HPR

High Pressure Regulator

EFS 8244 V2

Technical
Manual
EDITION : 13 May 2008 - VERSION : 1.9

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TECHNICAL MANUAL
CONTENTS

HPR

1.

INTRODUCTION

2.

UNPACKING

3.

SPARES LISTS

4.

OPERATING

5.

SPECIFICATION

6.

STARTING OPERATION

7. 7.1. 7.2. 7.3. 8. 8.1. 8.2. 9. 9.1. 9.2. 10.

EQUIPMENT DESCRIPTION FUNCTIONAL DIAGRAM CARDS DESCRIPTION INTERCONNECTION DESCRIPTION EQUIPMENT DESCRIPTION REAR PLATE PRESENTATION FRONT PLATE PRESENTATION REGULATION PRINCIPLE THE ASYNCHRONOUS MODE THE SYNCHRONOUS MODE APPENDIX REGULATION SYSTEM TYPES

8 8 8 9 11 11 15 25 25 26 27 27

10.1.

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10.2. 10.3. 10.4. 11. 11.1. 11.2. 11.3. 11.4. 11.5. 11.6. 12. 12.1. 12.2. 12.3. 13.

TECHNICAL MANUAL

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29 30 31 32 32 32 33 35 40 41 42 42 42 42 43

RCO HP REGULATION SYSTEM RCO BP REGULATION SYSTEM MODBUS REGISTER 32 TO 34 USE MODBUS COMMUNICATION PROTOCOL SERIAL LINE CHARACTERISTICS PROTOCOL MODBUS OUTPUT BITS MODBUS OUTPUT REGISTERS MODBUS INPUT BITS MODBUS INPUT REGISTERS ASAP3 COMMUNICATION PROTOCOL PHYSICAL CONNECTION COMMANDS TABLE PARAMETERS TABLE LIST OF ERROR CODES

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1. INTRODUCTION

TECHNICAL MANUAL

HPR

The HPR module ensures the pressure regulation in "common rail" system.

For the actuator card, please refer to the chapter 10.1 : Regulation system types.

4. OPERATING
The equipment is connected to a supervisor PC throw a serial line (RS232 or RS485) and use the MODBUS protocol. The WINHPR WINHPR software (working under Windows 98, Windows 2000) allows the operating parameters configuration and the pressure setting definition.

2. UNPACKING
List of items delivered :

The equipment is powered by a 230V or 115V (50/60Hz) single phase power supply and by a 10 to 36Vcc isolated continuous power supply. A pressure sensor mounted on the rail gives the feedback signal for the regulation loop.

electronic rack HPR power cord connectors to make cable RS232 cable (3 metres) WINHPR WINHPR software (on CD) with its documentation HPR technical manual

One (or more) electro-mechanical actuator allows the high-pressure regulation. The command is adapted for each system type depending upon : the number and the functioning principle of the actuators the signals from the pump

3. SPARES LISTS
Part Number for spare parts : Rack
84TE without actuator card 42TE without actuator card HPR2-T1-RACK HPR2-T2-RACK HPR2-ALIM

Power
Internal power card Option (only available with the 84TE rack)

Cable
RS232 cable to connect with a standard PC (Sub-D 9 points female female crossed) HPR2-CABRS3

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5. SPECIFICATION
Pressure sensor input :

TECHNICAL MANUAL
Actuators driving :

HPR

voltage input 0..5V (impedance 10k) current input 0..32mA

1 or 2 driving output(s)s on a single EFS1522 card (depending upon the type) maximum average current for one card 1522 : 10A maximum instantaneous current for one actuator driving output : 8A protection against short-circuits detection of actuator presence internal power supply (in option) 10 to 36V to drive the actuators the internal actuators power circuit is isolated from ground

The 2 inputs are available, the choice of which one is used is done by software.

filter : 0..1kHz Acquisition : 16 bits.

Power supply for the pressure sensor :

supply 1 : +5V 100mA supply 2 : +12V 100mA

Pump Synchronisation signals:

"1/Rev" signal : differential input for variable reluctance sensor "SYNCHRO" signal : differential input for variable reluctance sensor

Regulation :

PID type with the possibility to set the 3 parameters P, I and D. instantaneous and average errors are available in case of error greater than a pre-set upper limit the regulator automatically goes in SECURITY mode.

Characteristics for these 2 inputs input impedance : 10k The negative input can be connected to ground It is possible to add a negative signal (-2.5V) on the input signal Option for zero crossing detection (falling edge) : - automatic trigger level - fixed trigger level at 200mV - fixed trigger level at 0V

Control :

Throw a serial line with MODBUS protocol. WINHPR WINHPR software running on a PC under Windows 98 or Windows 2000. Logical Input/Output for connection with a PLC

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TECHNICAL MANUAL

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6. STARTING OPERATION
The next connections need to be done before starting regulation. For the description of each connector, refer to the chapter Equipment description . 1. Connect the power supply 220VAC/50HZ on connector X1. 2. Install the Ground cable on X2. 3. Connect the battery supply on X3 (except if the option HPR2-ALIM is installed) 4. Connect the actuators on connectors (X4, X5, X6 or X7) the It is not necessary to connect these cables if you are using the EFS 1522 cards type 3 or 7 (number written on the front end of the card) 7. Connect the RS485 cable (X18) or RS232 cable (X19) between the electronic rack and the control PC. (You need to install and run the WINHPR WINHPR software on the PC). 8. It is possible but not necessary to connect the logical inputs/outputs (connector X8 and X9) to a PLC to enable this system to control the regulator (start regulation, security). The pins 1 and 2 of X8 and X9 connectors are from the same signal "EMERGENCY STOP". These are 2 contacts (Normally Open) that are closed when there is no fault. The signal on X8-4 informs that the pressure in the rail is under a pre-set lower limit (in this case the contact is closed). This information can be used by the PLC to open the doors of a bench when the pressure is low enough. The user can now switch on the electronic rack. At this time, the user can configure the pressure regulator with the WINHPR WINHPR software.

5. Connect the pressure sensor (X10 connector) Be aware to don't connect the X10-5 to ground because a shunt is connected between X10.5 and ground to measure the supplying current of the sensor. If this current is not between 4mA and 50mA, a "pressure sensor fault" will be generated. The user, with the WINHPR WINHPR software, needs to define if the pressure sensor delivers a voltage or a current and also to give the sensor curve (voltage in function of pressure) 6. If your system synchronisation with the rotation, the SYNCHRO (X13) and the 3600/REV need to be connected. needs pump signal (X14)

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TECHNICAL MANUAL

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Depending upon the system, one or two actuators can be controlled. The regulation is done : either by an ASYNCHRONOUS control of the actuator opening, which make a leakage or a filling that make pressure variation. The control is generally of PWM type (Pulse Width Modulated). or by a SYNCHRONOUS control of the actuator opening, generally synchronized with a sensor placed in the pump. The control can be of PWM type (Pulse Width Modulated) or pulsing type.

Two analogue outputs enable real time display of the pressure in the rail.. The first one is the instantaneous pressure signal (pressure sensor signal multiplied by 2 ). The second one is the pressure signal sampled at a time defined by an external signal (0v=sample, 5V=Hold) or by an internal signal generated at an angle defined by a MODBUS register.

The input SECURITY (X9-4), if active, will stop the regulation and the regulator will drive the actuators so that the pressure decreases. Depending upon the type of Common Rail System it will stop the current in the actuator or on the contrary it will set the current at the maximum value. This signal has priority on all the others. It directly controls the actuator card driving stage. Many relay outputs (X8-3 to X8-8) report information (Status and faults) to external equipments. Faults reset needs to be done via MODBUS.

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TECHNICAL MANUAL

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7. EQUIPMENT DESCRIPTION
7.1. FUNCTIONAL DIAGRAM
Pressure sensor Synchro inputs Validation control input Serial interface

PRESSURE RAIL REGULATOR

Main supply Power supply for actuators

Actuator(s) output(s) Fault output

7.2.

CARDS DESCRIPTION

The regulator is comprised of 5 to 8 cards : EFS 1520 card : This card generates the power supply for the pressure sensor and is the interface card for the pressure sensor signal (voltage or current) and also for the signals "3600/REV" and "SYNCHRO".. EFS 1521 card : This is the central unit for the pressure regulator. EFS 1526 card : This is the interface card for the logical inputs/outputs.

1 to 4 EFS 1522 cards : This is the driving card for one or two actuators. There are many types for this card depending upon the type of Common Rail System to regulate. The electronic rack can received up to four 1522 cards enabling it to drive up to four different systems (but not simultaneously). EFS 0900 card : Power supply +5V, +15V, -15V. Battery supply (in option)

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7.3.

TECHNICAL MANUAL

HPR

INTERCONNECTION DESCRIPTION

The yellow arrowheads in the following diagram represent the interconnections :

EFS8244 SUPERVISOR
(1)

EFS1521
F

CPU PC104 INTERFACE TEST BENCH

B
EXTERNAL SECURITY I/O FAULT DISPLAY

EFS 0900 POWER SUPPLY +15V, -15V, +5V

AC/DC Vbatt (*)

G F F

EFS 1520
PRESSURE SENSOR CONDITIONING

EFS 1522 A, B et C
ACTUATOR CARD

D C

PRESSURE SENSOR

ACTUATOR(S)

COMMON RAIL SYSTEM

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7.3.1. INTERCONNECTION A The control PC (supervisor) dialogs with the regulator throws this interconnection. It is a serial line, RS233 or RS485, and uses MODBUS protocol. The supervisor PC can do the following actions : Modify the pressure setting

7.3.3. INTERCONNECTION C Interconnection between the pressure sensor conditioning card and the bench :

analogue output : instantaneous rail pressure (BNC) analogue output : sampled rail pressure (BNC) analogue input : Sample/Hold logical signal (BNC) analogue input : 3600/REV signal (BNC) analogue input : SYNCHRO pump signal (BNC)

Modify the regulation parameters (P, I, D, etc..) Read the faults Reset the fault indicators Read the instantaneous pressure in bar

7.3.4. INTERCONNECTION D 7.3.2. INTERCONNECTION B Interconnection between the bench and the regulator. The signals are :

Interconnection for the pressure sensor :

Power supplies for the pressure sensor : +5V, +12V. Analogue signal from pressure sensor

Two dry contacts NO for the security loops 6 dry contacts (with a common point) to send information to PLC 6 isolated logical inputs (with a common point) to receive information from a PLC

7.3.5. INTERCONNECTION E Interconnection between the actuators and the driving card.

7.3.6. INTERCONNECTION F Power supply distribution.

7.3.7. INTERCONNECTION G External battery supply for driving the actuators (10 to 36V dc).

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8. EQUIPMENT DESCRIPTION
The HPR module is an aluminum rack 3U, 19 , (360 mm deep)

8.1.
C

REAR PLATE PRESENTATION

B
1 2 3 4 5 6 7 8 9 10

E
3 4 1 2 3 2 3 4 1 2 3 4 1 2

X1
MAIN

X14 3600/T

X13 SYNCHRO

PRESSURE

X12

X8 SECURITY INPUT
1 2 3 4 5 6 7 8 9 10

4 1

I 0

SAMPLED PRESSURE

X17

SAMPLING INPUT

X16
1 2

X15
NC

SLOT 4

SLOT 3

SLOT 2

SLOT 1

X9 SECURITY OUTPUTS
1 2 3 4 5 6 7 8 9 10

X7
A1 +

X6

X5

X4

ACTUATORS DRIVE OUTPUTS

1 3

X18
Rs485

X10 SENSOR
1 2 3 4 5 6 7 8 9 10
A2 +

4 1

2 PE V BATT 10-36VDC

X3

X2

X19
Rs232

X11 ACTUATORS DIODE

8.1.1. CONNECTORS LIST X1 : X2 : X3 : X4 : X5 : X6 : X7 : X8 : X9 : X10 : X11 : X12 : X13 : X14 : X15 : X16 : X17 : X18 : X19 : Mains Incoming Switch GROUND connector Battery input Actuators outputs for card 1 Actuators outputs for card 2 Actuators outputs for card 3 Actuators outputs for card 4 Security contact outputs Security inputs Pressure Sensor (Power supply and signal) Output for selected card external LEDs Output "Instantaneous pressure" Input "PUMP-SYNCHRO" Input "3600/REV" not used Input "Sample/Hold" Output "Sampled pressure" RS485 connector RS232 connector

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8.1.2. CONNECTORS DETAILED DESCRIPTION X1 MAIN Switch Main witch (fuse : 1AT)

X2

GROUND To connect the GROUND protection cable. BATTERY input VBATT (10 to 36V) 1 : +VBAT : battery terminal + 2 : -VBAT : battery terminal 3 : not used Actuators driving outputs ( card 1) 1: Terminal + actuator channel B 2: Terminal + actuator channel A 3: Terminal - actuator channel A 4: Terminal - actuator channel B Actuators driving outputs ( card 2) 1: Terminal + actuator channel B 2: Terminal + actuator channel A 3: Terminal - actuator channel A 4: Terminal - actuator channel B Actuators driving outputs ( card 3) 1: Terminal + actuator channel B 2: Terminal + actuator channel A 3: Terminal - actuator channel A 4: Terminal - actuator channel B Actuators driving outputs ( card 4) 1: Terminal + actuator channel B 2: Terminal + actuator channel A 3: Terminal - actuator channel A 4: Terminal - actuator channel B

X3

2 3

JAEGER (fast series) female 3 points

X4

4 1

JAEGER (fast series) female 4 points

X5

4 1

JAEGER (fast series) female 4 points

X6

4 1

JAEGER (fast series) female 4 points

X7

4 1

JAEGER (fast series) female 4 points

The actuators terminals are active, and need to be free of any potential. The outputs are protected against this type of error by a differential current sensor and by the fuse (10AT) in the front plate.
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X8

TECHNICAL MANUAL
1526 OUT0 OUT1 AU OUT2 OUT3 OUT4 1526 IN0 IN1 IN2 IN3 IN4 IN5 1520

HPR
1

X9

X10

Logical outputs 1: contact 2 for security loop 2: contact 2 for security loop 3: Output "Actuator test OK" 4: Output "pressure < Pmin" 5: Output "Emergency Stop" 6: Output not used 7: Output not used 8: Output not used 9: not connected 10 : Common for outputs Logical inputs and outputs 1: contact 1 for security loop 2: contact 1 for security loop 3: Input "Actuator test" 4: Input "Security" 5: Input "Regulation" 6: Input not used 7: Input not used 8: Input not used 9: Power output 24V (125 mA max) 10 : Common for Inputs pressure sensor 1: Power supply output +5V. 2: Power supply output +12V. 3: Voltage Signal input 4: Current Input Signal 5: Return for sensor power supply 6: Ground Shield 7 to 10 : not used

2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

MINICONNEC 10 pins

MINICONNEC 10 pins

MINICONNEC 10 pins

X11

Actuator card selected LEDs output 1: card 1 "selected", led + 2: card 1 "selected", led 3: card 2 "selected", led + 4: card 2 "selected", led 5: card 3 "selected", led + 6: card 3 "selected", led 7: card 4 "selected", led + 8: card 4 "selected", led 9 to 10 : not used

1522 Select Select Select Select -

1 2 3 4 5 6 7 8 9 10

MINICONNEC 10 pins

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X12

TECHNICAL MANUAL

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Not isolated BNC

Instantaneous pressure Analogue output of the "instantaneous pressure" (pressure sensor signal multiplied by 2) Pump SYNCHRO Input for variable reluctance sensor, TTL compatible (falling edge) 3600/REV Input for variable reluctance sensor, TTL compatible (falling edge) not used

X13

isolated BNC

X14

isolated BNC

X15

Not isolated BNC X16 Sample/Hold input TTL input for sample/hold signal Not isolated BNC X17 Sampled pressure Output value of the sampled pressure. The time for sampling "Instantaneous pressure" is defined by the external signal "Sample/hold" (X16) or by software. RS 485 1: RS 485 A 2: RS 485 - B

Not isolated BNC

X18

MINICONNEC 2 pins

1 2

X19

RS 232 1: Not used 2: RxD 3: TxD 4: Not used 5: GND 6: Not used 7: Not used 8: Not used 9: Not used

1 2 3 4 5

SUB-D 9 points male

6 7 8 9

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8.2.

TECHNICAL MANUAL

HPR

FRONT PLATE PRESENTATION

The electronic rack HPR looks like this :

0900 1522 1522 1522 1522 1526 1521
Ele ctr oniq ue

1520
Ele ctronique

EFS
Ele ctronique

EFS
Electr onique

EFS
Ele ctroniq ue

EFS
Electr oniq ue

EFS
Ele ctroniq ue

EFS
Ele ctr oniq ue AU

EFS EFS

OUT0 OUT1

+ 5V Dfaut + 5V + 15V

OUT2 OUT3 OUT4

IN 0

Dfaut + 15V - 15V Dfaut - 15V

IN 1 IN 2 IN 3 IN 4

U - 15V U + 15V

IN 5

Type

Type

Type

Type

Type

8.2.1. 0900 CARD DESCRIPTION

0900 Card: Power supply +15V, -15V et +5V

0900

EFS
Electron ique

+5V +5V DEFAULT

+5V +5V

OK FAULT DETECTED

+ 5V + 5V Default + 15V + 15V Default - 15V - 15V Default

+15V +15V DEFAULT -15V -15V DEFAULT

+15V OK +15V FAULT DETECTED -15V OK -15V FAULT DETECTED

U - 15V U + 15V

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8.2.2. 1520 CARD DESCRIPTION

Pressure sensor interface

Voltage/Current selection X1 Voltage input (U)
Fc = 1 Khz

x1

Filtered pressure

ADC

Current input (I)

I/U

x2
Fc = 5 Khz

Instantaneous pressure x1

X12 BNC

+ Sensor Power supply

+5V / +12V Windows Comparator 4 - 50 mA

x1

Sampled pressure

X17 BNC

Current measurement

Sensor Fault

X16 Sample/Hold BNC

Synchronisation signals interface

X14 BNC

3600/REV + 3600/REV X7

x10
Fc = 340 Khz 2,5V

+ -

Falling front trigger

3600/REV

X6 X13 Synchro + Insulated Synchro BNC X4

+ Fc = 340 Khz 2,5V

X8

x10

Synchro

X2

X5

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This card generates the power supplies for the pressure sensor and interfaces the pressure sensor signal. Two power supplies are available : +5V and +12V. They are protected against short-circuits and have a current limitation of 100mA. This card can operate with a pressure sensor delivering a voltage signal (0..5V) or a current signal (0..32mA). Selecting Voltage or Current is done via a MODBUS register. The sensor signal can be linearized by a curve in 10 segments, these segments can be set via MODBUS registers. An analogue output on BNC delivers the instantaneous pressure (sensor signal multiplied by 2). An other analogue output on BNC delivers the "instantaneous pressure" sampled at a time defined by an external logical signal "Sample/Hold" or by software , in this case a MODBUS register defines the angle at which the signal must be sampled. Synchronisation signals ("3600/REV" et "PUMP-SYNCHRO") are also interfaced on this card. The two inputs are designed for variable reluctance sensor, but they are also compatible with TTL signals. The detection is made on the falling edge of the signals.

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TECHNICAL MANUAL

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There are the following configuration straps on the 1520 card :

Strap

Function Cut-Off frequency for the low-pass filter applied on the instantaneous pressure signal 1-2 : 1kHz (default value) 2-3 : 5 kHz This strap must NOT be modified buy the user.

X1

X2

Add a 2.5V constant signal on the PUMP-SYNCHRO signal before fallingedge detection stage NC : signal not modified (default value) 1-2 : add 2,5V

X4

Connect Terminal of PUMP-SYNCHRO signal to GROUND NC : Differential input 2-3 : SYNCHRO- connected to GROUND (default value)

X5

Falling edge detection mode for PUMP-SYNCHRO signal NC : automatic trigger level (default value) 1-2 : fixed level = 200mv 2-3 : fixed level = 0V

X6

Add a 2.5V constant signal on the 3600/REV signal before falling-edge detection stage NC : signal not modified 1-2 : add 2,5V (default value)

X7

Connect Terminal of 3600/REV signal to GROUND NC : Differential input 2-3 : 3600/REV - connected to GROUND (default value)

X8

Falling edge detection mode for 3600/REV signal NC : automatic trigger level (default value) 1-2 : fixed level = 200mv 2-3 : fixed level = 0V

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8.2.3. 1521 CARD DESCRIPTION

1521 card : CPU card

1521

SYSTEM ON BATTERY OK REGULATION ON SECURITY

EFS
Electronique

Lighting as soon as the system is initialised Lighting when the battery voltage is correct Lighting when the regulation is active Lighting when the regulator is in SECURITY mode (actuators are driven so that the rail pressure is minimum) A fault as been detected

ERROR

The 1521 card manages the general functioning of the regulator and computes the pressure regulation. The CPU communicates with other equipment throw a serial line (RS232 or RS485) in respect with MODBUS protocol. It can equally communicates with a PLC (programmable logic controller) via logical inputs/outputs interfaced by the 1526 card, for example the PLC can start an "actuator test", or put the regulator in "security mode" or activate the regulation. The pressure sensor signal is converted in numerical form with a 16 bits ADC / 250ksps. The software then computes the actuator command using a PID algorithm, the coefficients P, I and D are available in MODBUS registers. A PLD (programmable Logic Device) then transforms the PID numerical output in control signals, synchronized if necessary, with the pump rotation depending upon the Common Rail System type. Refer to appendix REGULATION SYSTEM TYPES to get more information concerning the functioning of these different systems.

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8.2.4.

TECHNICAL MANUAL

HPR

1522 CARD DESCRIPTION

1522 card : actuators driving card

1522

BATTERY ON SELECT OUT A ERROR OUT B ERROR

EFS
Electronique

Battery voltage available Active Card Fault on Actuator A (Short-circuit, overcurrent) Fault on Actuator B (Short-circuit, overcurrent)

If the fuse is blown or if a differential current has been detected the 2 LEDS are lighting together.

Type

There are different 1522 card types that allow the regulator to work with different Common Rail System types. Refer to appendix REGULATION SYSTEM to get more information these different regulation types. With the WINHPR WINHPR software, you can select the type of regulation system you want to work with, the 1522 card corresponding will be "selected", its LED "SELECT" will light (signals are available on the rear connector X11 to do an external display).

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TECHNICAL MANUAL

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The electronic rack can receive a maximum of 4 actuators card (whichever types). Each card can drive 1 or 2 actuators and have the following specifications :

Power circuit (battery voltage) is completely isolated from the electronic command circuit (GROUND is not connected to BATTERY -) Actuator impedance detector (settable level) The current in the actuator can be chopped (settable levels) Protection against short-circuit (fixed level = 8A) and against over-current (settable level) Protection against differential current in the actuator Automatic detection of blown fuse Automatic detection of battery not connected SECURITY mode (actuators driven so that the pressure decrease) in case of error detected. Protection against battery over voltage (if the battery voltage exceed 36V the protection circuit will blown the front plate fuse).

Actuators test

actuators current chopping

In case of over-current detection, the actuator power supply removing has priority on the SECURITY mode.

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TECHNICAL MANUAL

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8.2.5. 1526 CARD DESCRIPTION

1526 card : Logical inputs/outputs card

AU OUT 0
1526

EMERGENCY STOP Output "ACTUATOR TEST OK" active Output "PRESSURE < PMIN" active Output 2 active Output 3 active Output 4 active Input "ACTUATOR TEST" active Input "SECURITY" active Input "REGULATION" active Input 3 active Input 4 active Input 5 active

OUT 1 OUT 2 OUT 3 OUT 4 IN 0 IN 1 IN 2 IN 3 IN 4 IN 5

EFS
Electronique
AU

OUT0 OUT1 OUT2 OUT3 OUT4

IN 0 IN 1 IN 2 IN 3 IN 4 IN 5

This card is used to interface logical input/output signals. The LEDS are lighting when the corresponding inputs or the outputs are active. The card provides a power supply 24 Vcc / 125mA isolated for driving the inputs.

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8.2.5.1.detailed description of the 1526 card INPUTS

electronic circuit for one input of the 1526 card Min ETAT 1 - Voltage - current ETAT0 - voltage - current Response time 15 V 3 mA -0.6 V 0 mA Nominal 24 V 6 mA 0V 0 mA 1 ms Max 30 V 8 mA 10 V 1 mA

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8.2.5.2. detailed description of the 1526 card OUTPUTS

OUT-0

OUT-1

OUT-2

OUT-3

OUT-4

COMMUN-RELAIS

Two dry contacts are also available for security loop. X8-5 X8-10 X9-1 FAULT X9-2 X8-1 FAULT X8-2 EMERGENCY STOP COMMON Security loop 1

} }

Security loop 2

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9. REGULATION PRINCIPLE
The regulation principle can be of two types :

The asynchronous mode The synchronous mode

9.1.

THE ASYNCHRONOUS MODE

The actuator(s) command is done independently of the pump position and speed. The actuator(s) command, calculated with the PID algorithm is transformed in a PWM (Pulse Width Modulated) signal. The pressure regulation is done throw an actuator opening control.

Mechanical functioning of the pump It is a proportional command. The actuator valve position is controlled. The command is done throw a PWM signal operating at a frequency of some kilohertz, this allows a control of the average current in the actuator solenoid.

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9.2.

TECHNICAL MANUAL

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THE SYNCHRONOUS MODE

The actuator(s) command is done in function of pump position and/or speed. The actuator(s) command, calculated by a PID algorithm is transformed in an actuator command synchronized with a signal generally generated by the pump itself. The actuator command can be a PWM or a pulsed signal, this signal control the opening time of the actuator(s). Opening the actuator on a known position of the pump does the pressure regulation.

Mechanical functioning of the pump It is a TRUE/FALSE control. The actuator valve is opened or closed. Controlling the opening time of the valve does the command.

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10.APPENDIX

TECHNICAL MANUAL

HPR

10.1. REGULATION SYSTEM TYPES The following table list the different Common Rail System types that are supported by the HPR. For each type, a specific 1522 card is available. Type 1522-T1 1522-T2 1522-T3 1522-T4 1522-T5 1522-T6 1522-T7 1522-T8 System RCF BP SyANG Bi actuators RCO BP SyPWM Bi actuators RCO HP PWM Mono actuators RCO BP SyPWM Mono actuators RCO HP inverse PWM Mono actuators RCO BP PWM Mono actuators RCO BP PWM Bi actuators RCO HP PWM Mono actuators + IMV BP PWM Part Number
HPR2-ACT1 HPR2-ACT2 HPR2-ACT3 HPR2-ACT4

Corresponding Common Rail System bi-actuators system, angular driving on low-pressure, synchronized by the pump. bi-actuators system, PWM driving on lowpressure, synchronized by the pump. Mono-actuator system, asynchronous PWM driving on high-pressure. Mono-actuators system, PWM driving on low-pressure, synchronized by the pump. Mono-actuator system, asynchronous inverse PWM driving on high-pressure. Mono-actuator system, asynchronous PWM driving on low-pressure. Bi-actuator system, asynchronous PWM driving on low-pressure. Mono-actuator system, asynchronous PWM driving on high-pressure, and PWM IMV driving on low-pressure.

HPR2-ACT5

HPR2-ACT6 HPR2-ACT7

HPR2-ACT8

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Abbreviation used to defined the regulation system type : RCO / RCF : Regulation Command Opened / Closed. Defines the actuator functioning, RCO means that the actuator is opened when there is no current (the fluid can circulate), on the contrary RCF means that the actuator is closed when there is no current (The fluid cannot circulate). BP / HP : Low pressure / High pressure Defines if the regulation is done on the pump entry (low pressure) or on the rail (high pressure). SyPWM : Synchronous System, PWM driving SyAng : Synchronous System, angular driving PWM : PWM driving, 0% drive give output always low. inverse PWM: PWM driving, 0% drive gives output always high.

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10.2. RCO HP REGULATION SYSTEM Functioning:

The actuator, mounted on the rail, works like a valve having a pressure setting depending on the average value of the flowing throw current. The actuator is driven by a PWM signal having a settable frequency (generally between 150Hz and 1kHz). It is a PROPORTIONAL functioning mode, the actuator being driven by an asynchronous PWM signal.

SECURITY mode :
When the actuator is not powered, it drains the rail so the pressure decreases. In SECURITY mode, the 1522 card switches off the actuators.

Synchronisation signals :
No synchronisation signal is necessary.

Common Rail System on market :

DELPHI System for car. BOSCH System for car.
PWM frequency (can be set from 150Hz to 39KHz) Actuator A

PWM

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10.3. RCO BP REGULATION SYSTEM Functioning:

The actuator(s) are mounted on the high-pressure pump. They control the admission flow in the pump. When the actuator is not powered, the admission flow is maximum so that the pressure in the rail increases. The flow in the actuator is controlled by the average value of the current flowing throw it, it is why the actuator is driven by a PWM signal at a settable frequency (generally between 150Hz and 1kHz). It is a PROPORTIONAL functioning mode, the actuator being driven by an asynchronous PWM signal.

SECURITY mode :
When the actuator is not powered, the admission flow is maximum so that the rail pressure increases. In SECURITY mode, the 1522 card continuously powered the actuators.

Synchronisation signals :
No synchronisation signal is necessary.

Actuator B

Actuator A

PWM frequency (can be set from 150Hz to 39KHz)

PWM

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10.4. MODBUS REGISTER 32 TO 34 USE MODBUS registers parameters 1 to parameters 2, at addresses 32 to 34, have different use according to the E1522 card type. Actuator card 1522-T1 1522-T2 1522-T3 1522-T4 1522-T5 1522-T6 1522-T7 1522-T8 Parameter 1 Address 32 Pulse duration Not use Parameter 2 Address 33 Parameter 3 Address 34

Not use PWM period IMV duty cycle

Not use

IMV PWM period

Pulse duration : length of the command pulse, by step of 50s on 8 bits. PWM period : PWM period of the actuator driving. The period is generate according to this formula : P = (((parameter + 1 ) x 256) - 1 ) x 0,2s. The parameter on 8 bits, give an excursion from 51s (19,6KHz) to 13.1ms (76Hz). IMV duty cycle : Duty cycle of the IMV command from 0 to 100%. The IMV PWM period is the same than actuator PWM period. PWM IMV period : PWM period of the IMV driving. The period is generate according to this formula : P = (((parameter + 1 ) x 256) - 1 ) x 0,2s. The parameter on 8 bits, give an excursion from 51s (19,6KHz) to 13.1ms (76Hz).

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11.MODBUS COMMUNICATION PROTOCOL

11.1. SERIAL LINE CHARACTERISTICS There are two possibilities to connect to the pressure regulator : an RS232 line or an RS485 line. These two lines cannot be used together. The RS232 line is available on connector X19 (male, 9 points SubD ). The RS485 line is available on connector X18 (screw terminal).

Serial line parameters: Speed : 38400 bauds Number of bits : 8 bits without parity 1 stop bit

11.2. PROTOCOL The protocol used is the MODBUS RTU (binary mode) RTU The pressure regulator identification has been fixed to 8.

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11.3. MODBUS OUTPUT BITS (INFORMATIONS GIVEN TO THE REGULATOR) These values can be read and written by the supervisor. Write the bits via the MODBUS functions N 5 or 15. Read the bits via the MODBUS function N 1.
WRITE PERMISSION REGULATION ACTIVE

Address

DESCRIPTION

ACTUATOR TEST

GENERAL STOP

MST (*) OPEN LOOP

ACKNOWLEDGE This bit needs to set to 1 to acknowledge a FAULT. The FAULT bits are all reset to 0. The regulator then reset this bit to 0 after acknowledge and just before signalling a FAULT. SECURITY : When this bit is set to 1 the regulator goes into SECURITY MODE that means that it does everything needed to make the pressure decreasing in the rail. This bit has the same effect as the logical input signal SECURITY . OPEN_LOOP : When this bit is set to 1 , the regulator goes in OPEN LOOP MODE, the setting becomes the PID output (the value must be between 0 and 100%) REGULATION : When this bit is set to 1, the regulator goes into REGULATION MODE that means that the regulator control the rail pressure. This bit has the same effect as the logical input signal REGULATION .

SECURITY

ACTUATOR_TEST : When this bit goes from 0 to 1 the regulator starts an X actuator test. This bit has the same effect as the logical input signal ACTUATOR_TEST.

X X

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SAMPLE/HOLD : (0 : internal, 1 : external) This bit defines if the instantaneous pressure needs to be sampled by using the external signal (BNC X11) or if the sampled time is defined by the MODBUS register 30. Pressure sensors input type (0 : current, 1 : voltage) RESET : CPU reset EXIT : Ask program to stop END_TEST_ACTU: This bit is set at the end of the actuator test. This bit needs to be reset to 0 by the supervisor before starting an actuator test. MEASURE_TRANSFER : ask to transfer to supervisor all the acquisition data : pressure value, pressure setting, PID output in % Special Mode to start an external program LL3

X X

6 7 8

X X X

X X X

X X X

bank

0 0

X X

10 11

X X

X X

X X X

0 0

(*) The MST column : gives the value taken just after power on. When the box is yellow, the value is taken from the EEPROM (that means that value is saved by the regulator) The indication bank : means that this parameter is stored in EEPROM in a table depending upon the REGULATION SYSTEM TYPE. (Output register 0) which is itself stored in EEPROM.

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11.4. MODBUS OUTPUT REGISTERS (information GIVEN TO THE REGULATOR) These values can be read and written by the supervisor. Write the bits via the MODBUS functions N 6 or 1*6. Read the bits via the MODBUS function N 3.
WRITE PERMISSION REGULATION ACTIVE

Address

DESCRIPTION

ACTUATOR_TEST

GENERAL STOP

MST OPEN LOOP X X X X X X X X X X X X X X bank bank bank bank bank bank bank bank bank bank

0 1 2 3 13 23 24 25 26 27 28 29 30 31 32

Regulation System TYPE : between 1 and 16 PRESSURE SETTING : must be between 0 and max pressure setting order to start writing coefficients in EEPROM Pressure Sensor curve : voltage value in mV (10 values) Pressure Sensor curve : Pressure in bar (10 values) PID : Proportional band in bar PID : overlaying band in bar PID : Integral coefficient in ms PID : Derivative coefficient in ms PID : part of the integral action to take into account (0 to 100%) PID : part of the derivative action to take into account (0 to 100%) Slope of the ramp in bar/s used when the pressure setting is modified Sample/hold angle (from the 1/REV signal) used to hold instantaneous pressure Number of cylinders used to define the number of sample/hold during one revolution. Flex Parameter 1

X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X X

SECURITY X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

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WRITE PERMISSION REGULATION ACTIVE

Address

DESCRIPTION

ACTUATOR_TEST

GENERAL STOP

MST OPEN LOOP X X X X X bank bank bank bank bank X bank X bank X bank X bank

33 34 35 36 37

Flex Parameter 2 Flex Parameter 3 Sampling period for the instantaneous pressure (unit = 500s) PID Output maximum Value (de 0 to 100%) Low Pressure Level (in bar) used to activate the logical output signal PRESSURE < PMIN TOLERANCE 1 : Maximum tolerance on the average pressure. The average pressure need to be always between PRESSURE_SETTING TOLERANCE 1 et PRESSURE_SETTING + TOLERANCE 1 otherwise the regulator signals ALARM 2 TOLERANCE 2 : Maximum tolerance on the average pressure. The average pressure need to be always between PRESSURE_SETTING TOLERANCE 2 et PRESSURE_SETTING + TOLERANCE 2 otherwise the regulator goes into SECURITY MODE and signals a fault. TOLERANCE 2 needs to be higher than TOLERANCE 1 .

X X X X X

X X X X X

SECURITY X X X X X X X X X

X X X X X

38

39

40

TOLERANCE 3 : idem TOLERANCE 1 but the test is done on the instantaneous value of the pressure. The alarm activated if necessary is the ALARM 3 TOLERANCE 4 : idem TOLERANCE 2 but the test is done on the instantaneous value of the pressure.

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WRITE PERMISSION REGULATION ACTIVE

Address

DESCRIPTION

ACTUATOR_TEST

GENERAL STOP

MST OPEN LOOP X bank X bank X bank X bank X bank X

42

TOLERANCE 5 : Level in bar used to detect oscillation of the pressure. This test is done every 2 seconds after the stabilisation time. Stabilisation time allowed when the pressure setting is growing : Time in ms after changing the pressure setting during which no test will be done. Stabilisation time allowed when the pressure setting is decreasing : Time in ms after changing the pressure setting during which no test will be done.. Number of samples for averaging : Number of samples used to compute the average pressure (between 2 and 5000) Number of samples for the average pressure used by the PID : (value between 2 and 5000). These registers are the calibration data for the ADC. (it is necessary to start again after a modification of these values) These registers are the calibration data for the ADC. Forcing the output OUT 0 : PRESSURE < PMIN (0=no forcing, 1=force to 1, 2= force to 0)

SECURITY X X X X X X X X

43

44

45

46

47

X X X

X X X

57
67

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WRITE PERMISSION REGULATION ACTIVE

Address

DESCRIPTION

ACTUATOR_TEST

GENERAL STOP

MST OPEN LOOP X

68

Forcing the output OUT 1 : TEST_ACTUATOR_OK (0=no forcing, 1=force to 1, 2= force to 0) Forcing the output OUT 2 : (0=no forcing, 1=force to 1, 2= force to 0) Forcing the output OUT 3 : (0=no forcing, 1=force to 1, 2= force to 0) Forcing the output OUT 4 : (0=no forcing, 1=force to 1, 2= force to 0) Forcing the output AU (0=no forcing, 1=force to 1) HIGH_CURRENT : Value (in mA) used to chop the actuator current. LOW_CURRENT : Value (in mA) used to chop the actuator current. TEST_CURRENT : Value (in mA) that must be reached during the test actuator to decide that the actuator is connected. MAX_CURRENT : Maximum instantaneous value of the current in one actuator (value in mA), if this value is reached the power is switched off on the actuator card and a fault is generated. STARTING_MODE : Mode in witch the regulator will start after power on. The possible values are :

SECURITY X

69 70 71 72 73 74 75

bank

bank

bank

76

bank

77

0 : GENERAL STOP 1 : ACTUATOR TEST 2 : SECURITY 3 : REGULATION 4 : OPEN LOOP

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WRITE PERMISSION REGULATION ACTIVE ACTUATOR_TEST

Address

DESCRIPTION

GENERAL STOP

MST OPEN LOOP X bank X X

78

MAX_PRESSURE_SETTING : This value will limit the pressure setting parameter (register 1). This value can be between 0 and 1800 bars. ACTUATOR TEST LENGTH : actuator test duration from 0.1ms to 6.3ms (value between 1 to 63) PROTOCOLE : communication protocol choice, need to restart the system to validate : 0 = MODBus / 1 = ASAP ASAP switch : Flag used by the ASAP protocol for choosing between OFFLINE (0) and ONLINE (1) mode. VERSION COEFF : coefficient calibration version, used when updating the system.

SECURITY X X X X

68 69

70 71

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11.5. MODBUS INPUT BITS

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( information GIVEN BY THE REGULATOR) The supervisor cannot modify these values. Read the bits via the function MODBUS N 2. Address 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description State of IN 0 input State of IN 1 input State of IN 2 input State of IN 3 input State of IN 4 input State of IN 5 input State of AU (Emergency Stop) output State of OUT 0 output State of OUT 1 output State of OUT 2 output State of OUT 3 output State of OUT 4 output ALARM 1 : Serial buffer Overload (this bit is reset after one reading) ALARM 2 : Pressure out of tolerance 1 ALARM 3 : Pressure out of tolerance 3

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11.6. MODBUS INPUT REGISTERS (INFORMATIONS GIVEN BY THE REGULATOR) The supervisor cannot modify these values. Read the registers via the MODBUS function N 4. Address 0 Description Working MODE : 0 : GENERAL STOP 1 : ACTUATOR TEST 2 : SECURITY 3 : REGULATION 4 : OPEN LOOP This register gives the actual WORKING MODE of the regulator. The working mode can be changed via logical inputs or via MODBUS OUTPUT BIT N 1,2,3 and 4. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 FAULT : value of the error code (0 = no fault) Card type detected in place 1 (on the left part of the rack) : 0 = no card Card type detected in place 2 Card type detected in place 3 Card type detected in place 4 Average pressure in bar Average pressure in bar used by the PID Instantaneous pressure in bar (signed value) instantaneous pressure (output of the 16 bits ADC) PID output : 0 to 10000 (10000 means 100%) PID output for the FLEX (The exact value written in the FLEX register) Soft version Soft version (extension) INSTANTANEOUS PRESSURE SETTING : this pressure setting take into account the possible ramp. Error message (40 registers are used -> 80 ASCII characters) A 0 ends the string.

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12.ASAP3 COMMUNICATION PROTOCOL

12.1. PHYSICAL CONNECTION The connection is the same as for the MODBus protocol. This communication is working through an RS232 or RS485. Serial link characteristics Baud rate : 38400. Bits data : 8. No parity. 1 stop bit. 12.2. COMMANDS TABLE Command INIT : IDENTIFY : EXIT : SET PARAMETER : GET PARAMETER : SWITCH ON LINE/OFF LINE : Code 2 20 50 15 14 13 Definition Start the communication. Return the version of the installed protocol with the system name. Exit from the program (reboot). Set Parameters. Get parameters. Set the working mode in ON or OFF line for the regulator which means : OFF line mode : all modified parameters are stored in the RAM file but not taken into account. ON line mode : All parameters stored in the memory are activated when the system is entering in On line and all new set parameter is activated in real time. 12.3. PARAMETERS TABLE MODE ACTION PROTOCOLE ACKNOLEDGE SYSTEME TYPE ERROR CODE PRESSURE MEASURE PRESSURE SETTING Working mode see page 39 MODBus table. Value of the PID action, value between 0 and 10000. Protocol choice (0 = MODBus and 1 = ASAP3). Error acknowledge (1 = Ack). Type of regulation to activate. Error code (see defect table). Measured pressure in Bar. (Read only) Pressure setting.

The protocol modification is valid only after reboot.

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13.LIST OF ERROR CODES

1 2 3 4 5 6 7 8

EEPROM out of order FLEX out of order Incorrect Data for the pressure sensor Unknown Actuator Type Actuator Card not Detected Incorrect Power for Actuator Pressure sensor not Detected Incorrect Pressure Signal (negative pressure) Pressure sensor signal > 120% of full scale - if the pressure sensor is configured in voltage mode the input signal was higher than 6V (full scale is 5V) - if the pressure sensor is configured in current mode the input signal was higher than 38.4mA (full scale is 32mA) Regulation out of order : too many oscillations Regulation out of order : pressure out of tolerance 2 Regulation out of order : pressure out of tolerance 4

x x

x x

x x

x x x

OPEN LOOP

CODE

DESCRIPTION

REGULATION

SECURITY

WORKING MODE after the FAULT

x x x x x x x x x

GENERAL STOP GENERAL STOP GENERAL STOP GENERAL STOP GENERAL STOP SECURITY SECURITY SECURITY SECURITY

x x x x

x x x x x x

10 11 12

x x x

SECURITY SECURITY SECURITY

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ACTUATOR TEST

GENERAL STOP

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REGULATION ACTIVE ARRET DURGENCE x x x x x x x x x BOUCLE OUVERTE x x x x x x x x x

TEST ACTUATEUR

ARRET GENERAL

DEFAUT

DESCRIPTION

50 51 52 53 54 55 56 57 58 59 70 71 72 73

Card 1: Differential leakage current Card 1: Actuator A : over-current protection Card 1: Actuator A : maximum current reached in the actuator Card 1: Actuator A : impedance too high Card 1: Actuator A : impedance too low Card 1: Actuator B : over-current protection Card 1: Actuator B : maximum current reached in the actuator Card 1: Actuator B : impedance too high Card 1: Actuator B : impedance too low Card 1: Fuse error. Card 2 : Differential leakage current Card 2: Actuator A : over-current protection Card 2: Actuator A : maximum current reached in the actuator Card 2: Actuator A : impedance too high

SECURITE

RUNNING MODE after fault acknowledge

x x x

x x x

GENERAL STOP SECURITY GENERAL STOP

x x x x x x

GENERAL STOP GENERAL STOP SECURITY GENERAL STOP

x x X x x

GENERAL STOP GENERAL STOP GENERAL STOP

x x x

x x x

GENERAL STOP SECURITY GENERAL STOP

GENERAL STOP

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x x x x x x x

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GENERAL STOP SECURITY GENERAL STOP x x

Card 2: Actuator B : over-current protection Card 2: Actuator B : maximum current reached in the actuator Card 2: Actuator B : impedance too high Card 2: Actuator B : impedance too low Card 2: Fuse error. Card 3: Differential leakage current Card 3: Actuator A : over-current protection Card 3: Actuator A : maximum current reached in the actuator Card 3: Actuator A : impedance too high Card 3: Actuator A : impedance too low Card 3: Actuator B : over-current protection Card 3: Actuator B : maximum current reached in the actuator Card 3: Actuator B : impedance too high Card 3: Actuator B : impedance too low Card 3: Fuse error. Card 4: Differential leakage current Card 4: Actuator A : over-current protection
x x X x x x x X

76

77 78 79

GENERAL STOP GENERAL STOP x x x GENERAL STOP x

90 91

x x x

x x x

x x x

GENERAL STOP SECURITY GENERAL STOP

x x x

92

93 94

GENERAL STOP GENERAL STOP x x x x x x SECURITY GENERAL STOP x x

95 96 97 98 99 110 111

GENERAL STOP GENERAL STOP x x x GENERAL STOP x

x x

x x

x x

GENERAL STOP SECURITY

x x

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x x x

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GENERAL STOP x

112 113 114 115 116 117 118 119

Card 4: Actuator A : maximum current reached in the actuator Card 4: Actuator A : impedance too high Card 4: Actuator A : impedance too low Card 4: Actuator B : over-current protection Card 4: Actuator B : maximum current reached in the actuator Card 4: Actuator B : impedance too high Card 4: Actuator B : impedance too low Card 4: Fuse error.
x x X x x

GENERAL STOP GENERAL STOP x x x x x x SECURITY GENERAL STOP x x

GENERAL STOP GENERAL STOP x x x GENERAL STOP x

*****

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