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Digital PID-Controller

for hydraulic proportional valves BLS1

- 4 analog 12-bit inputs 0-10V / 4-20mA (command values, feedback values)

- 8 digital inputs / 2 digital outputs (OC)

- 2 analog power outputs (pulse width modulated max. 3 A)

- 2 digital power outputs (max 3 A)- (in overlayed 3/3-Way Mode also PWM`s)

- sampling time 1.0 msec

- commamd value / feedback value range adjustable

- 2 ramp generators

- digital command Values

- ON-LINE programming of parameters via PC software

- 2 programmable analog outputs ( 1

( 1 = optional

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Type: Controller Card BLS1 V4.0 Date 05-2004

Table of Contents
Table of contents

( 1 = OPTIONAL ................................................................................................................................................ 1

TABLE OF CONTENTS ..................................................................................................................... 2

1. INTRODUCTION............................................................................................................................................. 3

2. TECHNICAL DATA ........................................................................................................................................ 5

2.1. ELECTRICAL DATA........................................................................................................................................ 5


2.2. MECHANICAL DIMENSIONS ........................................................................................................................... 5
2.3. FRONT PLATE ................................................................................................................................................ 6
2.3.1. LED Power............................................................................................................................................ 6
When operating voltage Uv is available this light-emitting diode is illuminated. The LED is independent of
the computer.................................................................................................................................................... 6
2.3.2. LED Controller busy............................................................................................................................. 6
2.4. CONNECTOR BRACKET CONFIGURATION ...................................................................................................... 7

3. INSTALLATION OF THE CARD IN THE CONTROL CIRCUIT ........................................................... 7

FIG.5.1 ................................................................................................................................................................... 9

4. SETTING OF THE CARD ............................................................................................................................ 11

4.1. CONNECTION OF THE COMPUTER WITH THE CARD ...................................................................................... 11


4.1.1. Basic Currents .................................................................................................................................... 13
4.1.2. Feedback value/Command value Parameter Programming............................................................... 13
4.1.3. Dead Band .......................................................................................................................................... 13
4.1.4. P-I-D Setting ....................................................................................................................................... 13
4.1.5. Ramp Generator.................................................................................................................................. 13
4.1.6. Digital Command values.................................................................................................................... 14

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Type: Controller Card BLS1 V4.0 Date 05-2004

1. Introduction
RS232

2* analog off,
8bit resolution

10*digital PWM- 0-3A


inputs current
0-24V amplifier

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

Fig. 1 : Block diagram of the card

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).

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Type: Controller Card BLS1 V4.0 Date 05-2004

X Open

Control Pressure X

Y Close

Tank Y

BLS1 Feedback
value
PID
Control
Command
Power Driver value

Fig. 2: Function of the card in the control circuit

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

Fig. 3 : Further examples of possible control circuits

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Type: Controller Card BLS1 V4.0 Date 05-2004

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.

2.1. Electrical Data


Supply voltage UV 18-28V (typ.24V)
Intern. current ( UV without solenoids) 100mA

Valve voltage UW same as UV, valve current (max. 6A depending on solenoids)


Temperature range -20 - +70 oC

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

2.2. Mechanical Dimensions


Printed circuit board European standard size 100*160mm
Connector 48-pin to DIN 41612 type F
Width of front plate 8TE

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Type: Controller Card BLS1 V4.0 Date 05-2004

2.3. Front Plate


Figure 4 shows the front plate. The front plate is provided with light-emitting diodes indicating the
operating state and an interface connection for programming the card parameters.

Power

Controller /
Busy

PC-Terminal

RS 232

BLS1

Fig. 4 :

2.3.1. LED Power

When operating voltage Uv is available this light-emitting diode is illuminated. The


LED is independent of the computer.

2.3.2. LED Controller busy

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.

1. Sollwert/Command Value < 4 mA 2. Istwert1/Feedback1-Value < 4 mA

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Type: Controller Card BLS1 V4.0 Date 05-2004

3. Istwert2/Feedback 2-Value < 4 mA 4.Deviation Error

2.4. Connector Bracket Configuration


Figure 4 shows the location of the different inputs and outputs of the connector bracket at the rear.

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

3.Installation of the Card in the Control Circuit


Safety information :
Only trained personnel is allowed to change the settings on the card. An incorrect adjustment
of the card may lead to the distruction of connected components.

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

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Type: Controller Card BLS1 V4.0 Date 05-2004

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)

12d 12b 10d 14z 10b 2zbd 32zbd 28z

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

Proportional Proportional Solenoid 1


solenoid X solenoid Y Emergency
Stop

Command
value
4-20mA
0-10V Typical wiring diagramm for Standard PID1

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Type: Controller Card BLS1 V4.0 Date 05-2004

Fig.5.1

+24V

GND

Emergency stop
(Digital set point optional
SW0 SW1 SW2 SW3 selection if
required)

12d 12b 10d 14z 2zbd 32zbd 28z

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

Proportional Proportional Solenoid 1 Solenoid 2


solenoid X solenoid Y Direction 1 Direction 2

Actual
value 2 Command
4-20mA value
0-10V 4-20mA
0-10V Typical wiring diagramm for overlayed PID2

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Type: Controller Card BLS1 V4.0 Date 05-2004

Fig.5.2

+24V

GND

Emergency stop
(Digital set point
optional
selection if
SW0 SW1 SW2 SW3
required)

12d 12b 10d 14z 10b 10z 2zbd 32zbd 28z

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

Proportional Proportional Solenoid 1 Solenoid 2


solenoid X solenoid Y Direction 1 Direction 2

Actual
value 2 Command
4-20mA value
0-10V 4-20mA
0-10V Typical wiring diagramm for 4/3 Way valve

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Type: Controller Card BLS1 V4.0 Date 05-2004

4. Setting of the Card


For programming the controller parameters the card has to be connected to a PC via a serial interface
cable or a USB Adapter. Parameter programming is menu-controlled. Parameter changes are taken
over by the card without delay so that the results can be checked immediately on the controlled
system.

4.1. Connection of the Computer with the Card


The computer is connected to the controller card by means of a serial cable. Figure 6 shows various
options. The construction of the cable is shown in the figure for the different options.

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

Fig. 5: Connection of the controller with a PC or a terminal

Using the PC-Programm for BLS1 Card , you can select COM Port 1 to 10.

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Type: Controller Card BLS1 V4.0 Date 05-2004

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

Ramps off 2 optonal Analog release


Feedback Feedback Outputs
Comparator value error
Meaning
Signal flow Feedback
Switching threshold value
Software switch
0-10V Analog outputs 0,1
Hardware I/O 4-20mA
8 bit ( 1

Fig. 6: Survey of adjustable parameters

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.

Amplification range (P-factor)

Valve
current

Basic current X Basic current Y

-100 0 100
Contr.
Dead deviation [%]
band

Fig. 7::Diagram deviation with respect to output current

( 1 =optional

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Type: Controller Card BLS1 V4.0 Date 05-2004

4.1.1. Basic Currents

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.

4.1.2. Feedback value/Command value Parameter Programming

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.

4.1.3. Dead Band

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.

4.1.4. P-I-D Setting

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.

4.1.5. Ramp Generator

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

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Type: Controller Card BLS1 V4.0 Date 05-2004

4.1.6. Digital Command values

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.

Dig.Command Value 0 Dig.Command Value 1 Dig.Command Value 2


(12d) (12b) (10d)
Command value 1 1 0 0
Command value 2 0 1 0
Command value 3 1 1 0
Command value 4 0 0 1
Command value 5 1 0 1
Command value 6 0 1 1
Command value 7 1 1 1

If none of the inputs is activated the controller will switch over to the analog command value signal.

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