1. Overview
The JY4010 Type Electro-Hydraulic Proportional Valve Controller is a proportional power amplifier specifically designed for injection molding machines. It is compatible with various electro-hydraulic proportional valves from manufacturers such as Rexroth, Wicks, Oil Research, Taiwan Dongfeng, and Jieli, enabling precise control over pressure and flow. This amplifier plate offers stable performance and high reliability.
Key Components:
- Voltage Regulator
- Ramp Generator
- Input Value Preset Potentiometer
- 500Hz Sinusoidal Oscillator
- Controllable Constant Current Generator
2. Technical Specifications
| Parameter | Value |
|---|---|
| Power Supply Voltage (V) | AC 24-36V ±10% |
| Work Consumption (P) | Maximum 80VA |
| Control Voltage (U) | ±9V |
| Control Voltage Minimum Load Electronic Resistance (R) | 500Ω |
| Maximum Output Current (Imax) | 800mA |
| Maximum Load Electronic Resistance (R) | 45Ω (Corresponding to the Maximum Power Supply Voltage) |
| Pilot Current (ID) | 0-200mA |
| Flutter Frequency (F) | 500Hz |
| Ambient Temperature (T) | 0-45℃ |
| Temperature Drift Shift | 1‰ (OF Imax)/℃ |
| Appearance Size (L×W×H) | 160×110×50 mm |
3. Setup and Wiring
Ensure the amplifier is powered off before making any wiring connections.
Wiring Instructions:
- AC Power Supply (KL1 & KL2): Connect to AC power. Use AC24V if the proportional valve electromagnet's electronic resistance is less than 30 Ohms. Use AC36V if the resistance is greater than 30 Ohms.
- Flow Proportional Electromagnet (KL3 & KL4): Connect the flow proportional electromagnet. KL4 is the positive terminal, and KL3 is the negative terminal.
- Pressure Proportional Valve Electromagnet (KL5 & KL6): Connect the pressure proportional valve electromagnet. KL6 is the positive terminal, and KL5 is the negative terminal.
- Flow Control Input (KL7): Connect to the flow control input signal.
- Pressure Control Input (KL8): Connect to the pressure control input signal.
- Outward Output Control Power Supply (KL10, KL11, KL12): These terminals provide ±9V control power. KL10 is +9V, KL11 is 0V, and KL12 is -9V. The minimum output load electronic resistance is 500Ω.
Control Input Modes:
- Potentiometer Input Control Mode: If using an external potentiometer for control, the input control voltage amplitude should be 0-5V.
- 8421 Dial Switch Input Control Mode: The unit supports control via an 8421 dial switch.
4. Operation and Adjustment (Debugging)
The amplifier features several potentiometers (trimmers) for fine-tuning its operation. Refer to Figure 3 for the location of these adjustment points.
Adjustment Procedures:
- Initial Pressure Current (Pmin): Connect each input terminal to 0V (KL11) or disconnect. Adjust R1 to set the initial pressure current (Pmin). Clockwise rotation of R1 increases Pmin.
- Initial Flow Current (Qmin): Adjust R5 to set the initial flow current (Qmin). Clockwise rotation of R5 increases Qmin.
- Maximum Pressure Output Current (Pmax): Set the pressure input dial switch to "99". Connect each input separately. Adjust R2 to achieve the maximum pressure output current (Pmax), corresponding to the hydraulic system's maximum pressure. Clockwise rotation of R2 increases Pmax.
- Maximum Flow Output Current (Qmax): Adjust R6 to achieve the maximum flow output current (Qmax), corresponding to the hydraulic system's maximum flow (fastest movement speed of oil cylinder or motor). Clockwise rotation of R6 increases Qmax.
- Pressure Slope Rise Time (T↑): Adjust R3 to change the rise time of the pressure slope. The adjustable range is 0.1 to 5 seconds (corresponding to the maximum pressure output current Pmax). Clockwise rotation of R3 increases the pressure slope rise time.
- Pressure Slope Falling Time (T↓): Adjust R4 to change the falling time of the pressure slope. The adjustable range is 0.1 to 5 seconds (corresponding to the maximum pressure output current Pmax). Clockwise rotation of R4 increases the pressure slope falling time.
- Flow Slope Rise Time (T↑): Adjust R7 to change the rise time of the flow slope. The adjustable range is 0.1 to 5 seconds (corresponding to the maximum flow output current Qmax). Clockwise rotation of R7 increases the flow slope rise time.
- Flow Slope Falling Time (T↓): Adjust R8 to change the falling time of the flow slope. The adjustable range is 0.1 to 5 seconds (corresponding to the maximum flow output current Qmax). Clockwise rotation of R8 increases the flow slope falling time.
5. Measuring Points
For diagnostic purposes, the following measuring points are available:
- ±9V: Reference voltage.
- +9V: Measured between KL10 and KL11.
- -9V: Measured between KL12 and KL11.
6. Maintenance and Safety
Important Safety Information:
- The amplifier should only be wired when the power supply is completely off to prevent electrical shock or damage to the unit.
- Do not place radio transmitters within 1 meter of the circuit board to avoid electromagnetic interference.
General Maintenance:
Regularly inspect all wiring connections for tightness and signs of wear. Keep the unit clean and free from dust and debris. Ensure the operating environment adheres to the specified ambient temperature range (0-45℃).
7. Troubleshooting
This section provides general guidance for common issues. For complex problems, it is recommended to consult a qualified technician.
- No Output/Incorrect Output: Verify all wiring connections are correct and secure. Check the power supply voltage is within the specified range (AC 24-36V). Ensure the proportional valve electromagnet resistance matches the selected AC voltage.
- Unstable Control: Check for external electromagnetic interference, especially from radio transmitters. Re-verify the adjustment potentiometer settings (R1-R8) as per the operation section.
- No Power Indication: Confirm the AC power supply is active and connected correctly to KL1 and KL2. Check for any blown fuses if applicable (though not explicitly mentioned, it's a common point of failure).
