ATOS electro-hydraulic control: debugging and troubleshooting

The following are general recommendations and precautions for ensuring the good operation of electro-hydraulic systems, which are particularly applicable to closed-loop circuits represented by modern electro-hydraulic shafts and high-performance proportional valves with integrated analog and digital amplifiers.
For detailed information about the components, please refer to the relevant sample content. In order to ensure the normal operation of electro-hydraulic components, the following precautions should be taken:
1.6 Temperature regulation of hydraulic oil
1.7 Air exclusion
1 Hydraulic part
1.1 Cleaning of fuel tank and oil pipe
The fuel tank must be cleaned to remove all dirt and impurities; Oil pipes must be cold bent, deburred, and pickled to remove rust. After all pipelines are installed, they need to be flushed again to remove pollutants. During the cleaning process, remove the proportional valve and replace it with a bypass pipe or switch valve for cleaning.
1.2 Pipeline Connection
The pressure pipeline between the proportional valve and the pump station, as well as the proportional valve return pipeline, must be connected using steel wire wrapped hoses. If their potential risk of breakage may cause harm to equipment, systems, and operators, please adopt appropriate fixing methods (such as using chains to fix both ends of the pipeline) or use protective plugs.
The proportional valve must be installed as close as possible to the actuator to ensure the high stiffness value and dynamic characteristics of the system circuit.
1.3 Hydraulic oil
High quality hydraulic oil with high viscosity must be used in accordance with DIN51524~535 standards. Suggest a viscosity of 15-100mm/2s at 40 ℃. When the oil temperature exceeds 60 ℃, the sealing components of the components should be made of fluororubber products. At no time should the oil temperature exceed 80 ℃.
1.4 Filtration of Hydraulic Oil
The filtration of the medium avoids the wear of hydraulic components by pollutants present in the medium.
The pollution level of hydraulic oil must comply with the provisions of ISO18/15 standard. Therefore, a high-pressure oil filter with a filtration accuracy of 10 μ m and β 10=75 must be installed in the oil supply pipeline.
If possible, the line filter should be placed closely in proportion
The front of the valve should be installed, and the oil filter component should have a blockage electric indicator, but cannot have a bypass valve.
During the system debugging process, the pipeline must be flushed (for at least 15 minutes) to remove particles from the entire circuit.
The filter elements and filter components used after flushing,
If blocked, it cannot be used again. Please note the following:
-Choose an oil filter of appropriate size to ensure high efficiency
Rate;
2.6 Temperature and Environment
Install an air filter on the unit fuel tank.
-The new hydraulic oil injected into the oil tank (usually contaminated) is filtered using GL-15 oil filters or similar components (Chapter L150).
1.5 Drain port and return pipe of hydraulic system
In all hydraulic systems, a drain device is essential as it determines the system's low pressure level. The oil drain port must be directly connected to the fuel tank in order to
No back pressure will be generated.
The drain port shown in the figure is located on one side of the servo cylinder piston rod.
The return pipe from the proportional valve to the fuel tank must have sufficient cross-sectional area to avoid fluctuating back pressure<1bar in the system. Therefore, this return pipe is directly connected to the fuel tank.
1.6 Adjustment of Hydraulic Oil Temperature
In order to maintain the temperature within a limited temperature range
To ensure the system, a high-quality hydraulic system must be temperature adjustable (usually 40-50 ℃) in order to maintain the viscosity of the hydraulic oil.
The cyclic operation can only start after the oil temperature reaches the specified value.
1.7 Air exclusion
The air in the hydraulic pipeline will reduce the stiffness of the system and be the cause of the malfunction. There are air exhaust devices on both the proportional valve and servo cylinder. Exhaust valves must be installed in areas where air may accumulate in the hydraulic system pipelines.
Please also note the following:
-When the system starts, open all exhaust devices to exhaust the air. Special attention should be paid to exhaust the air inside the sensor chamber for the servo cylinder, and to do so, the exhaust valve at the piston rod end should be opened.
-Loosen the connecting parts on the pipeline.
3.6/Z Options Applicable to Digital Amplifier
3.7/SP and/ZP options applicable to digital amplifiers
4 Command signal wiring
5 Shielded Wiring
6 Fault Table
-A check valve that generates back pressure (such as adding back pressure to 4 bar) should be installed between the main return pipe and the fuel tank to prevent oil leakage in the pipeline when the system is not in use.
electronic part
2.1 Power Supply
The voltage value should be limited within the following range (depending on the type of power supply device)
Rated voltage: V=24VDC
Voltage after rectification and filtering: Vrms=21~33V (large pulsation=2Vpp)
The power supply device should have sufficient capacity. When all electrical equipment requires high current at the same time, the power supply equipment should be able to maintain normal voltage. In general, the large input electrical power of each valve can be considered as 50W.
Refer to the following diagram and pay attention to the following:
-Powered by batteries, high voltage (greater than 34V) will damage electronic components. It is recommended to use appropriate filters and voltage limiters.
-AC rectified voltage, with the average voltage limited to
Vrms=21~28V. During single-phase rectification, a 10000 μ F capacitor is installed every 3A load, and during three-phase rectification, a 4700 μ F capacitor is installed every 3A load.
-The main source of pollution in hydraulic systems is the exchange of air between the oil tank and the outside air. Therefore, it is necessary to focus on power
-After the system is restarted or repaired, it is necessary to exhaust the air completely.

ATOS electro-hydraulic control: debugging and troubleshooting