/25 Set-up to control hardware modules, ensure that the drivers are correctly
addressed. Refer to the ‘Drive for Hardware Modules of the EDC Family’ documentation.

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6.4.3 4IO

6.4.3.1 System Overview

The 4IO-Module provides EDC5/25 and EDC100 units with the following :
6 outputs, level 24V/100mA,
1 output, relay with a change over contact
5 inputs, 24V-level
Block Diagram 4IO

24V I/O

TTL I4-Bus
I/O
Interface

TTL
I/O

I4-Bus

Figure 26 4IO Block Diagram

Digital Inputs
Five digital inputs are fitted on the interface card, each having the following specification:
Low level: < +1,8V
High level: +9V to +30V

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Digital Outputs
All digital outputs (incl. the relay) are derived from an externally supplied voltage (+24V)
Six digital ouputs are fitted on the interface card, each having the following specification:
Driver components: with automatic shut-off if short circuited
Type open Emitter +24V (external supply voltage)
Low level open output
High level +10 to +30V/100mA (external supply voltage)
One relay output is fitted on the interface card, having the following specification:
Relay type Siemens V23042
Contact rating Change-over contact (150V, 2A)
Attention To guarantee correct relay functioning, the externally connected +24V
voltage supply MUST be greater than +20V at all times.

A Hardware reset erases the output registers and sets all outputs (incl. the relay) to the passive state.

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6.4.3.2 Pin Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 SubD Plug
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37-pin

Pin-No Inscription Function Signal Type

19 GND-ext Shield (case)
37 /KE1 Calibration data can be written into the 2nd IN TTL
E2PROM
18 /CON1 Transducer 2 plugged IN TTL
36 SDA I²C- E2PROM data IO OC/TTL
17 SCL1 I²C- E2PROM 2Clock OUT-OC/TTL
35
16
34 +5V Supply Voltage
15
33
14
32 O0 Digital output OUT +24V
13 O1 Digital output OUT +24V
31 O2 Digital output OUT +24V
12 O3 Digital output OUT +24V
30 O4 Digital output OUT +24V
11 O5 Digital output OUT +24V
29 COM Relays contact middle
10 NC Relays contact break
28 NO Relays contact make
9 +24V external voltage IN +24V
27 I0 Digital input IN +24V
8 I1 Digital input IN +24V
26 I2 Digital input IN +24V
7 I3 Digital input IN +24V
25 I4 Digital input IN +24V
6 GND-ext Shield (case) IN +24V
24
5 GND-ext Shield (case) GND
23 /KE0 Calibration data can be written into the 1st IN TTL
E2PROM
4 /CON0 Transducer 1 plugged IN TTL
22 SDA I²C- E2PROM data IO OC/TTL
3 SCL0 I²C- E2PROM 1 Clock OUT OC/TTL
21
2
20 +5V Supply voltage
1
Table 32 4IO Connector Pin Description

6.4.3.3 Triggering the Components

When adjusting the EDC5/25 Set-up to control hardware modules, ensure that the drivers are correctly
addressed. Refer to the ‘Drive for Hardware Modules of the EDC Family’ documentation.

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