IQAN-TOC8 Instruction book

Publ no HY33-8304-IB/UK Edition 2011-08-10

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Overview of relevant documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Read This . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IQAN-TOC8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Internal diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CAN-bus interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Current check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mounting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connector C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Reference voltage, VREF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Voltage inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Frequency inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Current outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PWM outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 IQAN-TOC8 Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Error codes, messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Dimensioning of the IQAN-TOC8 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 3 4

5 6

7 8

Instruction book, IQAN-XP2

ii

Warnings
1 Introduction

Introduction

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

Warnings
Sections marked with a symbol in the left margin, must be read and understood by everyone using the system, carrying out service work, or making changes to hardware and software. The different symbols used in this manual are defined below.
W ARNING

Sections labeled WARNING with a caution symbol in the left margin, indicate that a hazardous situation exists. We use warnings, marked with the warning symbol, in two ways. As a strong recommendation about work practices when using the product in the machine (e.g. routines when updating an application). This use is common to the term 'hazardous situation', that a person is exposed to a hazard. As a way of pointing out important information for the machine designer that in some way relates to safety. This includes the design of the physical machine, and also the application program being developed for the control system. Not all document sections that contain information about safety are marked with a warning symbol (there would be warnings everywhere). Failure to comply with the recommendations can cause unintentional, and unexpected behavior of the control system. This can potentially cause death, serious injury or property damage.
N OTICE

Sections labeled NOTICE with a notice symbol in the left margin, indicate there is important information about the product. Ignoring this could result in less than optimal performance, or damage to the product. Contact the manufacturer if there is anything you are not sure about or if you have any questions regarding the product and its handling or maintenance. The term "manufacturer" refers to Parker Hannifin Corporation.

Instruction book, IQAN- TOC8

Overview of relevant documentation

1 Introduction

Overview of relevant documentation

The following publications are relevant for users of this product. The main documentation contains information that is not found elsewhere. The additional documentation contains product information in a compact format, for details on the information found in those documents, consult this manual.
IQANdevelop User Manual Documentation
Main

IQAN-TOC8 Instruction Book HY33-8304-IB (this book)

Compact Documentation

IQAN-TOC8 Catalogue Datasheet HY33-8304

IQAN-TOC8 Installation Sheet HY33-8304-IS

IQAN-TOC8 Electrical Schematic HY33-8304-ES

The IQAN-TOC8 module documentation system.

Instruction book, IQAN- TOC8

Read This
2 Precautions

Precautions

Work on the hydraulics control electronics may only be carried out by trained personnel who are well-acquainted with the control system, the machine and its safety regulations.
W ARNING

Make sure that you have sufficient knowledge before designing, modifiying or servicing the control system. Read the relevant sections of this document before conducting any work on the control system.
W ARNING

This product is not field repairable.

N OTICE

As much as possible of the welding work on the chassis should be done before the installation of the system. If welding has to be done afterwards, the electrical connections on the system must be disconnected from other equipment. The negative cable must always be disconnected from the battery before disconnecting the positive cable. The ground wire of the welder shall be positioned as close as possible to the place of the welding. The cables on the welding unit shall never be placed near the electrical wires of the control system.

Read This
Design of control system
W ARNING

Risk of injury may be introduced by design of control system! This product is designed to control hydraulic outputs. The control application must be designed using basic safety principles so that unintentional movement is avoided. The machine must be equipped with an emergency stop that stops all movement. Please refer to see section Emergency stop, on page 9.
Before you start

Read this document, as a minimum sections 1-7 Read the IQANdevelop software user manual section on 'application safety'.

Instruction book, IQAN- TOC8

Read This
2 Precautions

Start-up, maintenance, and diagnostics

For all personnel carrying out installation, commissioning, maintenance or troubleshooting.
W ARNING

Work on the hydraulics control electronics may only be carried out by trained personnel who are well-acquainted with the control system, the machine and its safety regulations.
Before you start,

Read see section Start-up, on page 20.

Additional information for service

Mounting and maintenance instruction book.

Additional information for diagnosing the system

Read see section System Diagnostics, on page 21, and see Appendix B, on page 25, in this document. Use the IQANdevelop software user manual as a reference.

Instruction book, IQAN- TOC8

IQAN-TOC8
3 Product description

Product description

IQAN-TOC8
The IQAN-TOC8 is a stand alone controller designed for controlling hydraulic systems in vehicles and machinery, using 12/24 Vdc power supply.

The IQAN-TOC8 controller.

Input

The IQAN-TOC8 has ten (10) inputs. These can be used as voltage inputs for connection of 0-5 Vdc signals or as digital inputs. VIN A thru VIN D can be configured as frequency inputs for measuring frequency. Voltage inputs and frequency inputs, share positions, see below.
(10) Voltage inputs VINA, VINB,VINC, ......,VINJ or (10) Digital inputs DINA, DINB, DINC, ......, DINJ or (4) Frequency inputs FINA, FINB, FINC, FIND & (6) Voltage inputs VINE -VINJ
Output

The IQAN-TOC8 has 2 double current outputs for controlling proportional valves or devices. The unit has 6 digital outputs for on/off valves, or 3 double PWM outputs (Pulse Width Modulation) for controlling standard proportional and PulsarTM type valves. Digital and PWM outputs share positions, see below.
2 double Current outputs 6 Digital outputs, or 3 double PWM outputs

In order to increase the performance of the current outputs when controlling proportional valves, both the dither frequency and the dither amplitude can be adjusted. The digital output channels also have PWM, soft start and peak & hold features available. CAN related functions IQANsimulate software uses the CAN-bus (CAN = Control Area Network) to communicate with the controller when proving applications off of the machine (requires NI CAN card). The CAN-bus may be used by the TOC8 for SAE J1939 communication with engine electronics and for system control.

Instruction book, IQAN- TOC8

Internal diagnostics
4 Safety

Safety

Internal diagnostics
The module performs a number of self-checks that improve safety. Checks include monitoring of voltage supplies, checksums on memory and a watchdog that monitors software execution. The module is using a real time operating system which supervises software execution. If a critical error is detected, the module is stopped, with CAN-bus and outputs off.

CAN-bus interruption
The IQAN-TOC8 module monitors the CAN-bus (when used for SAE J1939) for interruptions in communication. An error will be presented with a related blink code on the IQAN-TOC8 status LEDs.

Current check
For the proportional outputs when used in current mode, a current check is performed. If an error is detected, this will be indicated on the module, and the output will shut off. The module can detect open-circuit, short-circuit to +BAT/-BAT or short-circuit to other proportional output and return pins.

Emergency stop
W ARNING

Risk of injury! The emergency stop must disconnect the power supply to the module; do not connect the emergency stop as a signal input only. The emergency stop must be installed so that the risk of reverse feed of the module is avoided, see section Emergency stop, on page 9.

Instruction book, IQAN- TOC8

Mounting the unit

5 Mounting

Mounting

Mounting the unit

The IQAN-TOC8 should be mounted according to the following instructions: Locate the unit eliminating the risk for the cabling to be folded, crushed or damaged in any way. Ensure the cabling cannot pull, twist or induce sideload on the connector. Locate the unit so that severe physical impact is avoided, e.g impact from falling objects or the unit being used as a step. Locate the unit so that air can circulate to eliminate excess heat. Ensure that no external heat, e.g. from the engine or heater, is transferred to the control. Locate the unit to protect it from high pressure washing or similar. Locate the unit so that the cable connector is facing down . Locate the unit so that the LEDs are visible.

Non-approved placing.

N OTICE

The IQAN-TOC8 must not be placed in any marine-related or similar continuously damp environment without external protection.

Instruction book, IQAN- TOC8

Connector C1
6 Installation

Installation

Connector C1
Connector kit Parker no. 5031063
42 28 14 29 15 1

Housing Casing Plane sealing, 42 p Pin types* Cables Seals Plugs (empty pos.)
IQAN toolkit Pos Signal name

Amp no. 1-963226-1 Amp no. 0-965643-1 Amp no. 963225-1 Amp no. 963711-2 (MT) 0,75-1,0 mm (MT) Amp no. 963530-1 (MT) Amp no. 963531-1 (MT)
Parker no. 5031061 Pos

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

Amp no. 929938-1 (JPT) 1,5-2,5 mm (JPT) Amp no. 828905-1 (JPT) Amp no. 828922 (JPT)

Signal name

Pos

Signal name

1 2 3 4 5 6 7 8 9 10 11 12 13 14

not used +VREF-A VIN-A/DIN-A/FIN-A -VREF-A VIN-E/DIN-E VIN-B/DIN-B/FIN-B VIN-F/DIN-F VIN-G/DIN-G VIN-C/DIN-C/FIN-C VIN-H/DIN-H +VREF-B VIN-D/DIN-D/FIN-D -VREF-B not used

15 16 17 18 19 20 21 22 23 24 25 26 27 28

-BAT CAN-H COUT-A CRET-A+ COUT-B CRET-B+ DOUT-A/ PWMOUT-A DOUT-B/ PWMOUT-B DOUT-E/ PWMOUT-E DOUT-F/ PWMOUT-F DATA-OUT DATA-IN VIN-I/DIN-I +BAT (+12 V, +24 V)

29 30 31 32 33 34 35 36 37 38 39 40 41 42

-BAT2 CAN-L COUT-A CRET-ACOUT-B CRET-BDOUT-C/ PWMOUT-C DOUT-D/ PWMOUT-D ALARM GND (DATA) READY-OUT BSL-IN VIN-J/DIN-J +BAT2 (+12 V,+24 V)

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

Instruction book, IQAN- TOC8

Supply voltage
6 Installation

Supply voltage
Before any installation of the IQAN system can take place, make sure the ignition lock is turned off and the battery is disconnected. Emergency stop Make sure an Emergency Stop disconnecting the power supply, is easily accessible at any time. The figure below shows how to connect the emergency stop. Connecting of Supply Voltage The supply voltage, should be within the operating interval, see Appendix A, on page 22. Connect the supply voltage to +BAT, position 28 and -BAT, position 15. Protect the control by using a fuse. Requisite fuse level should be 20 A, fast (F).
Emergency Stop * 20 A +BAT, pos. 28 IQAN-TOC8

-BAT, pos.15

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

Connecting the emergency stop and voltage supply.

N OTICE

Do not use the chassis as the negative terminal.

Supplying a high current draw system

If the IQAN-TOC8 is used to control several digital outputs simultaneously, it is recommended to source power thru the +BAT2 and -BAT2 positions in addition to the +BAT and -BAT. Change the fuse to 30A, fast.

Emergency Stop * 30 A

IQAN-TOC8 +BAT2, pos. 42 +BAT, pos. 28 -BAT2, pos.29 -BAT, pos.15

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

Connecting the emergency stop and voltage supply.

Instruction book, IQAN- TOC8

Communication
6 Installation

Communication
RS232 and modem connection The IQAN-TOC8 has an RS232 interface for communicating with the programming software, IQANdevelop. A flying lead, panel-mount, adapter cable, 5030089, may be connected to the TOC8 to provide an HR12 connector interface. This will match to the PC communication cable provided in the IQANdevelop software package. Instead of using recommended Parker adapter cable 5030089, a DB9-F serial connector may be wired to connect directly to a PC. The basic wiring for use of a DB9-F serial connector is shown below.
IQAN-TOC8 READY_OUT, pos. 39 BSL_IN, pos. 40 GND (DATA), pos. 38 1 6 DATA_IN, pos. 26 DATA_OUT, pos. 25

Connecting DB9-F for RS232 usage.

When using the recommended Parker adapter cable, 5030089, the connection from TOC8 to PC can be made with the IQANdevelop included cable, 5030024, and from TOC8 to modem with a separately purchased cable, 5030080.
N OTICE

The Remote Diagnostic cable 5030080 must be used when connecting a modem to the TOC8. Use of the MDM-RS232 cable 5030024 may damage the modem. Using a modem
Start modem communication as follows:

Attach the modem to the TOC8. Power up the modem first, then power up or reset the TOC8. Wait 45 seconds for the modem to initialize. The TOC8 will blink a double fast yellow code to indicate the modem is attached. Dial up the modem -- the TOC8 will automatically answer. A fast yellow-red double blink indicates ringing. If a Reset Master command is sent or a new application is downloaded, the TOC8 will reset. Modem communication will not cease but with some equipment the blink code will change from the fast double yellow blink code to the normal status single blink. CAN connection The module has a CAN interface that can be used to connect to SAE J1939 or similar bus for communication between IQAN-TOC8 and other systems.

Instruction book, IQAN- TOC8

10

Reference voltage, VREF

6 Installation

Connecting to CAN interface

The interface is connected from the engines SAE J1939 interface to the CAN_H and the CAN_L.
EXAMPLE

Connect the SAE J1939 CAN_H and CAN_L pins to the CAN_H, position 16 and the CAN_L, position 30 on the IQAN-TOC8.
IQAN-TOC8 CAN-H, pos. 16 Customer provided connector 120 ohm CAN-L, pos. 30

Connecting a SAE J1939 interface to the TOC8 CAN hub.

Reference voltage, VREF

The IQAN-TOC8 is internally equipped with two voltage regulators to generate the reference voltages VREF A and VREF B. These reference voltages will feed different kinds of sensors.
IQAN-TOC8 -VREF-B, pos. 13 +VREF-B, pos. 11 -VREF-A, pos. 4 +VREF-A, pos. 2

VREF positions.

N OTICE

Maximum load for the VREF A and VREF B is different according to 12/24 Vdc power supply, see Appendix A, on page 22.

Instruction book, IQAN- TOC8

11

Voltage inputs
6 Installation

Voltage inputs
Connecting sensors to the voltage inputs The sensor signal range must be 0-5 Vdc. To detect signal errors such as short circuits or interruptions the active signal range should be within 0.5-4.5 Vdc.
[V] 5

Error detection range Active signal Error detection range t

Active signal range.

The current consumption related to the voltage input is negligible. The positive terminal of the sensor is connected to the +VREF position and the corresponding negative terminal to the -VREF position. The sensor signal is connected to appropriate VIN position.
EXAMPLE

Connect the positive and negative terminals of the position sensor to +VREF-A, position 2, and -VREF-A, position 4, respectively. Then connect the sensor signal to VIN-A, position 3.
IQAN-TOC8 -VREF-A, pos. 4 VIN-A, pos. 3 +VREF-A, pos. 2 Position Sensor

Connecting VREF-A and sensor signal VIN-A.

N OTICE

The negative terminal of the sensor must not be connected to the chassis. Maximum load for each VREF position, see Appendix A, on page 22.

Instruction book, IQAN- TOC8

12

Voltage inputs
6 Installation

Connecting a 2-wire temperature sensor to voltage in When you connect a PTC (positive temperature coefficient) temperature sensor you may need to use a pull up resistor on the input signal. Please check the technical data for your specific temperature sensor.
EXAMPLE

Connect the negative terminal of the temperature sensor to -VREF-A, position 4, and the signal to VIN-A, position 3. The pull up resistor will be connected between VIN-A, position 3 and +VREF-A, position 2.
IQAN-TOC8

+VREF-A pos 2 pull up VIN-A pos 3

-VREF-A pos 4 Sensor

Connecting -VREF-A and temperature sensor signal VIN-A.

The pull up resistor value for a R25=2000, PTC sensor is 4,7 K.

Instruction book, IQAN- TOC8

13

Voltage inputs
6 Installation

Connecting switches to the voltage inputs Switches could be connected to the voltage inputs, to create a digital on/off signal. The switches may be connected to +VREF and VIN respectively. The current consumption for the voltage input is negligible. It is also possible (recommended) to connect system voltage +BAT to the voltage input through a switch.
EXAMPLE

Connect the positive and negative terminals of the switch to +VREF-A, position 2, and VIN-A, position 3, respectively.

IQAN-TOC8

+VREF-A, pos. 2

VIN-A, pos. 3 switch

Connecting a switch to VIN-A.

N OTICE

Maximum load for each VREF position, see Appendix A, on page 22.

EXAMPLE

Connect the positive and negative terminals of the switch to +BAT and VIN-A, position 3, respectively.

+BAT IQAN-TOC8

VIN-A, pos. 3 switch

Connecting a switch to VIN-A and +BAT.

Instruction book, IQAN- TOC8

14

Frequency inputs
6 Installation

Frequency inputs
Connecting sensors to the frequency inputs For the frequency ranges and trigger levels, see Appendix A, on page 22.
Simple frequency sensor

The positive terminal of the frequency sensor is connected to the +VREF and the negative terminal to the -VREF respectively. The sensor signal is connected to a FIN position. If the current consumption for the sensor exeeds the maximum load for the VREF, the sensor could be connected to the BAT positions.
EXAMPLE

Connect the positive and negative terminals of the frequency sensor to +VREF-A, position 2, and -VREF-A, position 4, respectively. Then connect the sensor signal to FIN-A, position 3.
IQAN-TOC8

+VREF-A, pos. 2
OR

FIN-A, pos. 3 -VREF-A, pos. 4

Frequency sensor

Connecting of frequency sensor.

N OTICE

The negative terminal of the sensor must not be connected to the chassis. Maximum load for each VREF position, see Appendix A, on page 22.

Instruction book, IQAN- TOC8

15

Current outputs
6 Installation

Current outputs
The current output signals control proportional valves and devices. For the current range see Appendix A, on page 22. Dither frequency and amplitude To obtain the best performance from proportional valves the control produces a direct current (DC) with a dither. The dither frequency and the dither amplitudes can be adjusted in IQANdevelop software. Depending on what kind of valve is to be used, a certain recommended dither frequency/amplitude set-up can be supplied by Parker Hannifin Corporation in order to obtain an optimized valve hysteresis. Both frequency and amplitudes will then be set using IQANdevelop software. Connecting loads to current outputs Connecting a load, e.g. one proportional valve, to the current output is done by using the COUT/CRET pair positions.
EXAMPLE

Positive direction: Connect the proportional valve to the COUT-A, position 17 and the CRET-A+, position 18 respectively. Negative direction: Connect the proportional valve to the COUT-A, position 31 and the CRET-A- , position 32 respectively.
IQAN-TOC8 COUT-A+ COUT-A-

CRET-ACRET-A+

Direction Valve

Connecting a load to the current output.

Instruction book, IQAN- TOC8

16

Digital outputs
6 Installation

Digital outputs
The digital outputs control relays and on/off valves . For the maximum load per output see Appendix A, on page 22. Soft start Soft start is used whenever start-up is required to be smoother than the normal procedure offers. A desired ramp function provides the smoother start-up according to the figure below. The ramp function is set up in IQANdevelop software.
Output signal [V] Max

Soft start

The Soft start function.

Peak and Hold The Peak and Hold feature makes it possible to decrease the voltage to the valve solenoid. Shortly after a valve has been activated, the voltage can be decreased to a lower level, sufficient to maintain the position of the valve, but also reducing the heat generated in the valve (due to this lower voltage). The reducing of heat, is the primary reason for selecting the Peak and Hold feature. Both the peak time and the hold value are set up in IQANdevelop software.
Output signal Hold value

Peak

The Peak and Hold value voltage graph.

Instruction book, IQAN- TOC8

17

Digital outputs
6 Installation

Connecting loads to digital outputs Connecting of loads to the digital outputs such as on/off valves is done by using the DOUT positions and chassis as ground.
Protection against voltage transients

A clamping diode must be placed between the digital output and ground, as close to the load as possible, to protect the output against high voltage transients. For example: use diode: 1N5408 (3A/1000V). Depending on load, other clamping diodes might be used instead.
EXAMPLE

Connect the on/off valve to the digital output using the DOUT-A, position 21, and the chassis as ground. A clamping diode must be placed as close to the load as possible, see figure below.
IQAN-TOC8

DOUT-A, pos.21

d1

Connecting a load to the digital output.

If the load is controlled in parallel with another system, the digital output shall be protected with a diode.
IQAN-TOC8

+BAT

d2
DOUT-A, pos.21

d1

Digital output protected with a diode.

Instruction book, IQAN- TOC8

18

PWM outputs
6 Installation

PWM outputs
The PWM outputs (Pulse Width Modulation) control pilot valves. Maximum load should not exceed 3.0 A per output. Connecting loads to PWM outputs The load is connected between the PWMOUT and the chassis ground. Maximum load per output, see Appendix A, on page 22.
Protection against voltage transients

A clamping diode must be placed between the output and ground, as close to the load as possible, to protect the output against high voltage transients. For example: use diode: 1N5408 (3A/1000V). Depending on load, other clamping diodes might be used instead
EXAMPLE

Positive direction: Connect the load between the PWMOUT-A, position 22, and the chassis as ground. Negative direction: Connect the load between the PWMOUT-B, position 21, and the chassis as ground. A clamping diode will be placed as close to the pilot valve as possible.
IQAN-TOC8 PWMOUT-A, pos. 21 PWMOUT-B, pos. 22 d2 d1

Directional valve

Connecting a load to the PWM output.

Instruction book, IQAN- TOC8

19

Start-up procedures
7 Start-up

Start-up

Start-up procedures
This chapter contains instructions for action to be taken in connection with the initial start.
W ARNING

Risk of injury! If the control system is not fitted properly, the machine could move uncontrollably. The machines engine shall not be started before the control system is completely fitted and its signals are verified. Starting the control system
Start the control system as follows:

Prior to start, all modules and cables are to be fitted correctly. Check fuses, i.e. make sure that the supply voltage to the modules is equipped with the correct fuse. Make sure that connections for supply voltage and return lines are correct in the cables conductor joint. Make sure an emergency stop is installed. The emergency stop should disconnect the supply voltage to all modules. Alternatively, the emergency stop may also shut off the diesel engine or a dump valve, and with that, depressurize the hydraulic system. Prepare for system start
W ARNING

Make sure no one is in dangerous proximity to the vehicle to avoid injuries when it starts.
Prepare for the initial system start as follows:

The engine for the hydraulic systems pump shall be in off position. Make sure that all connectors are properly connected. Turn on the control system. Make sure that voltage is being supplied to all modules; the power/status diode shall be illuminated on all modules. Also, make sure that the master is in contact with all modules by reading the masters display. Make sure the emergency stop is functioning properly. Start the system
Start the system as follows:

Start the engine for the hydraulic systems pump, assuming that the above mentioned inspections have been carried out and shown correct values. Calibrate and adjust input and output signals according to the instructions related to the master menu system and check each and every output function carefully.

Instruction book, IQAN- TOC8

20

Start-up procedures
8 System Diagnostics

System Diagnostics

The yellow blinking LED on the top of the unit indicates normal status. The TOC8 control indicates error status through the red blinking LED and a yellow secondary blinking pattern. This gives an immediate indication as to the cause of an error.
Yellow/ red, status LED Green, power on

The location of the LED indicators on the IQAN-TOC8 control.

The green LED indicates power on. The yellow/red LED, will be blinking a pattern showing status, and also when an error has been detected. To get futher information about the error messages, see Appendix B, on page 25.

Instruction book, IQAN- TOC8

21

IQAN-TOC8 Technical Overview

Appendix A

Appendix A
IQAN-TOC8 Technical Overview
Absolute maximum ratings

TA = +25 C (unless otherwise specified)

Limit values Parameter min. Operating ambient temperature, TA Storage temperature Voltage supply, VBAT Analog input levels, VIN Digital input levels, DIN Load current, COUT Load current, DOUT Load current, total all outputs 20 40 40 6 -36 -36 typ. max. +80 +100 36 36 36 C V V V A A A internally limited internally limited Unit Remark

Environmental ratings
Limit values Parameter min. EMI ISO 11452-2 ISO 14982 ISO11452-4 ISO7637-2 ESD EN 61000-4-2 (external) CAN-bus lengtha Mechanical environment IEC 60068-2-64 Fh (random, 10 - 250 Hz) IEC 60068-2-27 Es (shock, 11ms) IEC 60068-2-29 Eb (bump, 6ms) Climate environment IEC 60068-2-18 Rb2 (water) IEC 60068-2-30 Db (var1: damp, cyclic) IEC 60068-2-3 Ca (damp, heat steady state) IEC 60068-2-2-Bb (heat) IEC 60068-2-1 Ab (cold) IEC 60068-2-14 Nb (change of temperature) Chemical environment IEC 60068-2-52 Kb (salt mist, cyclic)
a.

Unit typ. max.

Remark

50 50

V/m V/m

15 100

kV m

0.1 40 40

g2/Hz g g min hour hour hour hour hour hour 30kPa, 12.5 l/min 25-55C, 95% RH 44C, 93% RH 70C -30C -30 - 70C

3 72 240 72 16 10 x 6 72

CAN is only used with IQANsimulate, SAE J1939 or during factory testing of the IQAN-TOC8 control.

Instruction book, IQAN-TOC8

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IQAN-TOC8 Technical Overview

Appendix A

Operation
-40 C < TA <+70 C (unless otherwise specified)
Limit values Parameter min. Ambient temperature (no load), TA Voltage supply, VBAT Output voltage, VREF Maximum load current, VREF A, B VBAT =14V VBAT = 28V Current supply VBAT =14V VBAT =28V 90 105 40 9 4.9 5.0 typ. max. +75 34 5.1 50 20 mA outputs = off C V V mA VREF A+ VREF B Unit Remark

I/O
-40 C < TA< +70 C (unless otherwise specified)
Limit values Parameter min. typ. max. Unit Remark

VIN (Voltage input) Signal range low Signal range high Input resistance Signal resolution Total unadjusted error 4.9 0 5.0 62 5 15 FIN (Frequency input) Trigger level high Trigger level low Frequency range Pulse width Frequency resolution < 1kHz < 5kHz < 10kHz 2 10 0,8 20 80 4.0 1.8 10000 V V Hz ms Hz
2 f ----------------------------6 1, 25 10

0.05 5.1

V V k mV

35

mV

(vref as source)

@1kHz @1kHz 5V source

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IQAN-TOC8 Technical Overview

Appendix A

I/O (cont.)
Limit values Parameter min. typ. max. Unit Remark

DOUT (Digital output) Load current each channel active (A,B,C,D,E,F) Load current one channel in each group (A or B, C or D, E or F) Voltage drop (VBAT -VDOUT ) load IL = 0,5A load IL = 3A Short Circuit current limit 0.2 0.8 6 A 3 4 A A The DOUT are divided into three groups.

PWMOUT (Pulse Width Modulation output) Load current each channel active (A,B,C,D,E,F) Load current one channel in each group (A or B, C or D, E or F) Voltage drop (VBAT -VDOUT ) load IL = 0,5A load IL = 3A Short Circuit current limit PWM frequency 25 COUT (Current out) Signal range Resolution Load Total unadjusted error Deviation between modulesa Power supply rejection VBAT= 9... 18V VBAT= 24... 34V Load regulation VBAT=14V, RL=4... 9 W VBAT=28V,RL=22... 34 W Dither frequency Dither amplitude
a.

3 4

A A The PWMOUT are divided into three groups.

V 0.2 0.8 6 2000 A Hz

50 0.7 4

1800

mA mA W

5 2

mA mA mA

TA = 25C

RL =6 W -25 W

1 1 mA 1 3 25 0 150 500 Hz mA

In case of switching modules, note that the current values differs between different modules.

Instruction book, IQAN-TOC8

24

Error codes, messages and actions

Appendix B

Appendix B
Error codes, messages and actions
If one of the following errors is detected, a message will be presented via the LED error codes on the control. In some cases, the control will stop operating or at least shut down the outputs, to increase safety.
W ARNING

Dont use the machine if an error message or error code is activated. LED indicator showing different TOC8 modes
Status Blink (yellow light)

Invalid application Modem connected Modem ring (yel./red) Normal operation IQANSimulate (red) Fatal software (red)
Error code Error Primary Blink (red) Error category Secondary Blink (yellow) Error description

1 1 1 1 2 3 3

Output error Input error VREF error Supply or checksum Temp. error Wrong modem SIM code Missing SIM code none

The following sections will present what measures to take for different error situations.

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Error codes, messages and actions

Appendix B

ERROR: OUTPUT HIGH Situation Error code Action TOC8 Comment

COUT: Current return low or high COUT: Both directions commanded DOUT: Overload PWMOUT: Both directions commanded COUT/DOUT: Internal driver failure
ERROR: INPUT Situation

Error 1-1

Active output shuts off. Active output shuts off. Active output shuts off. Active output shuts off. Active output shuts off.

Check wiring and loads Check application

Error 1-1

Error 1-1 Error 1-1

Check load Check application

Error 6

Contact supplier

Error code

Action TOC8

Comment

VIN: > specified max or < specified min

ERROR: VREF Situation

Error 1-2

Active input goes to error value.

Check wiring and sensors

Error code

Action TOC8

Comment

VREF_ < 4,9 V VREF_ > 5,1 V

Error 1-3 Error 1-3

Check voltage Check voltage

Instruction book, IQAN-TOC8

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Error codes, messages and actions

Appendix B

LOW/ HIGH SUPPLY VOLTAGE Situation Error code Action TOC8 Comment

+BAT < 8,5 V +BAT > 34 V

ERROR: PARAMETER Situation

Error 1-4 Error 1-4

Check voltage supply Check voltage supply

Error code

Action TOC8

Comment

Parameter error (checksum)

HIGH TEMPERATURE Situation

Error 1-4

Contact supplier

Error code

Action TOC8

Comment

Internal temperature > max temp Internal temperature sensor error

Error 2 Error 6

Check ambient temperature Contact supplier

ERROR: COMMUNICATION Situation Error code Action TOC8 Comment

Modem error (wrong SIM code) Modem error (missing SIM code)
ERROR: SOFTWARE Situation

Error 3-1 Error 3-2

Enter proper code in IQANdevelop Enter proper code in IQANdevelop

Error code

Action TOC8

Comment

Software error

Error 6

The unit stops operating.

Contact supplier.

Instruction book, IQAN-TOC8

27

Dimensioning of the IQAN-TOC8 module

Appendix C

Appendix C
Dimensioning of the IQAN-TOC8 module
Unit = mm

60

142

164

7 mm/M6(x2)

Instruction book, IQAN-TOC8

32

67

52

75

28

For latest information visit our website www.iqan.com

Information in this instructionbook is subject to change without notice

Parker Hannifin Electronic Controls Division SE-435 35 Mlnlycke Sweden Tel +46 31 750 44 00 Fax +46 31 750 44 21 www.parker.com

Parker Hannifin Electronic Controls Division 1651 N. Main Street Morton, IL 61550 USA Tel +1 309 266 2200 Fax +1 309 266 6674

Publ no HY33-8304-IB/UK Edition 2011-08-10