POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

This module is used in Turbine control system and can be plugged into a max PAC rack.
It is used preferably as position controller (PID) for electro-hydraulic drives. However the
existing structures and parameter ranges allow its application even in other closed loop
control circuits.

FEATURES

• Min/Max value selection

• PID controller
• Limiting Circuit
• Four channel current to voltage converter
• Isolated Voltage to Current converter
• Output current monitoring
• Power supply-potted blocks

BHEL/EDN/SAE Page 1 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

LED INDICATION

A GREEN LED at the bottom of the module front plate, is ON when the module is
healthy. A RED LED is ON when output current loop is open.

BUS ADDRESS

The module receives only +24V(Field Power supply) from the Bus ,other inputs and
outputs are hard wired through the front I/O connector. There is no bus communication

MODULE OPERATION

4 channel Current to voltage converter

Current to voltage converter converts 4-20mA current signal into a 0-10V voltage signal.
Channels 1, 2 & 3 are with isolation and 4 is without isolation. Converted voltage signals
are available at Jacks. I/O pins, I/O jacks and jumper selection for input current/voltage
are as shown below

Table 1

Channel Input pins Input Current Jumper selection Jumper selection O/p voltage
meas. Test Jacks for current for Voltage Test jack

Ch1 P3A-8 A9 w.r.t B9 S1-1&2 S1-2&3 A11(Vin1)

(Isolated) P3A-7 S5- close S5- open

Ch2 P3A-6 A8 w.r.t B8 S2-1&2 S2-2&3 B11 (Vin2)

(Isolated) P3A-5 S6- close S6- open

Ch3 P3A-3 A7 w.r.t B7 S3-1&2 S3-2&3 A12 (Vin3)

(Isolated) P3A-4 S7- close S7- open
LK4-open

S3-open A12(Vin3)
Internal S7- open
input LK4-close
S4-1&2 for±12V
S2-2&3 for 0V

Ch4 P3A-2 A6 w.r.t B6 S8 -close B12(Vin4)

P3A-1

BHEL/EDN/SAE Page 2 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

Min / Max value selection & limitation:

Three current to voltage converter outputs(Vin1, Vin2 & Vin3 ) are connected to a min/max
value selection circuit. A switch on the circuit board allows maximum value selection,
minimum value selection or limitation to be set in the maximum / minimum value selection
circuit and the output is available at test jack A4.

For maximum value selection switch SW1.1 & SW1.3 are closed and switch SW1.2 &
SW1.4 closed for minimum value selection. If the max/min value is to be selected from two
input parameters only, Vin1 must be one of the two channels used. The input and the two
switches for the channel not in use remains open.

Limit Range:

Limitation is selected by closing switches SW1.2 and SW1.3 or SW1.1 and SW1.4.The
value to be limited is connected to Vin1. At the first switch setting the upper limit value is
defined by the signal at i/p Vin2 and the lower limit value by the signal at Vin3. In the second
switch setting the effect of the limit values is reversed. If the upper limit value is smaller
than the lower limit value (overlap) the signal at Vin3 always assumes control.
Controller

The position controller consists of a PD-T1 and PI elements connected in series. The other
functions as mentioned below can be achieved by means of suitable circuit of inputs and
outputs or by means of parameter selection.

Other functions : P-, P - T1, PP - T1 - , PD - T1, PI or PDI - T1

PD - Element :

The transfer function can be expressed as follows :

F (P) = 1 + Kv . P . T1 / 1 + P. T1

Where as Kv = Derivative action gain

T1 = Time constant
Kv can be adjusted as follows.

* Range (Pre) selection with a switch SW2 on the printed board.

* Continuous setting with the Pot P19 on the front plate / panel.

BHEL/EDN/SAE Page 3 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

Depending on the setting of derivative action gain Kv , the PD - element shows the
following behavior :

For Kv = 0 : P- T1 - response
For Kv < 1 : PP - T1 - response
For Kv = 1 : P - response
For Kv > 1 : PD - T1 - response

The time constant T1 of the PD - element is adjustable with Pot P16 on the front panel.

The T1 range can be changed by changing the timing capacitor C90(47nF).

PI - Element

The transfer function can be expressed as follows :

FI (P) = Kp (1 + P. T2) / P. T2

Where as Kp = Proportional amplification factor

T2 = Time constant

Kp can be adjusted with Pot P17 and reset time of PI - element T2 with Pot P20 on the
front panel.

The ranges can be changed by changing the following components if required:

* Kp with resistor R83

* T2 with capacitors C111,C112 and C105
(effective value is the sum of capacitance values) as well as with resistor R109

Limiting

The output signal of PI - controller at Pin P3A-14 can be limited. The limiting values for
the output signal can be set with Pot P21 and P22.

The upper limiting is adjustable with Pot P21 (Socket A3) in the positive quadrants
between 0 and 12V.

The lower limiting in the negative quadrants between 0 and -12V with Pot P22
( Socket B3 ).

BHEL/EDN/SAE Page 4 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

V/I Converter with isolation ( 4 - 20mA ) and output current monitoring

Voltage to current converter converts the position voltage signal 0 to +10V into 4-20mA
with isolation. This can be connected to the load at pin P3A-13 & P3A-12 and also can be
measured at test jacks A10 and B10.
V/I output is monitored for loop break and Red LED on the front plate will glows when
there is a fault This signal is available at free contacts of the relay. O/P current monitoring
is optional and this can be done with jumper selection on connector S10. S10- 1&2 for
current monitoring and S10-2&3 for without monitoring.

Power Supply

The module taps and utilizes only field power supply available from the back plane pins
P1A-18 & P1A-19 (+24V) and P1A-21 & P1A-22 (GND). This power supply is protected
by resettable fuse, which do not require changing after fault occurs . When the fault is
removed and the fuse cools down, normal operation resumes. DC-DC converter blocks are
used to derive regulated +15V, -15V(without isolation) +15 & -15 (isolated) voltages
required for the internal circuits.

Surge Withstand

All field inputs and outputs are protected for surges .

ELECTRICAL SPECIFICATIONS

Current to voltage converter

Current input (Four channel)

Input and output pins , output measurement test jacks and switch settings are as per table 1
Rated current range : 4 – 20mA

Voltage output
Range : 0 to +10V(conversion accuracy 0.05%)
Max: 12V

Max /Min value selection and limiting circuit

BHEL/EDN/SAE Page 5 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

MAX value selection : Switches SW1.1 & SW1.3 closed

MIN value selection : Switches SW1.2 & SW1.4 closed

Limiting circuit

SW1.2 & SW1.3 closed SW1.1 & SW1.4 closed

Upper limit value at pin Vin2(ch2) Upper limit value at Vin3(ch3)
Lower limit value at pin Vin3(ch3) Lower limit value at Vin2(ch2)

Analog inputs
P3A-8 (Ch1) Vin1- ± 10V
P3A-6 (Ch2) Vin1- ± 10V Voltage inputs
P3A-3 (Ch3) Vin1- ± 10V

Analog output
At test jack A4 : ±10V
Zero point deviation ( max): ± 26 mV

CONTROLLER - PD

Analog inputs

1. Input from min/max section : 0 to ±10V

Jack A4 (Vin4 - Actual value )
Input delay at A4: 0.1 mS

2. Pin P3A-10 compensating input(jack B1)

3. Socket B4 optimizing input

Transfer function

F1 ( P ) = 1 + Kv. P. T1 / 1 + P.T1

Setting function

Pot P16 (on front plate) for time constants T1

Setting range : 0.45 to 4.7 ms

Setting function T1

Standard mounting
BHEL/EDN/SAE Page 6 of 13 OM69229S904A/REV00
POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

MTL Film capacitor C90: 47 nF

T1 Max. = 100 K . C90

Max. value of the capacitor C90: 4.7 uF / 63V - 10uF / 25V

* Derivative action gain Kv

* Switch SW2.1 to SW2.4 on the printed board for range selection.

* Pot P19 (on front plate) on the printed board for continuous setting.

Setting function Kv

Standard mounting

Resistor R89 : 1.3K

Thus for Closed switch SW2.4 and pot position maximum it gives rise to the following :

Kv Max. = 30.8

For different value of R89 the following expression is applicable :

Kv Max. = 40 ( K ohm ) / R89 ( K ohm )

If all switches of SW2 are open, then Kv = 0 and the PD - element shows only P - T1 -
behavior ( delay ).

CONTROLLER - PI

Analog inputs

1.Min/Max selection output, Test socket A4

2.Socket A5 optimizing input

Rated voltage range : ±10V ( Linear transfer Max. - ±11V )

Input resistance : 40 Kohm

BHEL/EDN/SAE Page 7 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

Analog outputs

Pin P3A-14 output of PI - element

Socket A2 output of the PI – element

Socket A1 output of the PD - element limited to ± 11.9V

Rated voltage range : ± 10V ( Linear transfer range ±11V.

For Rl >10K )
Short circuit resistance against Gnd (M) : Continuously

Capacitance load : < 10nF

Transfer function

Socket A1
(O/p of PD)

F1 F2 P3A-14
(O/p of PI)

F(A1) = F1(P) = KP . 1/ 1+PT3

F(P3A-14) = F1(P) . F2(P)

F(P3A-14) = KP . 1 / 1+PT3 . 1+PT2 / PT2

Setting functions Kp

Pot P17 (on front plate) for proportional amplification Kp

Setting range 0.45 to 5.5

Standard mounting

Resistor R83 - 18 K
For different value of R83, the following equation is applicable :

BHEL/EDN/SAE Page 8 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

Kp Min. = R83 (K) / 40 (K)

Pot P20 (on front plate) for resetting time constant T2 of the PI - element.

Setting range : 0.38 to 4.12 S

Setting function T2

Standard mounting

Capacitor C105, C111 & C112 : 3.3uF

Resistance R109 : 2.2 M ohm

For different values of capacitors, the following equation is applicable :

T2 Max. = 0.39 . R109 ( C105 + C111+C112 + 0.1 )

Max. value for C105,C111 & C112: Each 6.8 uF / 63V

Capacitor (C95+C104) & (C105,C111 & C112) for time constant ( of time delay ) T3

Standard mounting

Capacitor C95+C104 : 4.7uF

For standard mounting ( without C95+C104 ), T3 is negligible.

For different values of capacitors C95+C104, the following equation holds good :

T3 = Kp . 40 (Kohm) . C95+C104 (uF)

Pot P18 (on FP, multiturn) for setting

Socket B5

Setting range : -10V to + 10V.

BHEL/EDN/SAE Page 9 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

For standard mounting

Resistance R21 and R22: 1 Kohm

Limiting circuit (PID O/P)

Pot P21 multi turn for upper limiting

Socket A3
Setting range : 0 to 12.5V

Pot P22( multi turn ) for lower limiting.

Socket B3
Setting range : 0 to -12.5V

Voltage to current converter

Analog input voltage

(Jumper on link S9 to be mounted)

0 to +10V (output of PID controller)

Output Current

Pin P3A-13 w.r.t P3A-12 : 4 to 20mA ± 50uA

corresponds to 0 to +10V at P3A-14
Load resistance ( Max ) : 500 R

BHEL/EDN/SAE Page 10 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

Output Current Monitor

Switch S10 – Link on pins 1 & 2 – No monitoring
Link on pins 2 & 3 – output current monitoring for loop open

Fault indication through relay contacts in case of loop open

Relay Contact outputs : Pin P3A-15 (+ve) & P3A-16(-ve)

Alarm (Front Plate) : L1 - Red (fault)
- Green (Healthy)

POWER SUPPLY VOLTAGE

Operating voltage (field PS) : +24V (Nominal )

Range : +20 to +28 (P1A-18 & P1A-19)
Zero reference voltage : 0 V (P1A-21 & P1A-22)
No load current consumption : 300mA
Power dissipation : app. 7.2W

MECHANICAL SPECIFICATIONS

a. Module Size : 254 X 298.5 X 42 mm

b. Edge connector : 22 pin, EB83-L22SGFW
c. Weight : 700gms

ENVIRONMENTAL SPECIFICATIONS

a. Operating temperature range : 0 to 70°C.

b. Storage temperature range : 0 to + 85°C
c. Humidity : 95%RH
d. Vibration : 0.5g with sinusoidal exitation in X,Y,Z
axes with 15 to 500

BHEL/EDN/SAE Page 11 of 13 OM69229S904A/REV00

POSITION CONTROL (PID) WITH MIN/MAX SELE (ARS) 69229S904A

PIN CONFIGURATION

PIN NO. FUNCTIONAL RANGE

DESCRIPTION

P1A-18 & P1A-19 Power supply +20 to +28V

P1A-21 & P1A-22 Gnd. 0V

P3A-8 w.r.t P3A-7(Ch1) Current input + 4mA to +20mA

(actual i/p-PD)

P3A-6 w.r.t P3A-5(Ch2) Current input + 4mA to +20mA

(actual i/p-PD)

P3A-3 w.r.t P3A-4(Ch3) Current input + 4mA to +20mA

(actual i/p-PD)

P3A-2 w.r.t P3A-1(Ch4) Current input + 4mA to +20mA

(ref. i/p-PD)

P3A-10 Compensating I/P-PD ±10V

P3A-14 PID O/P ±10V

P3A-13 w.r.t P3A-12 Current O/P (PID) +4mA to +20mA

P3A-15(+) , P3A-16 Fault o/p thro’ 0.5A, 48V Max

relay Contacts

BHEL/EDN/SAE Page 12 of 13 OM69229S904A/REV00