Young Franklin PID Controller Manual

8/18/2019 Young Franklin PID Controller Manual

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Young & Franklin Inc.INSTALLATION & FIELD SERVICE MANUAL

Page 2 of 43FSM8605D200 REV. D

REVISIONS

REVISIONS DATE DESCRIPTION APP. BY

- 12/3/03 Released per ERN 190-03 GS A 1/28/04 Changed per ECN 14782 GSB 6/3/05 Changed per ECN 16334 PKC 10/4/05 Changed per ECN 16572 PKD 08/28/07 Changed per ECN 17391 PK


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TABLE OF CONTENTS

1.0 ADVISORY INFORMATION................................................................................................ 5

1.1 WARNING! ....................................................................................................................... 5 2.0 GENERAL ........................................................................................................................... 5

2.1 CASE 1: CONVENTIONAL INSTALLATIONS ................................................................ 5 2.2 CASE 2: EXPLOSION-PROOF INSTALLATIONS .......................................................... 5 2.3 FUNCTIONAL SETUP AND OPERATION ...................................................................... 5

3.0 CONVENTIONAL MOUNTING OF THE PID & PID-LVDT CARDS.................................... 6 4.0 EXPLOSION-PROOF MOUNTING OF THE PID & PID-LVDT CARDS.............................. 6 5.0 MOUNTING ARRANGEMENT FOR BOTH CASE 1 and CASE 2 ..................................... 6

6.0 ELECTRICAL WIRING REQUIREMENTS FOR BOTH CASE 1 and CASE 2 ................... 6 7.0 ANALOG PID CONTROLLER CARD ................................................................................. 7

7.1 PID Card Features........................................................................................................... 7

8.0 PID CARD SPECIFICATIONS ............................................................................................ 7 9.0 PID CARD (8605D200) INSTALLATION INSTRUCTIONS ................................................ 8

9.1 PID Card General Information ....................................................................................... 8 9.2 PID Card Wir ing .............................................................................................................. 9 9.3 PID Card Supply Connections ....................................................................................... 9 9.4 PID Card Input Connections .......................................................................................... 9 Direct and Reverse Acting Conf igurations....................................................................... 10

SEE SECTION 24.0 for detai ls ........................................................................................... 10 9.5 PID Card Output Connections ..................................................................................... 12 9.6 Application of the Enable feature................................................................................ 13

10.0 PID CARD ADJUSTMENTS AND TUNING.................................................................... 14

10.1 PID CARD WARNING!................................................................................................. 14 10.2 PID Card Ramp Module Adjustment ......................................................................... 15

10.3 PID Card Module Adjustment .................................................................................... 15 10.4 Driver Signal Offset Adjustment ................................................................................ 16

11.0 SINGLE LVDT CARD OPTIONS (Model 8605D201) ..................................................... 17 11.1 LVDT Card General Descript ion ................................................................................ 17 11.2 LVDT Card Features ................................................................................................... 17

12.0 LVDT CARD WIRING...................................................................................................... 18 13.0 LVDT CARD ADJUSTMENTS AND TUNING................................................................. 18

13.1 LVDT CARD WARNING! ............................................................................................. 18 13.2 LVDT Card Excitation Adjustment ............................................................................ 18

13.3 LVDT Card Position Output Adjustment ................................................................... 19

14.0 DUAL LVDT CARD OPTIONS (Model 8605D202)..................................................... 20 14.1 LVDT Card General Descript ion ................................................................................ 20 14.2 LVDT Card Features ................................................................................................... 20

15.0 DUAL LVDT CARD WIRING........................................................................................... 21 16.0 LVDT CARD ADJUSTMENTS AND TUNING................................................................. 21

16.1 LVDT CARD WARNING! ............................................................................................. 21


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16.2 LVDT Card Excitation Adjustment ............................................................................ 22 16.3 LVDT Card Position Output Adjustment ................................................................... 22 16.4 Channel A / B Select Switch ...................................................................................... 22

17.0 DC VOLTAGE FEEDBACK TO THE LVDT CARD......................................................... 23

17.1 General Appl ication Description ............................................................................... 23

17.2 Setting up the LVDT Card for DC Volt Feedback Operation ................................... 23

17.3 Wiring the LVDT Card for Vdc Feedback Operation ................................................ 23 17.4 Termination Table for 8605D201-G001 Signal LVDT................................................ 24 17.5 Termination Table for 8605D202-G001 Dual LVDT................................................... 25

18.0 PID CARD FUNCTIONAL BLOCK DIAGRAM ............................................................... 26 19.0 LVDT CARD FUNCTIONAL BLOCK DIAGRAM............................................................ 27 20.0 DUAL LVDT CARD FUNCTIONAL BLOCK DIAGRAM ................................................ 28 21.0 LVDT UNIT WIRING DIAGRAM 4 & 5 WIRE VERSIONS .............................................. 29 22.0 PID/ LVDT CARD 8605D201-G001 TYPICAL WIRING DIAGRAM ................................ 31 23.0 PID/ DUAL LVDT CARD 8605D202-G001 TYPICAL WIRING DIAGRAM ..................... 32

24.0 Direct Acting Wiring Diagram....................................................................................... 33

25.0 Reverse Acting Command Wiring Diagram................................................................. 34 26.0 Reverse Acting Feedback Wiring Diagram.................................................................. 35 27.0 10Vdc Reference Circuit Diagram and Information .................................................... 36 28.0 PID/ SINGLE LVDT CARD 8605D201-G001 OUTLINE DRAWING ............................... 37 29.0 PID/ DUAL LVDT CARD 8605D202-G001 OUTLINE DRAWING................................... 38 30.0 ELECTROSTATIC DISCHARGE ISSUES...................................................................... 39 31.0 PACKAGING OF ELECTRONIC ASSEMBLIES ............................................................ 40

31.1 Field Location to Factory ........................................................................................... 40 32.0 REFERENCE MATERIALS............................................................................................. 41

32.1 Proportional Loop Tuning.......................................................................................... 41

32.2 Proportional & Integral Loop Tuning ........................................................................ 41

32.3 Proportional, Integral and Derivative Loop Tuning ................................................. 42

33.0 LVDT Calibration Procedure......................................................................................... 43


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1.0 ADVISORY INFORMATION

1.1 WARNING!The successful design and setup of any closed loop control system requires

considerable forethought and a good understanding of control engineering practices.Brief descriptions are provided in SECTION 31.0.

Closed loop feedback control is a topic far exceeding the scope of this manual.It is the responsibility of the user to assure that adequate procedures are followed toprevent any hazards, losses, damage, injury or harm to objects and people.

ESD CAUTION STATEMENT: The PID/ LVDT controller is protected against highvoltages at all inputs and outputs. However electronic assemblies require special

handling to avoid damage by Electrostatic Discharge (ESD). See specialinstructions in SECTION 30 & 31

2.0 GENERAL

The PID Controller Model 8605D200 is a multiple input, multiple output controller boardproviding PID Algorithm (Proportional, Integral, Derivative) for closed loop automationsystems. It may optionally come with an LVDT signal conditioner, providing LVDTexcitation, 4 – 20mA feedback and digital display. The 8605D201 is a PID with a singleLVDT conditioner. And the 8605D202 is a PID with a Dual LVDT conditioner.

This MANUAL is intended to provide sufficient information to the end user to installthese assemblies under the following two circumstances:

2.1 CASE 1: CONVENTIONAL INSTALLATIONSFor benign applications (i.e. those that are without risk of encountering anexplosive atmosphere or dust environment) this information should providesufficient guidance for successful installations.

2.2 CASE 2: EXPLOSION-PROOF INSTALLATIONSIn this case we consider those installations that must involve an explosion-proofhousing for these controllers. The Category, Zone, Division and/or Group of theapplication are for the installer to determine.

2.3 FUNCTIONAL SETUP AND OPERATIONThe electrical setup and operation of these controllers is addressed inSECTIONS 7.0 through 27.0 of this document.

Irrespective of how the unit is physically mounted the electrical requirements andoperation should remain unchanged.


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3.0 CONVENTIONAL MOUNTING OF THE PID & PID-LVDT CARDS

• The PID-LVDT assembly can be mounted in any position.• The assembly should have a flow of air around it with an unimpeded volume within

the enclosure of at least 0.3 meter 3 ensuring the free convection of air and transfer

of heat to the enclosure walls.• Smaller enclosures may require the use of a circulating fan if it is not possible to

provide filtered air vents or louvers. In this case the interior air temperature of theenclosure must not exceed 70°C.

• Should the enclosure housing the PID-LVDT assembly be mounted to a structuralwall or similar solid surface no anti-vibration dampening techniques need to beemployed.

• However, when the PID-LVDT assembly and enclosure are attached to vibratingmachinery then absorption techniques are required.

4.0 EXPLOSION-PROOF MOUNTING OF THE PID & PID-LVDT CARDS

• All of the rules of SECTION 3.0, above, apply.• Additionally the use of an explosion-proof housing that meets the appropriate

agency and/or CE approvals for the application is mandatory.• Under certain circumstances mounting holes may be drilled through an explosion-

proof housing. Be sure that appropriate codes are met.• The mounting arrangement for an explosion-proof housing requires the use of rigid

conduit with properly applied sealing compound at every entry or exit port.

5.0 MOUNTING ARRANGEMENT FOR BOTH CASE 1 and CASE 2

• Refer to SECTIONS 9.0, below, for drawings concerning DIN rail mounting of this

assembly.• Air flow MUST flow freely across both sides of the assembly.

6.0 ELECTRICAL WIRING REQUIREMENTS FOR BOTH CASE 1 and CASE 2

• Within an enclosure good wiring practice dictates that service loops be included in allwires between the point of entry and the terminal strip on the PID-LVDT assemblies.

• The distance between terminals on the PID-LVDT assemblies and the barrier strip(when used) or enclosure wall (when no barrier strip is used) must exceed 3” (75mm).

• Wire bundles, in both Case 1 and Case 2 installations, must be secured to the wall

of the enclosure in an appropriate manner keeping in mind any code requirementsthat apply.• As specified in SECTION 9.0 of this document:

- Keep power and signal wires separated.- Should the bundles need to be crossed then do so at a right-angle if possible.- Properly select the wire size and insulation type or rating.


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7.0 ANALOG PID CONTROLLER CARD

7.1 PID Card Features

• Voltage and current differential Command and Feedback Inputs.• Ramp input.• Voltage and current outputs.• Adjustable Gains (PID).• Switchable Time Constants (ID).• Adjustable current offset.• Integrator (I) disable.• Selectable Integrator Limits• PID Gains test/measurements points• Integrator Antiwindup Circuitry.

• Inputs and Outputs Transient Voltage protected.• Dither.• Reset on power-ON & power-OFF preventing uncontrollable behavior.• Wide range of power supply voltages.• Provision for optional single or dual LVDT transducer interface card.• Standard board form factor with optional enclosure and DIN Rail Mounting.

8.0 PID CARD SPECIFICATIONS

TABLE 1

PARAMETER RANGE COMMENTS

Input Command +/-10 VDC, 0 – 10 VDC,+/-5 VDC, 0 – 5 VDC

100 Kohm input impedance,0 – 20 mA or 4 – 20 mA converted to

0 – 10 VDC,75 Ohm input impedance,

Feedback Command +/-10 VDC, 0 – 10 VDC,+/-5 VDC, 0 – 5 VDC

100 Kohm input impedance,0 – 20 mA or 4 – 20 mA converted from

0 – 10 Vdc (+/-0.2Vdc)

75 Ohm input impedance,Ramp Ratio “no change” to

1.5 Volt/SecOutput Signals 1. +/-10 Vdc w/ +/-15mA current capability

2. 4 – 20 mA3. +/- 8, 30, 60, 120, 240 mA

(See section 9.5)


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Proportional Gain (P) 0 – 20 XIntegral Gain 0 – 1 XIntegral Time Constant 10 Sec, 1 Sec, 100 mSec,

10 mSec, 1 mSecIntegral Limit 5%, 10%, 25%, 50% & 100%Derivative Gain 0 – 1 XDerivative Time Constant 1 Sec, 100 mSec, 10 mSec,

1 mSec, 0.1 mSecOffset (Current Output) +/-8 % of the output rangePower Supply 24 VDC, 300 mA

(10 – 30 VDC, 8 watts min.)Inrush current energy

0.4 AmpSec, 1 Amp min or optionally +/-15VDC 250 mA

Operating Temperature 0 °C to +70 °CHumidity 90 % max, non-condensingSize See SECTION 28 & 29 Terminals Pluggable Terminal Blocks

12 – 30 AWGFuse (Replaceable) 1.0 Amp Slow Acting

Order replacement fuses throughYoung & Franklin, Inc.YF P/N: 8605A020-P004

9.0 PID CARD (8605D200) INSTALLATION INSTRUCTIONS

9.1 PID Card General InformationThe Controller printed circuit board is mounted on a DIN rail adapter for easy,snap-in mounting to the control panel.

Mounting position is unrestricted. However provision should be made for goodaccess to the terminals, test points and potentiometers, as well as for anunobstructed flow of cooling air around the board.

Controller board environment should be free from any conductive contaminantssuch as liquids, vapors or metal chips.

Location should assure that ambient temperature extremes and humidity arewithin operating ranges.


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Power should come from an approved unit providing enough current to run thecontroller and supplying sufficient inrush current energy as well. The connectionsto the Controller Board should be made with appropriate cables, preferably # 22

AWG shielded and with twisted pairs for each signal. Power wires should be #

22 AWG minimum. Power supply and signals cables should be separated.

The Controller should be mounted within a conductive EMI shielded enclosure.The enclosure, cable shields, Controller ground need to have an electricalcontinuity and be chassis grounded to minimize unwanted noise disturbances.

9.2 PID Card Wiring Refer to SECTION 22.0 & 23.0 for the typical placement of wire terminals.Floating inputs need to be properly connected to the signal source or to the GNDto achieve correct signal polarity. Common Mode maximums are +/-10 VDC.

9.3 PID Card Supply Connections

J1 Description

1 + 24 Vdc (Supply)2 24 Vdc Return (Ground)3 Ground4 + 15 Vdc

5 - 15 Vdc

*optional external supply orpower (250 mA max) forauxiliary circuits

6 Ground

*Controller is equipped with DC/DC converter and when powered with 24 VDC

(J1-1, J1-2) will produce +/-15 VDC voltages, which are available (J1 pins 4 & 5)for any auxiliary device. Alternatively the DC/DC converter can be bypassed andController can be supplied from a +/-15 VDC source (J1-4, J1-5, J1-6).

9.4 PID Card Input Connections

J2 Description

7 Ground8 Signal in9 Ramped Signal Out

Ramp ModuleSee Section 10.2

10 Command Inverting Input11 Command Non-inverting Input

Floating,+/-10V

12 Ground13 Feedback Non-inverting Input

14 Feedback Inverting InputFloating,+/-10V

15 Ground

J1 Terminal Block

J2 Terminal Block


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Direct and Reverse Acting Configurations

- Direct Acting A typical configuration for the purpose of this

manual is a situation when an increasingcommand signal is match by an increasingfeedback signal. This is what is called directacting. Note that for a given change in positionthe command and feedback track in the samedirection.In an application using a 4 – 20mA command andLVDT the 0.7Vrms (0%) will be achieved with a4mA command signal. And the 3.5Vrms (100%)position will equal a 20mA command.SEE SECTION 24.0 for detai ls

- Reverse Acting CommandReverse acting command configuration is asituation when a decreasing command signal iscontrasted by an increasing feedback signal. Notethat for a given change in position the commandand feedback track perpendicular to each other.In an application using a 4 – 20mA command andLVDT the 0.7Vrms (0%) will be achieved with a20mA command signal. And the 3.5Vrms (100%)

position will equal a 4mA command.SEE SECTION 25.0 for details

- Reverse Act ing FeedbackReverse acting feedback configuration is asituation when an increasing command signal iscontrasted by a decreasing feedback signal. Notethat for a given change in position the commandand feedback track perpendicular to each other.In an application using a 4 – 20mA command andLVDT the 3.5Vrms (0%) will be achieved with a4mA command signal. And the 0.7Vrms (100%)position will equal a 20mA command.SEE SECTION 26.0 for details


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Current to Voltage Converters

J3 Block 1

16 Not Used17 Non-inverting Command Input (mA)18 Command Return

Floating

19 Voltage Command Output 0 – 10 V

J3 Block 220 Not Used21 Non-inverting Command Input (mA)22 Command Return

Floating

23 Voltage Command Output 0 – 10 V

Important Note: 4-20mA converter block 1 (J3-16 thru 19) is factory matched with theLVDT 4-20 feedback. This provides the highest level of accuracy between the inputcommand and the feedback. For this reason the 4-20mA command if used shouldalways go to the block 1 converter.

When the incoming signal, either Command or Feedback or both, is in the 0 – 20 mA or4 – 20 mA format it has to be converted to a voltage signal. Two current to voltageconverters are provided for this.Configuration for the current to voltage converter is as follows: Signal is connected tothe 4/20 + terminal (J3-17, J3-21) with J3-18, J3-22 as the respective returns. Voltage

Output (J3-19, J3-23) from the Converter (0 – 10 V) will be connected to the appropriateCommand or Feedback input (J2-10, J2-11, J2-13, J2-14).

J3 Terminal Block


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9.5 PID Card Output Connections

J4 Description Signal

24

Output Sink Optional

(when R97 removed)

4 – 20 mA

25 Output Source 4 – 20 mA26 Ground27 OUTPUT Voltage +/- 10 Vdc

J5 Description

28 Enable (Ground to Enable)29 Ground30 Ground31 Servo Current Output32 Ground

The Controller Board has three Driver Outputs:

• 4 – 20 mA Output (J4-24, J4-25) which when scaled to voltage correspondsto 4mA = -10Vdc / 20mA = +10Vdc signal range of the Controller.

• +/-10 V output (J4-27) with the current capability of +/-15 mA• Servo Current Output is programmable by placing jumper(s) as follows:

8 mA 30 mA

60 mA 120 mA

240 mA Disabled

Two or more jumpers can be combined to get adifferent maximum current limit – not to exceed250 mA.

Maximum Coil impedance so as not to exceed the voltage ceiling is:

Z max = 12 Volt / CURRENT

J4 & J5 Terminal Blocks

60mA setting shown


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9.6 Application of the Enable feature

While it is only necessary to ground the enable terminal (#28) it may be wise toconsider making it part of the system logic. To evaluate this, first you should

know what the enable does in the system.

The enable circuit has two functions. First it turns off all driver outputs andsecond it resets and holds the integrator at zero (anti-windup). The integratorwhen enabled will take even the very smallest error signal and compound it overtime. Based on the time constant and gain selected this can be produce a fullamplitude drive signal in a very short time.

Based on the design of the system to be controlled this can have a negativeimpact. Take for instance a system where the controller is powered for some timeprior to there being hydraulic pressure to the actuator. If there is a small error

signal showing that the actuator should open and the integrator is enabled, thiswill lead to the generation of a full open signal to the actuator. When thehydraulic pressure is supplied to the actuator it will result in a momentaryopening of the valve. How much it opens may vary and is based on the responseof the servo valve and actuator.

For this application the enable signal should be run though a relay connected tothe hydraulic power unit (HPU). Refer to the diagram below. This would allow thecontroller to be powered but only be enabled when the HPU is on and supplyinghydraulic pressure. This will eliminate the windup condition that will cause amomentary jump in position.

Contact Young & Franklin Inc. with other unique application questions.


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10.0 PID CARD ADJUSTMENTS AND TUNING

10.1 PID CARD WARNING!The successful design and setup of any closed loop control system requiresconsiderable forethought and a good understanding of the control engineeringknow-how and practices.

Closed loop feedback control is a topic far exceeding the scope of this manual.It is the responsibility of the user to assure adequate procedures preventing anyhazards, losses, damage, injury or harm to objects and people.

Front ViewPID Controller

P4 P5 P1 P2 P3 P8 P6 P7SW1Integral Time

SW2Derivative

SW3Integral Limit

Power OnIndication

Position

Display


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10.2 PID Card Ramp Module Adjustment

If it is desirable to slow the Command

Signal rate of change at the PIDcontroller, the Ramp Module can beused. The incoming voltage signal isconnected to the R IN (J2-8) terminaland the ramped output signal isconnected from the R OUT (J2-9) to theproper COM IN terminal (J2-10, J2-11).The delay is independently adjustablefor both the rising and falling signals asshown using P4 & P5.

P4 Ramp (-) Adjusts the trailing edge of the signal, CW slower edge.

P5 Ramp (+) Adjusts the rising edge of the signal, CW slower edge.

Adjustment range is from “no change” to 0.125 Volt/mSec

10.3 PID Card Module AdjustmentP1 Adjusts P (proportional) component, CW more gain.

P Gain range 0 – 20X

P2 Adjusts I (integral) gain, CW more gain.I Gain range 0 – 1X

SW1 Selects Integral time constant, as follows:

Disabled 10 Sec 1 Sec 0.1 Sec 0.01 Sec 0.001 Sec

1 ON/OFF OFF OFF OFF OFF ON2 ON/OFF OFF ON OFF ON OFF3 ON/OFF ON OFF ON OFF OFF4 ON/OFF OFF OFF ON ON ON5 ON/OFF ON ON OFF OFF OFF

6 ON OFF OFF OFF OFF OFF


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SW3 Selects Integral Limits, as follows:

5% 10% 25% 50% 100%

1 OFF ON ON ON ON2 OFF OFF ON ON ON3 OFF OFF OFF ON ON4 OFF OFF OFF OFF ON

The integrator limit is a percentage of the full scale command. In application theintegrator alone would only achieve 30mA of the 60mA full scale when 60mAServo drive and 50% limit was selected. This limit also applies to the +/-10Vdcand the 4 – 20Ma drive signals. This limit only affects the integrator circuit. Theproportional circuit can still drive the full command signal.

P3 Adjusts D (derivative) gain, CW more gain.D Gain range 0 – 1 X

SW2 Selects D (derivative) time constant, as follows:

1 Sec 0.1 Sec 0.01 Sec 0.001 Sec 0.0001 Sec

1 OFF OFF OFF ON ON2 ON ON ON OFF OFF3 OFF OFF ON OFF ON

4 OFF ON OFF ON OFF5 ON OFF OFF OFF OFF

10.4 Driver Signal Offset Adjustment

P7 Adjusts offset for all three output signals. Servo current (J5-31, J5-32),4 – 20 mA (J4-24, J4-25) and +/- 10 Vdc (J4-27)

Range is +/-8% of maximum value.


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11.0 SINGLE LVDT CARD OPTIONS (Model 8605D201)

11.1 LVDT Card General Descr ipt ionThe LVDT Signal Conditioner Card provides all signals and processing circuitsnecessary for the General Electric standard LVDT (or RVDT) positiontransducers. For DC voltage inputs see Section 17.0 for detailed applicationinstructions.

11.2 LVDT Card FeaturesTable 2


Drive voltage to LVDT 6 – 8 Vrms +/-5% 7 Vrms Standard. Otheramplitudes available. *

Input Impedance of LVDT Zmin = 30 ohmsImax = 270 mA

Frequency Output to LVDT 3 kHz +/-10% Other frequencies available *

Card output signal (PositionSignal)

Adjustable GAIN and ZERO To meet the requirements ofthe 8605D200 PID card.

Operating Temperature 0 °C to 70 °COperating Humidity 10 to 90 percent R.H. non-condensingStorage Temperature -50 °C to 125 °CTerminals, Pluggable 12 – 30 AWGPower Required ±15 Vdc @ 300 mA Supplied by the PID board

* Contact Young & Franklin Inc.

Course Fine Course FineExcitation

Am li tude Zero Adjust Span Adjust


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12.0 LVDT CARD WIRING

Refer to the SECTION 19.0 and SECTION 23.0 for the placement of wireterminals.

Description Signal

33 Voltage input to V / Iconverter

Signal from terminal 34

34 Output signal Position feedback 0 – 10 Vdc Nom.35 Ground36 Sink current Option disabled37 Source Current Position feedback 4 – 20 mA38 Ground39 Secondary lead

40 Center tap on primary

Signal (Position) fromLVDT

0.7 – 3.5 VrmsNominal

41 Ground42 Excitation

Excitation to LVDT7.0 Vrms

Note: Wiring for terminals 39 through 42 is for a standard four-wire GeneralElectric linear transducer. See diagrams in SECTION 21.0 for moredetailed transducer wiring instructions, including the five-wire versions.

J2 (Reference Only)

J2-1 Source Current return from LCD meter J2-2 Source Current to LCD meter

13.0 LVDT CARD ADJUSTMENTS AND TUNING

13.1 LVDT CARD WARNING!The successful design and setup of any closed loop control system requiresconsiderable forethought and a good understanding of the control engineeringknow-how and practices.

Closed loop feedback control is a topic far exceeding the scope of this manual.It is the responsibility of the user to assure adequate procedures preventing any

hazards, loses, damage, injury or harm to objects and people.13.2 LVDT Card Excitation Adjustment

(P1) AMPL: Potentiometer adjusts the excitation signal amplitude from 6 Volts to8 Volts RMS. Signal can be monitored with the Oscilloscope or TrueRMS Multimeter on the terminal 42. Ground Lead of the instrumentshould be put on the 41 (Ground).


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13.3 LVDT Card Position Output Adjustment

ZERO (P5 & P4): Potentiometer adjusts the signal level for the “zero” position.• P5 – Coarse adjust

• P4 – Fine adjust

SPAN (P3 & P2): Potentiometer adjusts the signal range for the full cycle/ travel.• P3 – Coarse adjust• P2 – Fine adjust

With the actuator in the closed position use ZERO (P2 & P6) to set theLVDT/RVDT output to the desired voltage level.

Now cycle the actuator to the full open position.

Measure the DC output voltage and calculate the difference from the desiredvalue. Adjust the output voltage using SPAN (P3) by half the calculateddifference. For example the desired output voltage is +10 VDC and themeasured voltage is +12 VDC. By adjusting SPAN to read +11 VDC this willeffectively reduce the span by 2 VDC.

Now cycle the actuator to the closed position. The output voltage will havechanged by half the calculated difference.

Use ZERO (P2) and SPAN (P3) to adjust for the desired voltage level. Continueto cycle between open and closed using this procedure until consistent readings

are achieved.


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14.0 DUAL LVDT CARD OPTIONS (Model 8605D202)

14.1 LVDT Card General Descr ipt ionThe Dual LVDT Signal Conditioner Card provides all signals and processingcircuits necessary for two General Electric standard LVDT (or RVDT) positiontransducers. For DC voltage inputs see Section 17.0 for detailed applicationinstructions.

14.2 LVDT Card FeaturesTable 2


Drive voltage to LVDT 6 – 8 Vrms +/-5% 7 Vrms Standard otheramplitudes available. *

Input Impedance of LVDT Zmin = 30 ohms

Imax = 270 mAFrequency Output to LVDT 3 kHz +/-10% Other frequencies available *

Card output signal (PositionSignal)

Adjustable GAIN and ZERO To meet the requirements ofthe 8605D200 PID card.

Operating Temperature 0 °C to 70 °COperating Humidity 10 to 90 percent R.H. non-condensingStorage Temperature -50 °C to 125 °CTerminals, Pluggable 12 – 30 AWGPower Required ±15 Vdc @ 300 mA Supplied by the PID board

* Contact Young & Franklin Inc.

Course Fine Course FineExcitation

Am li tude

Zero Adjust Span Adjust Course Fine

Course FineZero Adjust

Span Adjust

Channel B Channel A


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15.0 DUAL LVDT CARD WIRING

Refer to the SECTION 20.0 and SECTION 23.0 for the placement of wireterminals.

CH

Description Signal

33 B Output signal Channel B Position feedback 0 – 10 Vdc Nom.34 A Output signal Channel A Position feedback 0 – 10 Vdc Nom.35 Ground36 B Source Current Chan. B Position feedback 4 – 20 mA37 B Sink current Channel B Option disabled38 Ground39 A Source Current Chan. A Position feedback 4 – 20 mA

40 A Sink current Channel A Option disabled41 Ground42 High Select Voltage Position feedback 0 – 10 Vdc Nom.43 Secondary lead44 Center tap on primary



45 Ground46

C h a n n e l B

ExcitationExcitation to LVDT 7.0 Vrms

47 Secondary lead48 Center tap on primary



49 Ground50

C h a n n e l A

ExcitationExcitation to LVDT 7.0 Vrms

Note: Wiring for terminals 43 through 50 is for a standard four-wire GeneralElectric linear transducer. See diagrams in SECTION 22.0 for moredetailed transducer wiring instructions, including the five-wire versions.

J4 & J5 (Reference Only)

J4-1 & J5-1 Source Current return from LCD meter J4-2 & J5-2 Source Current to LCD meter

16.0 LVDT CARD ADJUSTMENTS AND TUNING

16.1 LVDT CARD WARNING!The successful design and setup of any closed loop control system requiresconsiderable forethought and a good understanding of the control engineeringknow-how and practices.

Closed loop feedback control is a topic far exceeding the scope of this manual.


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It is the responsibility of the user to assure adequate procedures preventing anyhazards, loses, damage, injury or harm to objects and people.

16.2 LVDT Card Excitation Adjustment

Excitation Amplitude (P1): Potentiometer adjusts the excitation signalamplitude from 6 Volts to 8 Volts RMS. Signal can be monitored withthe Oscilloscope or True RMS Multimeter on the terminal 46 or 50.Ground Lead of the instrument should be put on the 49 (Ground).

16.3 LVDT Card Position Output Adjustment

ZERO (Channel A P3 & P11) (Channel B P5 & P13):Potentiometer adjusts the signal level for the “zero” position.• P3 & P5 – Coarse adjust• P11 & 13 – Fine adjust

SPAN (Channel A P2 & P10) (Channel B P4 & P12):Potentiometer adjusts the signal range for the full cycle/ travel.• P2 & P4 – Coarse adjust• P10 & P12 – Fine adjust

With the actuator in the closed position use ZERO to set the LVDT/RVDT outputto the desired voltage level.

Now cycle the actuator to the full open position.

Measure the DC output voltage and calculate the difference from the desired

value. Adjust the output voltage using SPAN by half the calculated difference.For example the desired output voltage is +10 VDC and the measured voltage is+12 VDC. By adjusting SPAN to read +11 VDC this will effectively reduce thespan by 2 VDC.

Now cycle the actuator to the closed position. The output voltage will havechanged by half the calculated difference.

Use ZERO and SPAN to adjust for the desired voltage level. Continue to cyclebetween open and closed using this procedure until consistent readings areachieved.

16.4 Channel A / B Select Swi tch

The 8605D202 is equipped with a channel A/B select switch. This allows theposition feedback from Channel A or B to be displayed on the LCD readout.

Attention: Operating the switch will cause a momentary interrupt in the feedbackloop. This may case a fault or other problem in the monitoring circuit. For thisreason it is advisable not to operate the switch while the system is operational.


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17.0 DC VOLTAGE FEEDBACK TO THE LVDT CARD

17.1 General Application Description

For an application where the feedback device provides a Vdc signal, the followinginstruction can be used to interface to the LVDT card. While the PID card will canaccept a Vdc feedback signal directly, there are functional benefits to using theLVDT card to interface the Vdc feedback device. For example the LVDT card willgive the added features of 4-20mA feedback and in the case of the dual LVDTcard it will add the high select function.

17.2 Setting up the LVDT Card for DC Volt Feedback Operation

To set up the LVDT card for Vdc operation set the potentiometers in the following

manner. Refer the Sections 11 and 14 for potentiometers designations. Note thatthis applies to both the fine and course pots. And also to both channels on thedual LVDT card.

Zero Adjus t – Turn fully clock-wise*

Span Adjust – Turn fully counter clock-wise*

*Note that there is not a stop at the end on travel. These are 12 turnpotentiometers so 12 revolution in one direction will ensure that full travel hasbeen accomplished.

17.3 Wiring the LVDT Card for Vdc Feedback Operation

A 200K ohm resistor must be added in series with the Vdc input. Use the tablesand diagrams in Section 17.4 & 17.5 for wiring configuration. The resistor may beany 200K ohm 1% metal film resistor with a minimum ¼ watt rating.


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17.4 Termination Table for 8605D201-G001 Signal LVDT

Description Signal

33 Voltage input to V / Iconverter

Signal from terminal 34

34 Output signal Position feedback 0 – 10 Vdc Nom.35 Ground

36 Sink current Option disabled37 Source Current Position feedback 4 – 20 mA38 Ground39 Vdc Input

40 Ground (see note 1)


0 – 10 Vdc Nom.(see note 2)

41 Ground42 Excitation – Not used

Excitation to LVDT 7.0 Vrms

Notes:1. The common from the feedback source will be connected as shown and must

also be grounded to the LVDT card. This can be accomplished by adding a

jumper from noted terminal to a ground terminal.2. Any voltage range between 0 and 12 Vdc may be used (i.e. 0-5, 0-1, etc.).


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17.5 Termination Table for 8605D202-G001 Dual LVDT

CH

Description Signal

33 B Output signal Channel B Position feedback 0 – 10 Vdc Nom.34 A Output signal Channel A Position feedback 0 – 10 Vdc Nom.35 Ground36 B Source Current Chan. B Position feedback 4 – 20 mA37 B Sink current Channel B Option disabled38 Ground39 A Source Current Chan. A Position feedback 4 – 20 mA

40 A Sink current Channel A Option disabled41 Ground42 High Select Voltage Position feedback 0 – 10 Vdc Nom.43 Vdc Input44 Common (see note 1)

Signal (Position) fromVdc feedback device


45 Ground46

C h a n n e l B

Excitation – Not usedExcitation to LVDT 7.0 Vrms

47 Vdc Input48 Common (see note 1)

Signal (Position) fromVdc feedback device


49 Ground

50

C h a n n e l A

Excitation – Not used

Excitation to LVDT 7.0 Vrms

Notes:1. The common from the feedback source will be connected as shown and must

also be grounded to the LVDT card. This can be accomplished by adding a jumper from noted terminal to a ground terminal.

2. Any voltage range between 0 and 12 Vdc may be used (i.e. 0-5, 0-1, etc.).


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18.0 PID CARD FUNCTIONAL BLOCK DIAGRAM


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19.0 LVDT CARD FUNCTIONAL BLOCK DIAGRAM


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20.0 DUAL LVDT CARD FUNCTIONAL BLOCK DIAGRAM

Note: Operating the switch willcause a momentary interrupt in thefeedback current loop. This maycause a fault or other problem inthe monitoring circuit. For thisreason it is advisable not to operatethe switch while the system is

operational.


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21.0 LVDT UNIT WIRING DIAGRAM 4 & 5 WIRE VERSIONS


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22.0 PID/ LVDT CARD 8605D201-G001 TYPICAL WIRING DIAGRAM


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23.0 PID/ DUAL LVDT CARD 8605D202-G001 TYPICAL WIRING DIAGRAM


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24.0 Direct Acting Wiring Diagram

The following diagram shows the jumper configuration for a direct acting scenario asdescribed in Section 9.4 (page 10). Note that only the jumper wires are shown and the

8605D201-G001 is depicted. The configuration would be the same for the 8605D200-G001and the 8605D202-G001 (PID and PID Dual LVDT) models with the following exceptions.For the 8605D200-G001 the feedback would come from a compatible source. And for the8605D202-G001 the feedback would come from terminal 42.


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25.0 Reverse Acting Command Wiring Diagram

The following diagram shows the jumper configuration for a reverse acting command scenarioas described in Section 9.4 (page 10). Note the addition of a resistor and zener diode to

create a 10Vdc reference signal. See Section 26.0 for detail information on the referencevoltage circuit. Also note that only the jumper wires are shown and the 8605D201-G001 isdepicted. The configuration would be the same for the 8605D200-G001 and the 8605D202-G001 (PID and PID Dual LVDT) models with the following exceptions. For the 8605D200-G001the feedback would come from a compatible source. And for the 8605D202-G001 thefeedback would come from terminal 42.


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26.0 Reverse Acting Feedback Wiring Diagram

The following diagram shows the jumper configuration for a reverse acting feedback scenarioas described in Section 9.4 (page 10). Note the addition of a resistor and zener diode to

create a 10Vdc reference signal. See Section 26.0 for detail information on the referencevoltage circuit. Also note that only the jumper wires are shown and the 8605D201-G001 isdepicted. The configuration would be the same for the 8605D200-G001 and the 8605D202-G001 (PID and PID Dual LVDT) models with the following exceptions. For the 8605D200-G001the feedback would come from a compatible source. And for the 8605D202-G001 thefeedback would come from terminal 42.


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27.0 10Vdc Reference Circuit Diagram and Information

Parts List:

Voltage Reference DeviceManufacture National

SemiconductorManufacture P/N LM4040DIZ-10.0Voltage Output 10.0V

Tolerance 1%

Temp. Coefficient 150ppm/°CPackage TO-92

Part may be substituted with another 10.0V device. Note that a 1% tolerance rating isrecommended, as deviation in the reference voltage will introduce offset in the controller.

Resistor

Value 1 k OhmTolerance 5% or betterRating .25 - .5 WattWhile any resistor meeting the above description may be used thePanasonic Carbon Film Resistor, p/n:ERD-S1TJ102V meets the requirement.

Sources: Digi-Key 800-344-4539 | Newark 800-463-9275 | Mouser 800-346-6873

Schematic

Cut unusedpin Heat shrink insulation

Ground

10Vdc

15Vdc

Heat shrinkinsulation

22 AWG Bus Wire

The following illustrations show on ofthe possible packaging scenarios forthe 10 volt reference circuit.


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28.0 PID/ SINGLE LVDT CARD 8605D201-G001 OUTLINE DRAWING


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29.0 PID/ DUAL LVDT CARD 8605D202-G001 OUTLINE DRAWING


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30.0 ELECTROSTATIC DISCHARGE ISSUES

The PID/ LVDT controller is protected against high voltages at all inputs and outputs.However electronic assemblies require special handling as they are susceptible toseveral kinds of damage, some of which cannot be perceived by physical inspection.

An Electrostatic Discharge (ESD) event to components of an electronic assembly cancause internal, non-visible damage that prevents the unit from functioning correctly orcontributes to an early failure of that unit. We have all observed the effect ofaccumulating a static charge on our body and then discharging it to a metal object suchas a door knob. These high voltage discharges exceed what the typical semi-conductordevice can survive.

1. Keep the following materials away from electronic assemblies:• Styrofoam (polystyrene): cups, “peanut” packing materials• Cellophane: cigarette or candy wrappers• Vinyl: books or folders• Plastic: cups, bottles

2. Avoid synthetic clothing. Wear cotton or cotton-blend materials.

3. Before handling electronic assemblies, discharge static electricity buildup from yourbody by using a properly connected wrist strap and/or gripping exposed metal that isconnected to the building earth ground.

4. Do not handle assemblies in the field unless properly grounded by a wrist strap. Ifyou are not properly connected to the building earth ground:

• Do not pick up assemblies• Do not touch the printed circuit board or its connectors

5 Transport all static-sensitive assemblies only in static shielded carriers or packages.Place static awareness labels on all assemblies to prevent removal from staticshielded container during transit

6 Handle all static-sensitive assemblies at a static-safe work area that should include a

floor mat, wrist strap, air ionizer, grounded cords and conductive table mat.

7 Wear a grounded wrist strap in the field. Where wrist straps are impractical, weargrounded heel straps or special footwear on properly grounded dissipative flooringor grasp an exposed metal fixture that is connected to the building earth ground.


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8 Do not subject assemblies to sliding movements over any non-conductive surface atany time.

9 Waxed vinyl floors generate static electricity easily and should be avoided. Also,

modern shoes generally have electrically insulated soles and this requires the use ofa wrist strap.

31.0 PACKAGING OF ELECTRONIC ASSEMBLIES

Conductive table top coverings and conductive floor mats are standard elements forthose areas where electronic assemblies are processed. Before describing thepackaging requirements it must be stated that ANYONE handling electronic assembliesMUST be connected to the building earth ground with an approved ESD grounding wriststrap. Please note that a grounding wrist strap is not a dead short with zero ohms of

resistance but it has a series resistance that is typically 1,000,000 ohms.

31.1 Field Location to Factory

It is recommended that the recipient retain Y&F packaging materials, used in shippingelectronic assemblies from the factory, for use in the event a unit must be returned forevaluation, repair or replacement. The pink dissipative material is not to be used. Thefactory warranty could be voided should an inappropriate method of packaging be usedon returned goods.

A. All units containing an electronic assembly or component must be completelyenclosed in a thin sheet of special conductive plastic known as anti-staticplastic. This static shielding material comes in a variety of forms includingbags, bubbles and sheets and is shiny black, blue or even metalized silver.The pink dissipative material is not to be used.

B. Small assemblies weighing less than one-pound need to have at least one-inch of shock absorbing material on all surfaces.

C. Larger assemblies between one and ten-pounds require at least two-inches ofshock absorbing material on all surfaces.

D. Any assembly over ten-pounds will need at least four-inches of shockabsorbing material on all surfaces.

E. Shock absorbing material can be close-cell foam or the typical bubble-wrap.

F. The outside of the shock absorbing material shall be protected with boxesmade of heavy-duty cardboard, fiber board or wood, again depending uponthe weight of the assembly.


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32.0 REFERENCE MATERIALS

32.1 Proportional Loop Tuning

1. Set Kp to a low value

2. Apply a square wave command at about 10% of the desired loop bandwidth.Use a large amplitude but avoid saturation of the amplifiers.

3. Raise Kp to obtain little or no overshoot.

4. Check for noise in output. If too noisy:

• Reduce noise at source or• Increase resolution or• Lower Kp

5. Repeat steps 3 and 4 above until noise is at an acceptable level

6. Done

32.2 Proportional & Integral Loop Tuning

1. Set Kp and Ki to low values


3. Raise Kp to obtain little or no overshoot.


• Reduce noise at source or• Increase resolution or• Lower Kp

5. Repeat steps 3 and 4 above until noise is at an acceptable level

6. Raise Ki for 15% overshoot

7. Done


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32.3 Proportional, Integral and Derivative Loop Tuning

1. Set Ki and Kd to zero. Set Kp to a low value.


3. Raise Kp for 10% overshoot with no ringing.

4. Raise Kd to eliminate most of the overshoot


• Reduce noise at source or• Increase resolution or• Lower Kp or• Lower Kd or• Lower f d

6. Repeat steps 3, 4 & 5 above until noise is at an acceptable level

7. Raise Ki for 15% overshoot

8. Done


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33.0 LVDT Calibration Procedure

Documents

Young Franklin PID Controller Manual