W.E.ST.

Elektronik GmbH

Technical Documentation

PAM-193-P
PAM-193-L

Power amplifier for directional valves

 W.E.ST. Elektronik GmbH

CONTENTS

1 General Information....................................................................................................................................... 3
1.1 Order number ........................................................................................................................................ 3
1.2 Scope of supply ..................................................................................................................................... 3
1.3 Symbols used........................................................................................................................................ 4
1.4 Legal notice........................................................................................................................................... 4
1.5 Safety instructions ................................................................................................................................. 5
2 Characteristics .............................................................................................................................................. 6
2.1 Device description ................................................................................................................................. 7
3 Use and application ....................................................................................................................................... 8
3.1 Installation instructions........................................................................................................................... 8
3.2 Typical system structure ........................................................................................................................ 9
3.3 Method of operation ............................................................................................................................... 9
3.4 Commissioning .....................................................................................................................................10
4 Technical description....................................................................................................................................11
4.1 Input and output signals ........................................................................................................................11
4.2 LED definitions .....................................................................................................................................11
4.3 Circuit diagram .....................................................................................................................................12
4.4 Typical cabling......................................................................................................................................13
4.5 Technical data ......................................................................................................................................14
5 Adjustment elements ....................................................................................................................................15
5.1 Potentiometer .......................................................................................................................................15
5.2 Internal DIL switches ............................................................................................................................15
5.3 Start-up ................................................................................................................................................16
5.4 General behaviour: ...............................................................................................................................17
6 Appendix .....................................................................................................................................................18
6.1 Failure monitoring .................................................................................................................................18
6.2 Troubleshooting....................................................................................................................................18
6.3 Replacements / compatibility .................................................................................................................19
6.3.1 PAM-191......................................................................................................................................19
6.3.2 PAM-192......................................................................................................................................20
6.3.3 Special versions ...........................................................................................................................21
7 Notes ...........................................................................................................................................................22

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1 General Information

1.1 Order number

PAM-193-P-40211 - for single or double solenoid valves (max output current: 1.2 A and 2.6 A)
PAM-193-L-4021 - for single or double solenoid valves (max output current: 0.6 A and 1.2 A)

Alternative products

PAM-195 - power amplifier for directional valves

PAM-192 - power amplifier for control valves, adjustment via potentiometer

1.2 Scope of supply

The scope of supply includes the module plus the terminal blocks which are a part of the housing.
The Profibus plug, interface cables and further parts which may be required should be ordered separately.
This documentation can be downloaded as a PDF file from www.w-e-st.de.

1
The number of the version consists of the hardware-version (first two digits) and the software-version (second two dig-
its). Because of the development of the products these numbers can vary. They are not strictly necessary for the order. We
will always deliver the newest version.

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1.3 Symbols used

General information

Safety-related information

1.4 Legal notice

W.E.St. Elektronik GmbH

Gewerbering 31
D-41372 Niederkrüchten

Tel.: +49 (0)2163 577355 - 0

Fax.: +49 (0)2163 577355 - 11

Home page: www.w-e-st.de or www.west-electronics.com

EMAIL: [email protected]

Date: 08.09.2014

The data and characteristics described herein serve only to describe the product. The user is required to
evaluate this data and to check suitability for the particular application. General suitability cannot be inferred
from this document. We reserve the right to make technical modifications due to further development of the
product described in this manual. The technical information and dimensions are non-binding. No claims may
be made based on them.
This document is protected by copyright.

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1.5 Safety instructions

Please read this document and the safety instructions carefully. This document will help to define the product
area of application and to put it into operation. Additional documents and knowledge of the application should
be taken into account or be available.
General regulations and laws (depending on the country: e. g. accident prevention and environmental protec-
tion) must be complied with.

These modules are designed for hydraulic applications in open or closed loop control circuits.
Uncontrolled movements can be caused by device defects (in the hydraulic module or the
components), application errors and electrical faults. Work on the drive or the electronics must
only be carried out whilst the equipment is switched off and not under pressure.

This handbook describes the functions and the electrical connections for this electronic as-
sembly. All technical documents which pertain to the system must be complied with when
commissioning.

This device may only be connected and put into operation by trained specialist staff. The in-
struction manual must be read with care. The installation instructions and the commissioning
instructions must be followed. Guarantee and liability claims are invalid if the instructions are
not complied with and/or in case of incorrect installation or inappropriate use.

CAUTION!
All electronic modules are manufactured to a high quality. Malfunctions due to the failure of
components cannot, however, be excluded. Despite extensive testing the same also applies
for the software. If these devices are deployed in safety-relevant applications, suitable external
measures must be taken to guarantee the necessary safety. The same applies for faults which
affect safety. No liability can be assumed for possible damage.

Further instructions

 The module may only be operated in compliance with the national EMC regulations. It is
the user’s responsibility to adhere to these regulations.

 The device is only intended for use in the commercial sector.

 When not in use the module must be protected from the effects of the weather, contamina-
tion and mechanical damage.

 The module may not be used in an explosive environment.

 To ensure adequate cooling the ventilation slots must not be covered.

 The device must be disposed of in accordance with national statutory provisions.

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2 Characteristics

This module is used for the control of proportional valves with one or two solenoids. Various adjustable param-
eters enable an optimized adaptation to the respective valve. This power amplifier is inexpensive and a space-
saving solution.
The amplifier is controlled by voltage input or current input signals.
The output current is closed loop controlled and therefore independent from the supply voltage and the sole-
noid resistance.
Several potentiometers and DIL switches allow the adaption to valves of the various producers.

Typical applications: Control of proportional valves in different applications.

Features
 Power amplifier for proportional directional valves

 Various command signals

 Compact housing

 Adjustment via potentiometer

 MIN-, MAX-, RAMP- and PWM-frequency adjustment via potentiometer

 Current range (per DIL switch): up to 2,6 A

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2.1 Device description

99,0000 mm 23,0000 mm

9 10 11 12

13 14 15 16

114,0000 mm

Made in Germany
Date: Add.:
ID:
V:

W.E.ST. Elektronik
D-41372 Niederkrüchten
Homepage: http://www.w-e-st.de

Typenschild und Anschlussbelegung 1 2 3 4

Type plate and terminal pin assignment
5 6 7 8

W.E.ST.
LEDs
Klemmblöcke (steckbar) Ready A B
Terminals (removable) MINA
MINB
MAXA
MAXB
Potentiometer

9 10 11 12

13 14 15 16

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3 Use and application

3.1 Installation instructions

 This module is designed for installation in a shielded EMC housing (control cabinet). All cables which
lead outside must be screened; complete screening is required. It is also a requirement that no strong
electro-magnetic interference sources are installed nearby when using our open and closed loop con-
trol modules.

 Typical installation location: 24 V control signal area (close to PLC)

The devices must be arranged in the control cabinet so that the power section and the signal section
are separate from each other.
Experience shows that the installation space close to the PLC (24 V area) is most suitable. All digital
and analogue inputs and outputs are fitted with filters and surge protection in the device.

 The module should be installed and wired in accordance with the documentation bearing in mind EMC
principles. If other consumers are operated with the same power supply, a star-connected ground wir-
ing scheme is recommended. The following points must be observed when wiring:
 The signal cables must be laid separately from power cables.
 Analogue signal cables must be screened.
 All other cables must be screened if there are powerful interference sources (frequency
converters, power contactors) and cable lengths > 3 m. Inexpensive SMD ferrites can be
used with high-frequency radiation.
 The screening should be connected to PE (PE terminal) as close to the module as possi-
ble. The local requirements for screening must be taken into account in all cases. The
screening should be connected to at both ends. Equipotential bonding must be provided
where there are differences between the connected electrical components.
 With longer lengths of cable (>10 m) the diameters and screening measures should be
checked by specialists (e. g. for possible interference, noise sources and voltage drop).
Particular care is required with cables of over 40 m in length – the manufacturer should be
consulted if necessary.

 A low-resistance connection between PE and the mounting rail should be provided. Transient interfer-
ence is transmitted from the module directly to the mounting rail and from there to the local earth.
 Power should be supplied by a regulated power supply unit (typically a PELV system complying with
IEC364-4-4, secure low voltage). The low internal resistance of regulated power supplies gives better
interference voltage dissipation, which improves the signal quality of high-resolution sensors in partic-
ular. Switched inductances (relays and valve coils) connected to the same power supply must always
be provided with appropriate overvoltage protection directly at the coil.

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3.2 Typical system structure

This minimal system consists of the following components:

(*1) proportional valve

(*2) hydraulic cylinder
(*3) power amplifier PAM-193
(*4) interface to PLC with analogue and digital signals

*
2

POWER STAGE
INPUT RAMP MINMAX
A B
PLC

+
- P T *
1
* *
4 3

3.3 Method of operation

This power amplifier will be controlled via an analogue signal (from the SPS, from a joystick or a potentiome-
ter). An ENABLE signal (24 V typical) activates the function and the READY output indicates the active mod-
ule, if no internal or external error was detected.
The integrated standard functions will be configured via different potentiometers.
In case of a fault the power output stage will be deactivated and the fault will be indicated via deactivating the
READY output and the flashing READY LED.
The output current is controlled whereby a high accuracy and a good dynamic will be obtained. All customary
proportional valves (up to 2.6 A) could be controlled with this power amplifier.

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3.4 Commissioning

Step Task
Installation Install the device in accordance with the circuit diagram. Ensure it is wired cor-
rectly and that the signals are well shielded. The device must be installed in a pro-
tective housing (control cabinet or similar).

Switching on for the Ensure that no unwanted movement is possible in the drive (e. g. switch off the
first time hydraulics). Connect an ammeter and check the current consumed by the device.
If it is higher than specified, there is an error in the wiring. Switch the device off
immediately and check the wiring.
Pre-parameterization Now set up the following parameters (with reference to the system design and cir-
cuit diagrams):
The output current and the typical input function (DIL switches)
Control signal Check the control signal with a voltmeter. The control signal (the current of the so-
lenoid is within the range of 0... 2, 6 A). In the actual status it should show approx-
imately 0 A.

Switching on the The hydraulics can now be switched on. The module is not yet generating a sig-
hydraulics nal. Drives should be at a standstill or drift slightly (leave its position at a slow
speed).
Activating ENABLE CAUTION! Drives can now leave their position and move to an end position at full
speed. Take safety measures to prevent personal injury and damage.
The hydraulic axis can be moved over the analogue input value.
Optimize controller Now optimize the remaining parameters (MIN function and RAMP time) according
to your application and your requirements.

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4 Technical description

4.1 Input and output signals

Connection Supply
PIN 7 Power supply (see technical data)

PIN 8 0 V (GND) Power supply (ground).

Attention, PIN 8 is connected with PIN 11 internal. PIN 11 is used as the GND potential for
the analogue command signals.

Connection Analogue signals

PIN 9 / 10 Command (input) signal (W), range +/-100 % corresponds with +/-10 V or 4… 20 mA.

PIN 11 0 V (GND) for the signal inputs

PIN 12 Reference output voltage (8 V).

PIN 13 Input resistor (390 Ohm) used for 4… 20 mA. PIN 13 have to be connected with PIN 9.

PIN 1 / 2 Current controlled PWM outputs for solenoid A and B.

PIN 3 / 4
Connection Digital inputs and outputs
PIN 14 or ENABLE Input:
PIN 15 This digital input signal initializes the application, fault messages are reset.
The output and the READY signal will be activated.
PIN 5 READY output:
ON: No internal or external errors are detected
OFF: ENABLE is deactivated or an error is detected.

4.2 LED definitions

LEDs Description of the LED function

GREEN Identical to the READY output.
OFF: No power supply or ENABLE is not activated
ON: System is ready for operation

Flashing: Error detected.

YELLOW A / B ON: related solenoid is activated.
OFF: solenoid not activated.

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4.3 Circuit diagram

12...30V 7 PAM-193-*
8 5
0V READY output

MAX A MAX B
Power supply 12 8 V reference voltage P3 P4

11
ia 3 Solenoid A

S1.3 S1.4 S1.5 S1.6 4

Input
+/- 10 V, 10 1
+/- 8 V, Power stage
MCU
0...10 V 9 ib 2
0... 8 V Solenoid B

13
essential for
4... 20 mA
S1.1 S1.2
P1

P2

P5

P6

14 / 15
RAMP
MIN B
MIN A

PWM

Enable Solenoid current range

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4.4 Typical wiring

SWITCH S1
Magnet B /
2 1
Solenoid B
OFF OFF 1,2 A
Magnet A /
Solenoid A ON ON 2,6 A
Joystick
PIN 12 8V
SWITCH S1
PIN 10 +In 5 4 3
ON OFF ON +/- 4V ( 8 V)
PIN 9 -In
ON ON OFF +/- 5V (10 V)
1 2 3 4
PIN 11 GND Ready output
12 V / 24 V
+/- 10 V (SPS / PLC) or 0V
+/- 8 V SWITCH S1 Spannungsversorgung /
PIN 10 +In 5 4 3
Power Supply
5 6 7 8
PIN 9 -In OFF OFF OFF +/- 10 V

PIN 11 GND OFF OFF ON +/- 8 V

PE

PE
Potentiometer
PIN 12 8V
SWITCH S1
5 4 3 9 10 11 12
PIN 10 +In
OFF ON OFF 0...5... 10 V
PIN 9 -In Referenzspannung/
OFF ON ON 0...4... 8 V reference voltage
PIN 11 GND

13 14 15 16

4... 20 mA (SPS / PLC) Schirm/

SWITCH S1 Screen
PIN 10 +In 5 4 3
PIN 9 -In ON OFF OFF 4... 12... 20mA +/- 100%
ON ON ON 4... 20mA 0... 100% Analoger Sollwert /
PIN 13
Analogue command signal
Brücke/
bridge 0V
4... 20 mA Enable

Caution: if using 4… 20 mA command signal PIN 9 has to be connected to PIN 13.

For unipolar voltage signal PIN 9 has to be connected to PIN 11.

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4.5 Technical data

Power supply [VDC] 12… 30 (incl. ripple)

Current consumption [mA] <100 + solenoid current
External fuse [A] 3 medium time lag
Reference voltage [V] 8 ( maximum 10 mA)
Digital inputs [V] logic 0: < 2
[V] logic 1: > 10
Input resistance [kΩ] 25
Digital outputs [V] logic 0: < 2
[V] logic 1: > 12 (50 mA)
Analogue inputs (sensor and command [V] ±10 / 0… 10; 90 kΩ
signals) [mA] 4...20; 390 Ω
Resolution [%] 0,025
PWM Output current [A] 1,2 or 2,6 (switchable via DIL); cable break controlled
PWM frequency [Hz] 80... 340 or 2000
Sample time (pressure control) [ms] 1
Sample time (solenoid current control) [ms] 0,167
Adjustments
MIN [%] 0… 60 (0 = pre-adjusted)

MAX
DIL 1.1, DIL 1,2 = ON [A] 1,0… 2,6
DIL 1.1, DIL 1,2 = OFF [A] 0,5… 1,2 (pre-adjusted)

RAMP [s] 0,05… 15 (0,05 = pre-adjusted)

PWM Frequency
DIL 1.6 = OFF [Hz] 80… 340 (340 = pre-adjusted)
DIL 1.6 = ON [Hz] 2000
Dither amplitude
DIL 1.6 = ON [%] 0… 20
Dither frequency: fg = 60 Hz
Housing Snap-On Module EN 50022
Polyamide PA 6.6
Combustibility class V0 (UL94)
Weight [kg] 0,170

Protection class IP20

Temperature range [°C] -20… 60
Storage temperature [°C] -20 …70
Humidity [%] <95 (not condensing)
Connections 4 x 4pol. screw terminals
PE: direct via DIN rail
EMC EN 61000-6-2: 8/2002
EN 61000-6-3: 6/2005

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5 Adjustment elements

5.1 Potentiometer

Front:
P1 = MINA
P2 = MINB
P3 = MAXA
P4 = MAXB

Inside:
P5 = PWM / DITHER
P6 = RAMP

5.2 Internal DIL switches

Command signal range

S1.5=OFF S1.4=OFF S1.3=OFF ±10 V Input

S1.5=OFF S1.4=OFF S1.3=ON ±8 V Input
S1.5=OFF S1.4=ON S1.3=OFF 0… 5… 10 V Input
S1.5=OFF S1.4=ON S1.3=ON 0… 4… 8 V Input
S1.5=ON S1.4=OFF S1.3=OFF 4… 12… 20 mA for ± 100%
S1.5=ON S1.4=OFF S1.3=ON ±4 V Input (Joystick)
S1.5=ON S1.4=ON S1.3=OFF ±5 V Input (Joystick)
S1.5=ON S1.4=ON S1.3=ON 4… 20 mA for 0… 100%

Output current range:

S1.1 = OFF, S1.2 = OFF (up to 1,2 A)

S1.1 = ON, S1.2 = ON (up to 2,6 A)

PWM / DITHER function:

S1.6 = OFF – PWM frequency is adjustable in the range of 80... 340 Hz.
S1.6 = ON – PWM frequency is 2000 Hz, dither frequency is 60 Hz, dither amplitude is
adjustable (0… 20 %).

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5.3 Start-up

Because of the type these valves have relatively great tolerances in comparison to the electronics. The adjust-
ment can vary from valve to valve.

MAX: Maximum current adjustment (P3 and P4). The maximum output current can be set from about
40% to 100% of the rated current range..

MIN: Zero- / deadband adjustment (P1 and P2). The MIN-adjustment should be carried out after the
MAX-adjustment. The presetting is 0 (fully anti-clockwise). According to valve adjustments ap-
prox.0 % to 60 % of the rated current are necessary.
Preset a small input signal of nearly 3 % to 5 %. Increase the MIN value (rotate clockwise) contin-
uously until the drive moves. From there you reduce the value (anti-clockwise) until the drive
came to standstill again.

Caution: By changing of the MAX-adjustment also the MIN-adjustment changes.

RAMP: The ramp time is preset on roughly 50 ms (P6, smallest value, fully anti-clockwise). It will be pro-
longed by turning clockwise up to approx. 15 s. All ramp times are identical.
Caution: Long ramp times and simultaneously short cycle times (cycle time < ramp time) can re-
sult in a hardly understandable behaviour because all movements are carried out strongly de-
layed.

PWM/
DITHER: With the adjustment of PWM / DITHER the valve hysteresis can be reduced clearly.

PWM frequency (pre-adjusted): The PWM frequency (S1.6 = OFF) can be chosen within the
range of 80… 340 Hz. For many valves PWM frequency ad-
justment is best way trying to reduce the hysteresis.
DITHER Amplitude: The dither amplitude (S1.6 = ON) can be adjusted between
0… 20 %. If this mode is activated the PWM frequency is
about 2000 Hz and the DITHER frequency nearly 60 Hz.

Caution: the best setting please take out of the valve data specification.

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5.4 General behaviour:

Power ON: After switching on the input signal (4… 20 mA) is checked and the system is gets activated. When
ENABLE is active (ENABLE directly connected with the supply voltage) the current is activated by
an internally defined ramp (smooth starting) in order to drive onto the demand value with the pre-
set ramp time.
If an error is detected the module changes over into error status.

ENABLE: By this switching-input the internal signal processing and the power stage are enabled. While acti-
vating the input the valve current will be driven up the pre-set ramp. In case of deactivating the
current is switched off immediately. PIN 5 monitors the state of readiness.

Caution: This input is not suitable for stopping power stage in security relevant systems.

LEDs: Green LED ON = ready for operation.

Green LED flashes if command signal is lower than 2mA (4… 20mA adjustment) and in case of
detected cable break to the solenoid. The output current is switched off immediately.

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6 Appendix

6.1 Failure monitoring

Following possible error sources are monitored continuously:

Source Fault Characteristic

Command signal PIN 9 / 10 Out of range The power stage is deactivated.
4...20 mA
Solenoid A PIN 3 / 4 Broken wire The power stage is deactivated.
Solenoid B PIN 1 / 2

6.2 Troubleshooting

FAULT CAUSE / SOLUTION

ENABLE is active, the Probably the power supply is disconnected or the ENABLE signal is not present.
module does not re-
spond, and the READY
LED is off.
ENABLE is active, the The flashing READY LED indicates that a fault is detected by the module. The fault
READY LED is flashing. could be:
 No signal at the input, if 4… 20 mA signal is chosen
 A broken cable or incorrect wiring to the solenoids.

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6.3 Replacements / compatibility

The PAM-191 and the PAM-192 are replaced by the PAM-193. If using the module as spare parts for older
ones the wiring has to be adapted. It also has to be paid attention to the different configuration of the DIL-
switches and potentiometers.

6.3.1 PAM-191

12..30V 7 PAM-191
8
0V

Power supply 12 8V
reference voltages
S2.3
10 V
11 MAX
0V 4... 20 mA P2
PWM input 13 S2.2
Input
0... 10V, 3
0... 20 mA, 10 MCU Power stage
4... 20 mA... 4
S2.1

S1.1 S1.2
9
1,6 A
1A

0V
DITHER
P1

P3

P4
RAMP

14
MIN

Enable

Changes (PAM-193 / PAM-191)

Wiring:

1. PIN 9 and PIN 10 are realized as differential input. For using unipolar voltage signals PIN 9 has to be
connected with PIN 11.
2. The input resistor for current signals can’t be switched on by DIL-switch anymore, but has to be acti-
vated by connecting PIN 9 and PIN 13.

Adjustment:

3. Reference voltage on PIN 12 is 8 V and not changeable anymore. Further function is still possible by
different signal ranges adjustable via DIL-switches.
4. There are now only two output current ranges available: 1,2 A and 2,6 A. Default setting remains 1 A.
For significant lower currents the L-Version with half output current is available.
5. The function, position and name of the potentiometers and DIL-switches partially have changed, (have
a look at 5.1 und 5.2 in this documentation).

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6.3.2 PAM-192

12..30V 7
5
8 Ready
0V
MAX A MAX B
Power supply 12 8 V Reference voltage P3 P4

11
13 2 Solenoid A

Input
1+4
10
+/- 10 V,
+/- 5 V, MCU Power amplifiers
4...20 mA 9 3
Solenoid B
S1.6

U/I switch

15
Ramp down

Enable
Ramp up
P1

P2

P5

P6
MIN B
MIN A

Changes (PAM-192 / PAM-193)

Wiring:

1. The input resistor for current signals can’t be switched on by DIL-switch anymore, but has to be acti-
vated by connecting PIN 9 and PIN 13.

2. CAUTION: Solenoid A and solenoid B have to be swapped.

Adjustment:

3. There are now only two output current ranges available: 1,2 A and 2,6 A. Default setting remains 1 A.
For significant lower currents the L-Version with half output current is available.
4. The function, position and name of the potentiometers and DIL-switches partially have changed, (have
a look at 5.1 und 5.2 in this documentation).

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6.3.3 Special versions

These special versions can be replaced by the PAM-193:

PAM-191-*-S1 (PWM = 100Hz) = PAM-193-P

PAM-191-*-S2 (PWM = 100Hz) = PAM-193-L
PAM-192-*-S1 (PWM = 100Hz) = PAM-193-L
PAM-192-*-S2 (PWM = 135Hz) = PAM-193-L

PAM-191-P-S3 (MIN directly active) = PAM-193-P-S3

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7 Notes

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