AxisPro Servo conversion instructions How to get servo valve-like performance from a servo-performance proportional valve

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1 White Paper xispro Servo conversion instructions How to get servo valve-like performance from a servo-performance proportional valve Per Danzl Global Product Manager - Industrial Valves The xispro proportional industrial valve is a cost-effective and reliable alternative to the traditional servo valve. xispro four-way solenoid-operated proportional valves offer high dynamic performance which enables them to be used in closed loop motion control applications previously only possible using conventional servo valves. Compared to servo valves, xispro proportional valves offer excellent performance and better reliability at a significantly lower price point. Servo valves: expensive with limited availability Servo valves provide excellent accuracy and high repeatability. Servo valve technology has been in constant use for over 0 years. But servo valves are typically more expensive than other valves: they require elaborate production methods (involving machining and assembling two stages). nd when placed into service, servo valves require sophisticated electronic control cards adding additional costs. In addition, servo valves require use of a pilot-filter (typically) supplied by the manufacturer, which can become contaminated and require costly maintenance. The new xispro line of proportional directional valves provide a cost-effective alternative to traditional nozzle-flapper servo valves. Proportional valves, like xispro, benefit from a simpler mechanical design that costs less to manufacture, while utilizing onboard integrated electronics and feedback to achieve servo-quality spool control performance. Plus, since the xispro power stage directly drives the spool, there is increased robustness to contamination (no need for pilot stage filtration to protect the fragile nozzle-flapper interface of a traditional servo valve).

2 xispro Servo conversion instructions Converting to xispro servo-performance valves: step-by-step NNote: This conversion process applies to xispro Level valves. Contact your Eaton representative for information about converting to xispro Level and Level valves. Converting to the xispro valve requires a simple six-step process: Step. Determine maximum flow rate of the servo valve Step. Choose the proper replacement xispro valve Step. Define parameters Step. Determine where motion control is handled Step. Mount xispro Valve Step. Wire xispro Valve You will find model codes, installation dimensions and other useful information in the appendix. Step : Determine maximum flow rate of the servo valve Maximum flow and pressure rating is typically listed as part of the model code and appears on the on the model code/serial number label (Figure ). NNote: The xispro valve is not recommended for pressure ratings higher than 0 bar. Step : Define conditions, output and electrical connections. Define the xispro valve failsafe conditione: Servo valves typically define the failsafe condition as all ports blocked in the neutral position. Because proportional valves are driven by a solenoid in only one direction, it is necessary to match the correct failsafe condition of the servo valve in the xispro valve. Choose the forced position as an all ports blocked position for the new xispro valve.. Select the xispro valve spool and sleevte: Spool/sleeve settings will vary according to the flow rate of the valve. Choose the correct flow when setting the valve by determining these parameters: a. Symmetric vs. symmetric (valves are typically symmetric, but verify with your valve) b. Correct failsafe position c. Select flow rate. Using the spool sleeve codes, choose the correct flow rate that allows for at least the desired flow. Select a. Select : +/- 0V Voltage b. Select : -0m current c. Select : +/- 0m current d. Select : +/- m current e. Select : +/- 0m current. Select monitor outpuoe: Use monitor output to locate the position of the valve spool for the PLC. Typical monitor output involves using the +/- 0V voltage feedback signal. The spool position may or may not be used in the existing system ignore if not used/needed by the PLC. The xispro valve internally controls spool position, this external feedback is optional only for monitoring purposes. a. Select : +/- 0V voltage feedback signal b. Select : -0m current feedback signal Figure. Locate serial number to determine flow rating. Step : Choose the proper xispro replacement valve Choose the proper xispro Level replacement valve according to desired flow (note single-stage xispro valves have flows rated at 000 psid pressure drop across the valve, i.e. 00 psi per metering edge): Flow < 0 gpm: choose the Eaton KBS- proportional directional valve Size D0 mounting pattern Flow > 0 gpm: choose the Eaton KBS- proportional directional valve Size D0 mounting pattern To assist in choosing the right xispro model configuration, please refer to the appropriate xispro product catalogs, available on PowerSource.. Select electrical connectione: Typical use involves the pin connector with plug a. Select E: pin connector with plug Step : Determine where motion control is handled: PLC or card Motion is typically controlled through the servo card or through the PLC. If motion is controlled through the servo card, talk to your Eaton representative about using an xispro level valve as a replacement valve If motion is controlled through the PLC: Ensure the PLC parameter scaling is equivalent to the xispro valve parameters Verify that the PLC PID parameters are performing well/as expected

3 xispro Servo conversion instructions Step : Mount the xispro valve in place of the servo valve. Mount the adapter plate where the servo valve had been located (Figure ). Verify installation dimensions for desired xispro valve model code a. xispro valves may require a larger size envelope than servo valves b. Verify there is adequate space to accommodate the xispro valve by measuring space around the mounted servo valve (Figure ) Figure. Verify adequate space to accommodate the xispro valve.. Determine required adapter plate a. n xispro KBS- valve requires a D0-to-S0 manifold adapter plate. Order a D0-to-S0 manifold adapter plate. Order four mounting screws: a. UNC #0- x.00 long SHCS, or b. ISO H M-0. x mm SHCS mounting screws. Order four O-rings (typically Viton Durometer-0) b. n xispro KBS- valve requires a D0-to-S0-manifold adapter plate is required. Order a D0-to-S0 manifold adapter plate. Order four mounting screws, either: a. UNC #0- x.00 long SHCS, or b. ISO H M-0. x mm SHCS c. Order four O-rings (typically Viton Durometer-0) Figure. Mount adaptor plate to servo valve location.. Mount the xispro valve to the adapter plate (Figure ). Remove servo valve by removing the mounting bolts (Figure ) Figure. Mount the xispro valve to the adaptor plate. Figure. Remove the four mounting bolts to remove the servo valve.

4 xispro Servo conversion instructions Step. Wire the xispro valve NNote: While no external amplifier card is needed, the xispro valve does require a VDC power supply.. Supply V volts (DC) and rated to. mps to xispro valve (Figure and Figure ). a. Recommended power cable sizes for V are 0. mm ( WG) up to 0m ( ft.) and.00 mm ( WG) up to 0 m (0 ft.). Power Supply +v GND EE-PM-9 SM-0 mplifier. Connect input from PLC to xispro valve. a. Command signal goes to pin D with a ground reference at pin E (Figure and Figure 9). PLC +V or current in V or current GND Voltage input pins: B, B or Z Current input pins: Z and Z EE-PM-9 SM-0 mplifier Figure. Before mounting the xispro valve, with no external feedback. Figure. Wiring prior to mounting the xispro valve. Power Supply +v GND Current mplifier No Longer Needed with xispro Onboard Electronics EE-PM-9 SM-0 mplifier PLC +V or current in V or current GND Voltage input pins: B, B or Z Current input pins: Z and Z EE-PM-9 SM-0 mplifier G F B C F G B C Figure 9. fter mounting the Level xispro valve. E -pin mphenol xispro Connector D E -pin mphenol xispro Connector D Figure. Wiring after mounting the xispro valve.

5 xispro Servo conversion instructions ppendix Model codes KBS* ** - NS - - * - CO - * - NS - VSC - NS Control Level Level plus Network enabled and DS0 control modes Level plus Integrated pressure and temperature sensors Command Signal +/- 0V voltage NNote: Command signal is shipped with configuration. You may configure to other options using Pro-FX: Configure software. -0m current +/- 0m current +/- m current 9 Command over Fieldbus Monitor Output ±0V voltage feedback signal NNote: Monitor Output is shipped with setting. You may configure to other monitor signal options using Pro-FX: Configure software. -0m current feedback signal 9 Feedback over Fieldbus Electrical Connection C pin connector without plug E pin connector with plug NNote: You may reconfigure pin C as the enable signal using Pro-FX configure software. 9 Digital Communication Interface CO CNOpen 0 External Sensor -0m external sensor analog inputs and discrete inputs D SSI external digital sensor input Customer pplication Programming Space NS Not Selected CW CODESYS White Space Control Mode VSC Valve spool position control NNote: Control Mode is shipped in valve spool closed loop position control (VSC) configuration. You may reconfigure to other control mode options using Pro-FX: Configure software. DPC - DS0 Drive Position Control Mode Enabled DSC DS0 Drive Speed Control Mode Enabled DFP DS0 Drive Force/Pressure Control Mode Enabled DPQ Eaton Custom Drive Pressure / Flow Control Mode Enabled To find available product configurations go to

6 xispro Servo conversion instructions Model codes KBS ** - NS - ** - * - NS Valve Type KBS Servo performance proportional valve with integral amplifier and electronic feedback Level Interface 0 ISO 0, size NSI/B9.M-D0 Spool/Sleeve Symmetric -00l min - t Failsafe -all ports blocked (legacy 9L00) Symmetric - 0l min - t Failsafe -all ports blocked (legacy 9L0) Symmetric - 0l min - t Failsafe -all ports blocked (legacy 9L0) Symmetric - l min - t Failsafe -all ports blocked (legacy 9L) Symmetric -00l min - t Failsafe -P port blocked,,b,t connected (legacy 9L00) Symmetric - 0l min - t Failsafe -P port blocked,,b,t connected (legacy 9L0) Symmetric - 0l min - t Failsafe -P port blocked,,b,t connected (legacy 9L0) Symmetric - l min - t Failsafe -P port blocked,,b,t connected (legacy 9L) symmetric -00l min ; 0l min B - t Failsafe -all ports blocked (legacy 9L00N0) symmetric -00l min ; 0l min B - t Failsafe -all ports blocked (legacy 9L00N0) 9 symmetric -00l min ; l min B - t Failsafe -all ports blocked (legacy 9L00N) 0 symmetric - 0l min ; l min B - t Failsafe -all ports blocked (legacy 9L0N) symmetric -00l min ; 0l min B - t Failsafe -P port blocked,,b,t connected (legacy 9L00N0) symmetric -00l min ; 0l min B - t Failsafe -P port blocked,,b,t connected (legacy 9L00N0) symmetric -00l min ; l min B - t Failsafe -P port blocked,,b,t connected (legacy 9L00N) symmetric - 0l min ; l min B - t Failsafe -P port blocked,,b,t connected (legacy 9L0N) -gain Symmetric 0l 0% -all ports blocked (legacy 9L0T00) -gain Symmetric l 0% - -all ports blocked (legacy 9L0T0) -gain Symmetric 0l 0% -P port blocked,,b,t connected (legacy 9L0T00) -gain Symmetric l 0% - -P port blocked,,b,t connected (legacy 9L0T0) Valve Special Feature NS Not Selected Command Signal +/- 0V voltage +/- -0m current +/- 0m current +/- m current +/- 0m current Monitor Output ±0V voltage feedback signal -0m current feedback signal Electrical Connection C pin connector without plug E pin connector with plug H s E but with pin C used for enable signal R s C but with pin C used for enable signal Electrical Special Feature NS Not Selected Software Revision XXX Software Revision Design Number 0 series To find available product configurations go to

7 xispro Servo conversion instructions Installation dimensions KBS-0 - Pin connector.9 [.00].0 [.]. [0.]. [0.]. [.]. [.]. [9.] KBS-0 - Pin Connector.0 [9.]. [.] 9. [.] 9. [.].0 [0.]. [0.9] 0. [.]

8 xispro Servo conversion instructions Mounting surfaces KBS-0 Mounting Surfaces to ISO 0 (Size 0) This interface conforms to: ISO plus location pin hole NSI/B9.M (and NFP) size 0 CETOP RH.--0, plus location pin hole DIN 0 Form plus location pin hole holes, M-H x (0.) min. full thread depth,9 (.0),0 0, (. 0.00), (0.), (0.0), (0.) 0, (.), (0.) T B 0, 0, ( ), 0, (. 0.00) (.9) min. P ports Ø, (0. dia). For all Eaton size 0 valves this diameter may be increased to Ø, (0.9) Ø,0 x, min. depth (0. dia x 0.) for locating pin, (0.9) 0, 0, ( ) 0 (.) min. #0- UNC-B optional. KBS-0 Mounting Surface Interface to ISO 0 (Size 0) This interface conforms to: ISO NSI/B9.M (and NFP) size 0 CETOP RH.-0 DIN 0 Form 0, (.), (0.), (0.) 0, (.0), (.),0 (.0), (0.), (0.) P holes, M-H x (0.) min. full thread depth B 9,0 (.) min.,0 ±0, (. ±0.00) T T B ports Ø, (0. dia) including opt. tank port / " -0 UNC-B optional.,0 ±0, (. ±0.00) 90,0 (.) min. Optional port (T B ),0 (0.) P 0, (0.0) L B Ø,0 (0. dia) T TB

9 xispro Servo conversion instructions Operating data KBS-0 Connector Details -pin plug connector Pin Description Note: G Power supply positive (+) Present at location of the electronics B Power supply 0V and current command return enclosure (see figure below). F B C Not connected (Field = C,E) To ensure EMI protection use only metal shielded C Valve enable (Field = H,R) mating connectors. Mating -pin (connector) is D Command signal (+V or current in) Eaton part number 999 E C E Command signal (-V or current GND) F Output monitor D G Protective earth M -pin CN Connector (Male) Pin Description Note: CN shield Present at location and of the electronics mating connectors Not Connected CN High enclosure (see figure below). Selection based on option enabled. Power supply 0V CN Low model code field number 9, present when CO To ensure EMI protection use only metal shielded Use only shielded twisted pair (STP) cables for mating connection. M -pin CN Connector (Female) Pin Description Note: CN shield Present at location of the electronics Not Connected enclosure (see figure below). Selection based on Power supply 0V model code field number 9, present when CO CN High option enabled. CN Low To ensure EMI protection use only metal shielded mating connectors Use only shielded twisted pair (STP) cables for mating connection. M -pin External Digital Sensor Pin Description Note: Power supply 0V Present at location of the electronics +V Supply enclosure (see figure below). Selection based CLK- on model code field number 0, present when DT- D option enabled. DT+ To ensure EMI protection use only metal shielded Not Connected mating connectors CLK+ V to Power supply 0V (pin, ) short circuit Not Connected protected (max current. ). Use only shielded twisted pair (STP) cables for mating connection. M -pin External nalog Sensor Port Pin Description Note: Speed Sensor Input Present at location of the electronics Speed Sensor Input enclosure (see figure below). Selection based -0m External Sensor Signal on model code field number 0, present when +V Supply option enabled. -0m External Sensor Signal -0m External Sensor Signal To ensure EMI protection use only metal shielded V to Power supply 0V (pin, ) short circuit Power supply 0V -0m External Sensor Signal mating connectors protected (max current 00 m). Location Location Location Location Location NNote: See above for connector plugs specifications. Figure 9

10 xispro Servo conversion instructions Operating data KBS-0 Connector Details -pin plug connector Pin Description Note: G Power supply positive (+) Present at location of the electronics B Power supply 0V and current command return enclosure (see figure below). F B C Not connected (Field = C,E) To ensure EMI protection use only metal shielded C Valve enable (Field = H,R) mating connectors. Mating -pin (connector) is D Command signal (+V or current in) Eaton part number 999 E C E Command signal (-V or current GND) F Output monitor G Protective earth D M -pin CN Connector (Male) Pin Description Note: CN shield Present at location and of the electronics mating connectors Not Connected CN High enclosure (see figure below). Selection based on option enabled. Power supply 0V CN Low model code field number 9, present when CO To ensure EMI protection use only metal shielded Use only shielded twisted pair (STP) cables for mating connection. M -pin CN Connector (Female) Pin Description Note: CN shield Present at location of the electronics Not Connected enclosure (see figure below). Selection based on Power supply 0V model code field number 9, present when CO CN High option enabled. CN Low To ensure EMI protection use only metal shielded mating connectors Use only shielded twisted pair (STP) cables for mating connection. M -pin External Digital Sensor Pin Description Note: Power supply 0V Present at location of the electronics +V Supply enclosure (see figure below). Selection based CLK- on model code field number 0, present when DT- D option enabled. DT+ To ensure EMI protection use only metal shielded Not Connected mating connectors CLK+ V to Power supply 0V (pin, ) short circuit Not Connected protected (max current. ). Use only shielded twisted pair (STP) cables for mating connection. M -pin External nalog Sensor Port Pin Description Note: Speed Sensor Input Present at location of the electronics Speed Sensor Input enclosure (see figure below). Selection based -0m External Sensor Signal on model code field number 0, present when +V Supply option enabled. -0m External Sensor Signal -0m External Sensor Signal To ensure EMI protection use only metal shielded V to Power supply 0V (pin, ) short circuit Power supply 0V -0m External Sensor Signal mating connectors protected (max current 00 m). Location Location Location Location Location NNote: See above for connector plugs specifications. Figure 0

11 xispro Servo conversion instructions

12 xispro Servo conversion instructions Eaton 000 Eaton Boulevard Cleveland, OH United States Eaton.com 0 Eaton ll Rights Reserved Printed in US February 0 Eaton is a registered trademark. ll other trademarks are property of their respective owners.