CybVA 6

Amplifier Board
For Two Hoerbiger Servo Solenoid Valves
and Two Pressure Valves

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TABLE OF CONTENTS
General Information ...................................................................................................................................... 4
System Specification ..................................................................................................................................... 4
Connection .................................................................................................................................................... 4
Key Features ................................................................................................................................................. 5
RS232 Connection ........................................................................................................................................ 5
LEDs.............................................................................................................................................................. 6
Jumper Settings ............................................................................................................................................ 6
Connecting CybVA 6 Board to Power Supply ............................................................................................... 6
Precautions ................................................................................................................................................... 6
Application in Hydraulic Press Brakes .......................................................................................................... 7
Valve Amplifier CybVA 6 Software Program in USER MODE ...................................................................... 8
Valve Amplifier CybVA 6 Software Program in DEVELOPER MODE ........................................................ 15
Valve Amplifier Board without LVDT Feedback .......................................................................................... 16
Typical Parameter Values for Different Valves ........................................................................................... 16

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General Information
CybVA 6 board is a multichannel amplifier board developed to drive hydraulic valve coils.
The CYBVA 6 board simultaneously operates two Hoerbiger proportional servo solenoid
valves, one pressure valve and one proportional valve for crowning.
System is equipped with a feedback mechanism controlling the spool position of the each
valve with an LVDT DC signal input.
The package includes the following items:

Board

CybVA 6 Amplifier Board

Software

CybVA6 Valve Amplifier Setup Program

Documentation

This manual + Cybelec datasheet CybVA6

System Specification
Power Supply (Logic)

15-30V DC

Power Supply (Valves)

+24V DC +/- 10%

Power Consumption

Approx. 150mA @24V DC (Logic)

Dimensions

122mm x 250mm

Weight

400 gr

Connection
The board can be mounted into a ventilated electrical cabinet. The following installation
instructions must be followed strictly.

CybVA_6_UserManual_v1.1.doc

The cables must be shielded on their entire length.

The mass braid must be connected to the connector housing.

The valve feedback cables must be separated from the other cables especially
from motors (electromagnetic disturbances).

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Key Features
Current

I 4.5A for proportional valves

Ambient
Temperature
Range

Minimum 00 C, Maximum +500 C

Inputs

2 set values: 10V, 10bit ADC

2 set values: 0..+10V, 10bit ADC
1 set value for controller enable: 0-24VDC
2 set values from LVDT displacement sensor: +3V.. +12V, 10bit ADC

Extra Output

1 set value for error signal: 0-24VDC

Interfaces

RS232 Sub-D connector for PC communication

Control
Functions

Offset
Dither Frequency: Independently adjustable by software: 50Hz to 250Hz
Dither Amplitude: Independently adjustable by software: 0 to 10% of max
current.
Ramp Rise/Ramp Fall: Independently adjustable by software: 0.01 to 0.5 s.
Parameter for load sensing for each output
LED indication in case of emergency condition for each output

Features

LED indication of power on/off condition

Short circuit proof
No reverse polarity protection!
Can be disconnected from coil when powered
Adjustable current limit feature by software and hardware
Software programmable PID closed loop parameters
Connections

Screw terminals for AWG 16-30 Wire

RS232 Connection
CybVA 6 amplifier board can be connected to a PC via a DB9 connector as shown in
Figure 2. The amplifier board communicates with PC in compliance with the RS-232
standard.

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LEDs
There are seven LEDs on the CybVA 6 amplifier board to visually indicate the state of
each amplifier stage, separately. Each LED is associated with one amplifier stage.
As soon as there is a problem in the system, an illuminated LED position shows the
amplifier stage with the error.

Jumper Settings
For each valve output, there is one parameter used to adjust the maximum current
allowable in the valve.
As soon as the maximum current is above the tolerated current set by the parameter, the
system will shut down all valves at the same time. In the case of shut down, CybVA 6
amplifier board requires repowering.

Connecting CybVA 6 Board to Power Supply

In order to turn the board on, it is necessary to provide the power supply voltage via DC
connector on the right top of the board as shown in Figure 1.
The power supply voltage should be between +15V and +32V DC. Power rating of the
PSU should be determined according to the valves used in the machine. But, it is
recommended to have at least 150 W PSU.

Precautions
1. Enable signal (+24V DC) from the PLC should be applied to the ENB pin of the
CybVA 6 amplifier board.
2. LVDT sensor cables from both Y1 and Y2 valves should be connected to CybVA 6
amplifier board.
If the above two conditions are not satisfied, the CybVA 6 amplifier board is not activated.
3. Unit impulse test should be applied only when the main pump is not active.
Software activates only one valve during the test. If the main pump is working
during the impulse test, catastrophic results may occur in the machine. Therefore, it
is strictly forbidden to run the impulse test if the main pump is active.
4. It is always better to connect the main power supply (+24V) for the valves via a
SSR or relay that is controlled by Enable signal (+24V DC) of the PLC control unit.
This makes the whole system more robust in case of any failure in the CybVA 6
amplifier board.

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Application in Hydraulic Press Brakes

Figure 1. Wiring diagram of the CybVA 6 Amplifier Board

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Valve Amplifier CybVA 6 Software Program in USER MODE

Valve Amplifier CybVA 6 program allows to modify the factory-default PID parameters of
CybVA 6 board amplifier for each servo solenoid valve.
The following steps are required for update process.
1. Run the Valve Amplifier CybVA 6 program.
2. Ensure that the RS232 cable is connected between PC and amplifier board.
3. User can see the current status of the CybVA 6 board amplifier on the top left
corner of the CybVA 6 Program.
4. If there is no communication established yet between the CybVA 6 board amplifier
and CybVA 6 Program in the PC, this is indicated as No Communication in
purple back color in the program as shown in Figure 2:

Figure 2. Initial screen look when the program is first run

5. CybVA 6 board amplifier Program communicates with the CybVA 6 amplifier board
with the following communication parameters:

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9600 bps

8 Data bits

No Parity

No Software flow control

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6. In order to communicate with CybVA6 amplifier board, user should choose the
communication port.
Figure 3 shows the screenshot of the program as soon as communication is
established.
As you can see, although communication is Ok, system is not ready to run since no
enable signal is received from the PLC or machine controller. However, this is not a
requirement for the flash update process:

Figure 3. Open PID Parameters File Dialog window

7. Open the PID parameters file by clicking Load Parameters button.
These parameter files are located at C:\Program Files\Cybelec\CybVA 6 Valve
Amplifier Software\Parameters if default installation settings are chosen while
installing the program.
Figure 4 shows the Open PID Parameters File... dialog window:

Figure 4. Open PID Parameters File Dialog window

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8. Choose the appropriate file from this dialog window.
As soon as the file is selected, click on Open button.
The parameters on the selected file will be loaded automatically to the program as
shown in Figure 5.

Figure 5. PID parameters and LVDT limits are loaded into the program.
9. At this step, the parameters are ready to be downloaded into the nonvolatile flash
memory of the CybVA 6 amplifier board.
a. In order to send the parameters to the CybVA6 amplifier board, click on
Send Parameters button to store the parameters into the volatile RAM.
b. Then, click on the Write to Flash button to write all parameters into the
nonvolatile flash memory.
10.At any time, user can return back to default factory setting by clicking on Reset to
Factory Settings button on the Parameters Update group.

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11.If the Enable signal is not yet active, user can connect +24V Enable signal to the
CybVA 6 amplifier board. The status of the CybVA 6 amplifier board will change to
default state as shown in Figure 6. In the default state, Error LED should not be
illuminated and seven LEDs should start to flash sequentially. Now, the system is
ready to run:

Figure 6. Default state of the CYBVA6 amplifier board while waiting for command.
12.Finally, you can click on Start button to activate the system. In order to stop the
system to return back to default state, user can click on Stop button.
13.If the LVDT limits have not yet known by the CYBVA6amplifier board, you can
automatically measure their values by simply clicking on LVDT Auto Scaling
button. Figure 7 shows the initial screen look as soon as LVDT Auto Scaling
button is clicked.

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Figure 7. Updating LVDT limit values automatically.

As you can see in Figure 7, a black text screen appears on the left hand side of the
program.
The maximum and the minimum positions are shown on this black text screen. The chart
on the right hand side shows the measurement of the LVDT sensors.
Horizontal scale on this chart goes up to 1024 positions. The first half of this horizontal
scale is for LVDT Y1, and the second half is for LVDT Y2.
The null position of the CybVA 6 is approximately at 512 ADC units
For the example shown in Figure 8, the null position of the LVDT Y1 is at 509, whereas
the null position for LVDT Y2 is at 507.
The user should be careful with the automatic limit measurement system. The following
points summarize the error conditions:

Max Limit should always be greater than both Middle (Null) and Min limit.

Middle Limit should always be greater than Min limit.

All limits should be greater than 50. (That indicates broken cable!)

They should not be equal to each other. (That indicates power stage is not
activated)

For Figure 7, by looking at the black text screen, we can easily say that Y2 amplifier stage
is either not connected or not activated. This condition is also shown in the chart on the
right hand side. Second part of the horizontal scale is a horizontal line meaning that no
spool movement is detected by the CybVA 6 board during the automatic LVDT limits
measurement.

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At the end of the measurement, the program presents two alternatives to the user.

Cancel: User can click on Cancel button, to discard all measurements.

Update Only: User can choose Update Only button to update the
program values on GUI. This choice does not affect CybVA 6 amplifier board
parameters. Later on, if user wants to update the CybVA 6 amplifier board
with the values in the PC program, instructions are available at step 9.
14.Once the parameter values are found the current machine, the parameters can be
saved for future reference by clicking Save Parameters button as shown in
Figure 8

Figure 8. Save PID Parameters

15.User can also test the response of each valve, Y1 or Y2 by clicking on Start Test
Button. CybVA6 amplifier board will try to hold the spool position at the value
given in Amplitude box for the selected valve. An example screen is displayed in
Figure 9.
Note: While testing the response of each valve, the main pump should
not be activated.
16.Clear button clears the chart and Save button saves the contents of the chart as
a text file.
17.Finally, if all parameters of the system are determined, user can click on Start
Button. The Figure 10 depicts the status of CybVA 6 amplifier while running.

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Figure 9. Response of Valve Y1 to amplitude 500 with the given PID parameters.

Figure10. Status of CybVA 6 amplifier while running.

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Valve Amplifier CybVA 6 Software Program in DEVELOPER MODE

User can also run the Valve Amplifier CybVA 6 Program in developer mode. The default
mode of the program is User Mode. In order to enter Developer mode, user should click
on User Mode button and enter the developer password correctly in the developer
password form as shown in Figure 11:

Figure11. Developer password form.

A typical developer screen will have more options, as shown in Figure 12.
But two of the options are most important:

Set as Factory Settings button: saves the current parameter

configuration of the program as default factory settings.

The other option are the buttons used to test each LVDT separately as shown
in TEST LVDTs group on the left bottom of the screen.

Figure12. Developer Mode of the Valve Amplifier CybVA Program.

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Valve Amplifier Board without LVDT Feedback

The CybVA 6 Valve Amplifier board can also be run without feedback in open loop
configuration.
In order to run the system in open loop mode, the Jumper 1 (program) should be
connected together as shown in Figure 13.

Figure13. Open Loop Mode Jumper (prog)

Typical Parameter Values for Different Valves

For Hoerbiger type valves PIL500PC06P12 and PIH500C06
Kp Feedforward

1024

Kp

2000

Ki

45

Kd

LVDT Max Limit

788

LVDT Middle Limit

512

LVDT Min Limit

236

For other valves and / or open loop management just set the maximum current correctly
according to the valve specifications.

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