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- 2 digital power outputs (max 3 A)- (in overlayed 3/3-Way Mode also PWM`s)
- 2 ramp generators
( 1 = optional
Page -1-
Type: Controller Card BLS1 V4.0 Date 05-2004
Table of Contents
Table of contents
( 1 = OPTIONAL ................................................................................................................................................ 1
1. INTRODUCTION............................................................................................................................................. 3
FIG.5.1 ................................................................................................................................................................... 9
1. Introduction
RS232
2* analog off,
8bit resolution
89C52
PWM- 0-3A
4* analog on current
optional amplifier
0-10V
or
4-20mA
switching 3A
output
3A
switching
internal output
voltages
+-12V / 5V
2*digital
supply 24V+-15%
outputs
open collector
valve supply
The digital PID controller BLS1 is designed for the pilot control of hydraulic proportional valves. The
use of a 24 Mhz. – clocked microcontroller and assembler programming permits to achieve computing
times that are adequate to control highly dynamic hydraulic circuits.
Figure 1 shows the hardware arrangement of the card. In addition to the controller with PID-
characteristics and power amplifiers it is equipped with two power drivers for digital auxiliary functions.
The digital inputs are also designed for extra functions such as e.g. direction of the 4/3-way valve
combinations.In Overlayed 3/3-Way-Mode this outputs operate as 2nd pair of proportionals.
Programming of the functional setting and of the controller parameters is made by the PC Programm
for BLS1 Card via a RS232 interface and the data are stored in a non-volatile memory (EEprom).
X Open
Control Pressure X
Y Close
Tank Y
BLS1 Feedback
value
PID
Control
Command
Power Driver value
Figure 2 shows a typical control circuit into which the card can be inserted. Further possibilities are
given in figure 3.
Hydraulic Drive
less more Supply Pressure
Y X
Position Transmitter
Consumer
Qmax ~ 10-20 L/min
Controller
Controller
BLS1
2. Technical Data
The supply voltage lines are protected against polarization errors.The power outputs are protected
against shortcut and over-temperature.The power drivers should have a separate voltage supply line
connected to supply voltage ground.
Analog inputs:
adjustable variants
voltage 0-10V/Internal resistance 20KΩ
current 4-20mA working resistance 500Ω
Digital inputs:
control inputs 0/24V max UV
Analog outputs:
voltage 0-10V, max. current-carrying capacity 100mA
power (PWM) 0-3A
Digital outputs:
open collector max. 100 mA
power outputs 0/24V (max 3A)
Controller sampling time 1.0 ms
Power
Controller /
Busy
PC-Terminal
RS 232
BLS1
Fig. 4 :
This LED glows to indicate a deviation, continued glowing indicates an error or a constant deviation.
The following error messages will be shown when you click on the read controller button.
z b d
2 +24V (Uv) +24V +24V
4 Ground SW Command value 0-10V Command value 4-20mA
6 Ground IW1 Feedback value 1, 0-10V Feedback value 1, 4-20mA
8 Ground IW2 Feedback value 2, 0-10V Feedback value 2, 4-20mA
10 Dig.In 0/Direction 2 Dig.In 1/Direction 1 Dig. Command Value 2
12 Dig.In 8/ Valve interlock Dig. Command Value 1 Dig. Command Value 0
14 Feedback value 1b, 0-10V Feedback value 1b, 4-20mA Dig.In 3/ 2. Pair of ramps
16 Dig.In 2/ ramps off Dig.Out 1/ Iw-compar. Dig.Out 2/ error
1
18 Prop solenoid X (-) Analog 0 Out ( Analog 1 Out ( 1
20 +12V +12V +12V
22 Ground Ground Ground
24 -12V -12V -12V
26 Ground SW-solenoid 1 (-) SW-solenoid 1 (+)
28 +24V(Uw) Ground SW-solenoid 2 (-) Prop solenoid Y (-)
30 Prop solenoid Y (+) Prop solenoid X (+) SW-solenoid 2 (+)
32 Ground Ground Ground
Fig. 4: Connector bracket configuration
For the function of the controller card in connection with a certain hydraulic configuration a
guarantee will only be given after release.
Fig 5 shows an example of how the card should be connected. The command value is an assumed
pilot controller signal of 4-20mA. Such a signal may also come directly from the PLC control. The
feedback value transmitter is an assumed transmitter with 4-20mA signal output.
( 1 =optional
Fig.5
+24V
GND
Emergency stop
(Digital set point optional
SW0 SW1 SW2 SW3 selection if
required)
6d: 4-20mA
BLS1 V2.0
6b: 0-10V
4d: 4-20mA
4b: 0-10V
6d/6b 6z/8z 8d/8b 4z 4d/4b 30b 18z 30z 28d 26d 26b
Actual
value 1
4-20mA
0-10V
Command
value
4-20mA
0-10V Typical wiring diagramm for Standard PID1
Fig.5.1
+24V
GND
Emergency stop
(Digital set point optional
SW0 SW1 SW2 SW3 selection if
required)
6d: 4-20mA
BLS1 V2.0
6b: 0-10V
8d: 4-20mA
8b: 0-10V
4d: 4-20mA
4b: 0-10V
6d/6b 6z/8z 8d/8b 4z 4d/4b 30b 18z 30z 28d 26b 26d 28b 30d
Actual
value 1
4-20mA
0-10V
Actual
value 2 Command
4-20mA value
0-10V 4-20mA
0-10V Typical wiring diagramm for overlayed PID2
Fig.5.2
+24V
GND
Emergency stop
(Digital set point
optional
selection if
SW0 SW1 SW2 SW3
required)
Direction 1
Direction 2
6d: 4-20mA
BLS1 V2.0
6b: 0-10V
8d: 4-20mA
8b: 0-10V
4d: 4-20mA
4b: 0-10V
6d/6b 6z/8z 8d/8b 4z 4d/4b 30b 18z 30z 28d 26b 26d 28b 30d
Actual
value 1
4-20mA
0-10V
Actual
value 2 Command
4-20mA value
0-10V 4-20mA
0-10V Typical wiring diagramm for 4/3 Way valve
Controller
D-Sub
Socket board D-Sub
Pin board
9-Pin 9-Pin
2 TXD 2 TXD
3 RXD 3 RXD
5 GND 5 GND
Using the PC-Programm for BLS1 Card , you can select COM Port 1 to 10.
0...........7
Dig. Ramp period, Basic current X
Ramp
SW0 Switching- Command on/off
1.pair, Bypass Controller setting
Basic current Y
Logic 2.pair P-component
: Values Dead band
I-component
SW2
D-component
+24VDC
Bypass
PID1
Prop.
Valve
X
+
+ PID2
-
Command Value
0-10V +24VDC
4-20mA
Prop.
Valve
Y
1./2. Pair of ramps
The basic current is constantly admitted to the solenoids in order to ensure that the proportional
solenoids react quickly. Via the proportional amplification (P-amplification) the slope of the solenoid
excitation curve is adjusted. It is possible to choose different basic currents for the two solenoids.
Valve
current
-100 0 100
Contr.
Dead deviation [%]
band
( 1 =optional
The basic current is a constant current used to excite the respective solenoid so that the proportional
band operates direct. The range of adjustment is 0 - ..100% of the maximum current depending on the
solenoid connected. It is possible to set different values for solenoid X and solenoid Y.
Here the upper and/or lower limit of the analog inputs is taken over. The respective limit value is
programmed by operating the valve manually and then taken over.
The dead band is the maximum controlling difference around the zero position which does not yet
cause the controller to respond. Otherwise the controller works constantly.
With these menu items the amplification of the controller can be adjusted. First the proportional
amplification should be adjusted such that the controlled system connected just not yet oscillates.
Then the I- and D-components are used for correction. Experience has shown that hydraulic drives
very rarely require a high proportion of I- and D-components.
The card is equipped with a ramp generator the signal pattern of which can be adjusted separately for
positive and negative slopes. ( 1 An external input permits to switch-over 2 pairs of ramps with different
slopes.
( 1=0ption
The software allows to define command values which are activated based on the position of external
inputs. It is possible to define 7 command values. With digital inputs (SW0 – SW2) the respective
constant command value is activated.
If none of the inputs is activated the controller will switch over to the analog command value signal.