Spider II - 1

AS-1
Introduction
Spider
Engineering manual
04-04-02
1.1 Description
The Spider unit is a microcontroller based system, configurable to suit different application
needs. It is designed to match the two or three door power unit also with one door unit added.
The control system can control pumps with double coil (Denison 9A, Brueninghaus EP, Sauer
Sundstrand KA or similar pumps) or single coil in one direction (Denison 5A).
The unit can be mounted inside the power unit, in the power unit door, on the outside of the
power unit or delivered separate with wall brackets or panel flange to be wired in by the
customer. Cable sets can be supplied as an option.
The configuration of the pre-programmed system functions is done using the front panel with
help from the text displays or via a serial connection from a laptop. The configuration mode can
be protected with a password.
The Spider unit can control the system with different settings of electric motor/pump
configuration.
One to four pumps for one drive:
EM
DRIVE
DRIVE
EM
DRIVE
EM
DRIVE
EM
EM
EM
EM
EM
EM
Two to four pumps for two drives with separate function:
DRIVE
EM
EM
DRIVE
DRIVE
DRIVE
EM
EM
EM
EM
EM
DRIVE
DRIVE
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN
1(14)
AS1, Introduction, Engineering manual
04-04-02
Two to four pumps for two drives with common function. If one stops by a fault the other will
also stop:
EM
EM
DRIVE
DRIVE
DRIVE
DRIVE
EM
EM
DRIVE
DRIVE
EM
EM
DRIVE
DRIVE
EM
DRIVE
DRIVE
EM
DRIVE
DRIVE
EM
DRIVE
DRIVE
EM
EM
EM
EM
EM
EM
EM
The Monitor function can health monitor the power unit switches and give information on the text
display about warnings or alarms. An alarm will stop the electric motor or motors if the digital
interlock output is connected via a relay to the starter interlock circuit. Up to 4 pumps can be
controlled in parallel for the same drive
M
M
2(14)
04-04-02
The Basic function has added functions for power limitation and closed loop speed feedback via
a PID-regulator. Inputs are available for analog or digital speed encoders.
The unit can also monitor analog signals on the display such as speed, E-motor current,
pressure etc.
The Shredder function has the same functions as Basic and added functions for reversing by an
overload-stopped drive. It is possible to maximise the number of reversals within a time limit and
stop the drive when exceeded. The drive can be set to change direction after an adjustable time
interval.
3(14)
04-04-02
The Friction function has the same functions as Basic and added functions for control of two
hydraulic drives driven together with a ratio between the motors.
The Friction slave function has the same functions as Basic and added functions for control of
two hydraulic drives driven together with a ratio in relation to the master setpoint.
4(14)
04-04-02
The Synchro function has the same functions as Basic and added functions for position control
between two hydraulic drives. It is possible by an external signal to set the angle between the
rolls. Ratio drive is also possible. This mode requires digital speed encoders.
The Spider unit front has push-buttons for start and stop of the drive, local/remote, speed
setpoint by increase and decrease in local mode, inch reverse, regulated/non-regulated drive
and auto/manual drive in shredder mode. These push-button functions can be bypassed in the
configuration of the system functions.
All inputs and outputs are configurable and can be connected to pre-programmed functions in
the setup of the system. All signals are as standard wired to contact terminals or via fieldbus port
(optional).
The digital inputs can be configured to functions for eg. start/stop, reverse, reset, monitoring of
the power unit, auxiliary monitor where it is possible to set the function and display monitor text.
The digital outputs can be configured to functions for eg. common alarm/warning, ready to use,
drive started, shredder blocked, cooler and heater control. The outputs are of dry relay contact
type.
The analog inputs can be configured to functions for eg. tank temp, speed, pressure, power for
monitoring and control. The inputs can be configured for current loop or voltage.
The analog outputs can be configured to monitor eg. speed, pressure, temp. The outputs can be
configured for current loop or voltage.
The system includes a drive monitoring function with drive time counters, alarm/warning list and
8 scalable log channels with data download via serial interface. A remote drive monitoring
system with access via GSM can be added as an option.
5(14)
04-04-02
1.2 Serial number
E01P x x x - xxxx
Article group for Spider
Serial number
Function:
Drive 2 config:
M= Monitor function
0= No Emotor, No pump
1= 1 Emotor - 1 Pump
2= 1 Emotor - 2 Pumps
3= 2 Emotors - 2 Pumps
8= Emotor common w.drive 1 - Tandem pump1
9= Emotor common w.drive 1 - Tandem pump2
B = Basic function
S = Shredder function
Z = Synchro function
F = Friction function
R = MRC function
Drive 1 config:
1= 1 Emotor - 1 Pump
2= 1 Emotor - 2 Pumps
8= 1Emotor - Tandem pump 1
9= 1Emotor - Tandem pump 2
1.3 Card number

The individual card number is marked on the card at final test. The number consists of an individual
number and year and week for the production test.
2011 0347
Individual number
Year and week for production test
6(14)
04-04-02
1.4 Versions and changes

1.4.1 Software versions
The software version is shown on the display for drive 1 at power up of the system.
Version 0.2, 1.0-1.3

Test versions during the first time of developement of the system.
Version 1.4.0
Ready 96-05-26
First delivered version. Four prototype systems were delivered to customers in Sweden.
Function block diagrams Block 1B, Block 2B and Block 3B.
Version 1.4.1
Ready 96-08-23
New version of OTool operating system.
Bug fixes:
-Idle function could cause watchdog problem by stack overflow.

-PWM (Pulse Width Modulation for the output signal to the pump strokers) routine
changed. Problems with PWM frequency >1000Hz.
Function block diagrams Block 1B, Block 2B and Block 3B.

Version 2.0.0
Ready 96-08-30
Adapted to the new version of the hardware (rev.A).
Bug fixes
-PWM routine changed. Problems with PWM frequency <1000Hz caused by

software compilator bug.
Function block diagrams Block 1C, Block 2C and Block 3C.

Version 2.1.0
Ready 96-11-27
Readings from both drives can be used in any position. Only readings for drive 1 could earlier be
used on display 1.
Better protection against uncontrolled reversing of drive with use of analogue encoder for speed
feedback.
Better accuracy for reading of speed encoder.
New digital inputs:
-Local1 -Change between Local and Remote drive 1.
-Local2 -Change between Local and Remote drive 2.
-Shutdown1 -Open output to pump 1 without open e-motor interlock.
-Shutdown2 -Open output to pump 2 without open e-motor interlock.
-Shutdown1+2 -Open outputs to pumps without open e-motor interlocks.
Function block diagrams Block 1D, Block 2D and Block 3D.
Version 2.2.0
Ready 97-06-27
Slower change of local set point command. Change stops at zero before change of direction.
Reset of shredder blocked with stop button.
Ramp for ratio in synchro mode.
Functions in synchro mode to give priority for the ratio between the rolls independent of the
settings of speed and ratio commands.
7(14)
04-04-02
New digital outputs:

-Auto1 -Indication man/auto in auto for drive1.
-Auto2 -Indication man/auto in auto for drive2.
Bug fixes:
-Some monitor reading changed selections after power up.

-Interference between speed measuring could occur if two digital encoders
were used.
-Feedback is disconnected at zero input command with analogue speed
encoder to protect against uncontrolled reversing of drive.
-Stop reverse always active with digital encoder detection of blocking in
shredder mode.
-When more than 20 reversals in Shredder mode, reverse counter could
start to write in forbidden area.
Function block diagrams Block 1E, Block 2E and Block 3E.

Version 2.3.0
Ready 98-03-09
Functions for swashangle feedback (Hydrokraft) pumps.
Output enable (for PWM output) open if e-motor is not started and by swashangle error.
Parameter for valve resistance changed to feedback gain.
Letter changed to A in HGGLUNDS due to text problems during start-up.
-Failsafe 1 -Output for fail safe valve drive 1.

-Failsafe 2 -Output for fail safe valve drive 2.
Function block diagrams: Block 1F, Block 2F and Block 3F.

Version 2.3.1
Ready 98-04-03
Bug fixes:
-Bug in PWM function could destroy register.
Function block diagrams: Block 1F, Block 2F and Block 3F.
Version 2.4.0
Ready 98-05-04
Max current settings for both drives and password can be changed with drives started.
Readings of speed can be shown with 2 decimals.
Set point can be indicated in rpm.
Feedback can be indicated in % of max speed.
Slower update time for readings of speed and power.
More configurable digital inputs by change of fixed digital inputs for Low oil temp, High e-motor
temp and High work pressure to configurable input choices.
Shutdown 1, 2 and 1+2 removed. The function for direct stop of the drive without opening of the
e-motor interlocks is set in the Auxiliary monitor settings (Interlock).
New digital inputs:
-Start 1+2 -Starts both drives in remote mode.

-Speed up 1 -Increase speed command for drive 1 in local mode.
-Speed down 1-Decrease speed command for drive 1 in local mode.
-Speed up 2 -Increase speed command for drive 2 in local mode.
-Speed down 2-Decrease speed command for drive 2 in local mode.
-Speed reset 1 - Reset speed command for drive 1 in local mode.
-Speed reset 2 - Reset speed command for drive 2 in local mode.
-Filter interlock - Blocks the filter warning inputs.
-Started 1+2 -One of the drives started.

-Started 1*2 -Both drives started.
8(14)
04-04-02
-Ready 1+2 -One of the drives ready for use.

-Ready 1*2 -Both drives ready for use.
-Power limit 1 -Power limit active drive 1.
-Power limit 2 -Power limit active drive 2.
-Power limit 1+2 -Power limit active on one of the drives.
-Interlock 1 -Interlock active drive 1.
-Interlock 2 -Interlock active drive 2.
-Interlock 1+2 -Interlock active on one of the drives.
-Forward 1 -Drive 1 active forward.
-Reverse 1 -Drive 1 active in reverse.
-Forward 2 -Drive 2 active forward.
-Reverse 2 -Drive 2 active in reverse.
Shutdown indication on the display if the supply relay is not activated (by watchdog or external
connection between terminal 1 and 2).
Speed error too large gives a warning, puts the drive to manual (no speed feedback) and has to
be reset as other warnings. The maximum allowed error can be set.
Shredder blocked gives an interlock, puts the drive to manual and can not be restarted in auto
before the interlock is reset in the alarm menu.
Analog and set point inputs can be calibrated.
All alarms/warnings are indicated on display 1 if drive type 2 is selected (two pumps driving one
motor).
The choice if both or only one of the pumps has to be running before the drive can be started in
drive type 2.
Local speed set point can only be changed in local mode and can be configured for automatic
reset when command is changed to remote mode.
All parameters can be reset to default values.
Counter reset time in synchro-counter mode reduced to 8msec.
Swashplate feedback potentiometer error configurable to give Alarm or Interlock.
Analog input to set an angle difference between the motors in synchro-counter mode.
Selection of different inputs to enable the latches for counter reset in synchro-counter mode.
Diagnostic readings to indicate program run.
Bug fixes:
-Bug in swashangle feedback could stop the PWM output for drive 2.
-Interrupt disable time shortened down.
-Encoder interrupt time reduced to give better performance with two
5000ppr pulse encoders.
-Error in reading of REG 106 and REG206 could cause watchdog problem.
-Counters reduced to one turn in synchro-counter mode.
Function block diagram: Block2_4

Version 2.4.1
Ready 98-05-14
0.3 sec filter for swashangle feedback inputs.
Start/stop of drive 2 can be activated from drive 1 keypads in setup mode.
Indications for drive 2 (ON/OFF, E-MOTOR STOPPED, STARTING UP, READY TO USE) can
be read on drive 1 display if drive type 2 is selected (two pumps driving one motor).
Bug fixes:
-Text for digital input Ready 1*2 was Ready 2*2.

-Default settings for analogue inputs mixed.

Version 2.5.0
Ready 98-06-25
Scaling function to give friction ratio in synchro-counter mode.
9(14)
04-04-02

Version 2.6.0
Ready 98-10-05
Lower limit for setting of feedback gain in output decreased to 15.
Password better protected. Each sign will change to a * when selected.
Possibility to set the limits for the friction ratio in synchro mode.
Error too large warning can be reset by a remote digital signal.
Man/Aut-selection can be remote controlled by a digital input.
Shredder blocked interlock can be reset by a remote digital signal.
Version 2.7.0
Ready 99-05-26
Improved functions in synchro-counter mode.
Increased time delay for filter indication (possible setting up to 15 minutes).
Increased time delay for high pressure indication (possible setting up to 60 seconds).
Bug fixes:
Error too large warning not possible for slave in Synchro mode

Version 3.0.0
Ready 00-02-29
Drive monitoring function with log channels.
Language selection for alarm/warning texts.
Filters for speed feedback signal.
Possibility to set inverted function for digital outputs.
Improved function for regulator D part.
Check of output signal compared to setpoint signal.
Amp. reading as default for power limitation.
Handling of analogue inputs grouped to analogue input menu.
Power limit function is cross connected between drives at common drive.
Warning if parameter storage fails.
Internal sequence warnings must be confirmed.
New digital inputs:
Bug fixes:
-Forward2- Forward run with fixed speed for drive 2.

-Reverse2- Reverse run with fixed speed for drive 2.
-Synchro- Indication of slave within limits in counter mode.
Change in drain filter delay is reset after restart of system.
Version 3.0.1
Ready 00-05-30
Bug fixes:
MAN/AUT indication failed at shredder blocked when using digital input for
MAN/AUT switching
Version 3.0.2
Ready 00-08-16
Bug fixes:
Error time in ERROR TOO LARGE function accumulates with too short drop-out
time as a result.
10(14)
04-04-02
Version 3.0.3
Ready 00-10-05
Error function in ERROR TOO LARGE function bypassed when speed signal is higher then setpoint
signal if parameter C(I)11 is set to 100%.
Version 3.1.0
Ready 00-12-06
Analog output function.

Max ramptime increased to 10minutes
Local speed stores in Eeprom each hour and is set at power up.
Reading kNm kan be set for reading registers T(U)05 and T(U)07.
Parameters A(G)16-18 for power limitation can be set during drive.
Accelerating parameter value change in setup menu.
New digital inputs:
-PressA1+2- Paralleling of high pressure functions to both drives.

-PressB1+2- Paralleling of high pressure functions to both drives.
-Sh Res1+2- Paralleling of shredder blocked reset function.
-Err1+2Res- Paralleling of Error too large reset function.
-Forwa.1+2- Forward drive with fixed speed for both drives.
-Rever.1+2- Reverse drive with fixed speed for both drives.
-Auto 1+2- Switching of regulated drive on/off for both drives
-Negative1- Negative reading Register for analogue out 1.

-Negative2- Negative reading Register for analogue out 2.
Version 3.1.1
Ready 01-09-27
Bug fixes:
Parallel functions for power limitation not possible with two pumps driving one
motor in Shredder drive mode.
Version 3.2.0
Ready 01-12-03
Function for negative friction.

Friction ratio limit increased to 300%.
Interlock indication removed from Alarm log list.
Improved synchro function.
Alternative sort of reading for analog function in shredder mode
Reading of digital speed can be filtered
Version 4.0.0
Ready 03-06-19
Function to fit new version of Spider hardware.
Version 4.0.1
Ready 03-09-10
Bug fixes:
Keyboard will not be locked if local stop is open

Update of downloaded parameters at reset
Change of EMOTOR STOPPED-indication
11(14)
04-04-02
1.4.2 Hardware versions

The hardware revision is marked on the printed connection board close to the Hgglunds Drives
logotype.
276 0004
Prototype during first time of developement of the system.
276 0004 rev.A
Layout ready 96-07-26
Card no. 11-57
New amplifiers for the PWM output.
Pull-down resistors for keypads.
Inputs for swashangle feeedback.
100 msec filter for the analog inputs.
Normally closed inputs for external stop buttons.
276 0004 rev.B
Card no. 58-271, 273-281, 355-360, 442-444
Pull-up and pull-down resistors for the serial communication port.
Two positions on input selection jumper (voltage/current) for analogue inputs.
Smaller changes to avoid jumpers on the backside of the card caused by missing connections in
rev.A version.
276 0004 rev.C
Card no. 272, 282-290
Relays on digital outputs.
Fuses for PWM outputs.
Separate memory card for configurated parameters and Real Time Clock.
Connections for front panel membrane switches.
245V supply jumper.
Changed circuit for swashangle feedback.
276 0004 rev.D
Card no. 291-354, 361-370, 446
Smaller changes to avoid jumpers on the backside of the card caused by short circuit in rev.C
version.
Card no. 371-441, 445, 447-453, 502-521
Smaller changes to simplify mounting of terminals.
276 0004 rev.E
Card no. 454-501, 522-573
Indication for supply to stroker output amplifiers.
Test pins for supply voltages and current feedback.
276 0004 rev.F
Card no. 574 Connection for analogue output card.
12(14)
04-04-02
276 0020
Prototype during first time of developement of updated Spider .
Card no. 2001-2005
276 0020 rev.A

Card no. 2011 First serial version of the card.
13(14)
04-04-02
1.5 Ordering code

Spider - A B C D - E F G H I - K
Function *)
Monitor
Basic
Shredder
Synchro
Friction
MRC
Power supply
M
B
0
1
2
S
Z
F
R
None (external 24VDC)

150W (Standard)
250W
Drive 1 config.
No Emotor - No pump
1 Emotor - 1 pump
1 Emotor - 2 pumps
2 Emotors - 2 pumps
2 Emotors - 3 pumps
2 Emotors - 4 pumps
3 Emotors - 3 pumps
3 Emotors - 4 pumps
1 Emotor - Tandem pump 1
1 Emotor - Tandem pump 2
Pressure control
0
1
2
3
4
5
6
7
8
9
0
1
2
3
RMS
0
1
2
Drive 2 config.
No Emotor - No pump
(Single)
1 Emotor - 1 pump
1 Emotor - 2 pumps
2 Emotors - 2 pumps
2 Emotors - 3 pumps
2 Emotors - 4 pumps
3 Emotors - 3 pumps
3 Emotors - 4 pumps
Emotor common w. drive1- Tandem pump1
Emotor common w. drive1- Tandem pump2
0
1
2
3
4
5
6
7
8
9
Monitor [M]:
Basic
[B]:
Shredder [S]:
Synchro [Z]:
Friction [F]:
None
With antenna on Spider box
With antenna on Power unit
Fieldbus card
0
1
2
3
Mounting
None
Profibus
Not decided
Not decided
Heater
Loose item with bracket excl. cables

Loose item with flange excl. cables
Loose item with welded flange excl. cables
Mounted inside Power Unit
Mounted on Power Unit door
Flange mounted in Power Unit door
Mounted on Power Unit side
*)
*)
*)
*)
*)
Not used
Drive 1
Drive 2
Both drives
1
2
3
4
5
6
7
0
1
None
Installed in Spider box
Display
0
1
LCD (Standard)
VFD (Required for Chinese characters)
Driver and functions for monitoring of power unit

Monitor with added functions for Speed feedback and powerlimitation
Basic with added functions for shredder drives
Basic with added functions for synchronization between two drives
Basic with added functions for friction control between two drives
14(14)

Spider II - 1

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AS-1

Two to four pumps for two drives with separate function:

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

1.2 Serial number

1.3 Card number

Year and week for production test

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

1.4 Versions and changes

Version 0.2, 1.0-1.3

-Idle function could cause watchdog problem by stack overflow.

Function block diagrams Block 1B, Block 2B and Block 3B.

-PWM routine changed. Problems with PWM frequency <1000Hz caused by

Function block diagrams Block 1C, Block 2C and Block 3C.

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

New digital outputs:

-Some monitor reading changed selections after power up.

Function block diagrams Block 1E, Block 2E and Block 3E.

-Failsafe 1 -Output for fail safe valve drive 1.

Function block diagrams: Block 1F, Block 2F and Block 3F.

-Start 1+2 -Starts both drives in remote mode.

New digital outputs:

-Started 1+2 -One of the drives started.

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

-Ready 1+2 -One of the drives ready for use.

Function block diagram: Block2_4

-Text for digital input Ready 1*2 was Ready 2*2.

Function block diagram: Block2_4

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Function block diagram: Block2_5

Function block diagram: Block2_7

-Forward2- Forward run with fixed speed for drive 2.

Change in drain filter delay is reset after restart of system.

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

Analog output function.

New digital inputs:

-PressA1+2- Paralleling of high pressure functions to both drives.

New digital outputs:

-Negative1- Negative reading Register for analogue out 1.

Function for negative friction.

Function to fit new version of Spider hardware.

Keyboard will not be locked if local stop is open

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

1.4.2 Hardware versions

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

276 0020 rev.A

Hgglunds Drives AB. S-890 42 Mellansel, SWEDEN

AS1, Introduction, Engineering manual

-Text for digital input Ready 12 was Ready 22.