ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

A. APPLICATION: The drive control module in conjunction with the MAX

controls system forms the output stage of the servo valve together with a
blocking unit for hydraulic actuators. It serves as an input amplifier for
position transducers like the SG10 capacitive transmitter. This module is
used in Turbine control using MAX control systems in HP bypass valve
interface for actuating Electro-hydraulic converters.

FUNCTIONAL BLOCKS:
• Position signal receiver circuit.
• Summing amplifier stage.
• Voltage to current converter.
• Fault monitoring
• Logic circuit.
• Power and switching amplifiers.

BHEL / EDN / SAE / PROMAX Page 1 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

B. MODULE OPERATION:

Position Signal Receiver circuit:

Position signal receiver circuit receives input through position transmitters of
different current and voltage ranges such as

1. Two-wire position transmitters like the capacitive position transmitter SG10

of M/s Sulzer with a current signal of 5...15mA . The current flowing
through the position transmitter can be measured between P15V (P2A-3) and
SG1 (P2A-1).
It can also operate with a current signal of 4...20 mA.

2. The slide wire position transmitter SGP of Sulzer make having a live-zero
voltage signal of 2.5...12.5V can be connected to the position receiver. The
resistance of the transmitter must not be too large, as a non-linearity is
produced by the module input resistance of 18K. Recommended values of
transmitter resistance are 2K or 1K. The non-linearity is better than 1% for
1K and better than 2% for 2K.

The setting is carried out principally in the same way for both types of position
transmitters.
With the valve closed, the line zero is first set with the position feedback
'OFFSET' pot on the front plate to zero volt at the Position Feedback Indication
PFI (P2A-6).
With the valve fully open (100% position) the amplification is then set with
Position feedback 'GAIN' pot n the front plate.
The output shows a voltage change of 10V over the complete stroke of the
valve. The corresponding output of the I to V stage can be set with two pots
to the standard range of 0...10V in any of the above cases.

BHEL / EDN / SAE / PROMAX Page 2 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Buffered reference voltage 'V_ref ' at pin P2A-10 can be adjusted between 0 to
10V by using internal pot P6 .

Position feedback indication outputs:

The position Feedback Indication signal PFI is made available at pin P2A-6.
Internal pot P12 is used to scale down this signal between 0 to 10 V and is
made available at pin P2A-7 (Vp).

Voltage to current converter :

Internal Pots P8 and P9 may be used to obtain linear range of 4 to 20mA at
the Position feedback current output I_PFI (Io).

Fault monitoring:
The lines connected with the respective position transmitter are continuously
monitored for short circuits, interruptions of input signal. Also continuously
monitored is the stabilized power supply voltage of ± 15V. The healthy status of
the module is indicated by module 'OK LED' (green).
An alarm is generated in the following cases and is signaled by glowing of the
module 'FAULT' alarm LED (red) in the front plate and picking-up of the relay
K2 which closes ohmic contact between SME-P (P3A-15) and SME-N (P3A-14) .
1. Short circuited Transducer
2. PFT field-cable breakage
3. PFT signal out of range
4. Positive supply under voltage
5. Negative supply under voltage

Current to voltage converter:

Internal pots P10 (offset), P14 (gain) is factory adjusted to obtain linear
range of 0 to 10V corresponding to 4 to 20 mA at the output signal Vo (P2A-13)
in case BY signal of the input module is configured in current mode.

BHEL / EDN / SAE / PROMAX Page 3 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Summing amplifier stage:

The summing amplifier has
three positive voltage inputs P2 (P2A-14), P3 (P2A--15) , P4 (P2A-16) and
one positive 4 to 20 mA current input P1P (P2A-12), P1G (P2A-11) and also
one internal negative inputs Vp.
A buffered reference voltage Vref with short circuit protection is available at
pin P2A-10 which can be set to 0 to 10V by adjusting the internal trim-pot P6.
One positive input P4 ( P2A-16 ) is multiplied by four, all the other inputs are
single valued.
The summing amplifier acts normally as a low-pass filter with a cut-off
frequency of 4 Hz. For fast positioning circuits, the bridge S1 can be cut out,
which increases the cut-off frequency to 15Hz.

Variable gain amplifier:

The amplification factor of the final amplifier stage can be set between 6 and
120 'Position feedback GAIN' pot on the front plate.
Position Deviation Signal PDS (Xw) is available at P3A-1. The valve
displacement and deviation from the set point can be read out by meters
connected to these points. The output of the final amplifier of the receiver
circuit is applied to the input of the pulse-width modulated oscillator.

Pulse-width modulated oscillator:

This voltage input to the oscillator influences the ratio of the positive to
negative dwelling time of the rectangular voltage and thereby the average DC
value of the output voltage. This voltage effects a light dither of the fork
which reduces the effects of friction and hysteresis. The ratio between the
input voltage to the oscillator and the average output voltage is about 1 : 1.4.
Duty-cycle of the pulse width modulated square wave oscillator maybe
adjusted to 50% using internal pot P7 with zero voltage signal at the input.

BHEL / EDN / SAE / PROMAX Page 4 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Servo amplifier:
A rectangular voltage waveform with an amplitude of approx. 11.5V at
about 60Hz appears at the servo valve output SV (P3A-16) in automatic mode.
Upon manual open or close orders, the maximum voltage of +11.5V or -
11.5V respectively, is applied to the output SV.
The sense and amplitude of the servo valve output SV can be estimated by
comparing the light emission of the UP (↑) and DOWN (↓) LEDs on the front
plate.

Switching amplifier and Blocking Unit:

The Blocking Unit is connected between output BE_P (P3A-12) and -24V,
BE_N, (P3A-11). In the Auto mode it is permanently excited, as well as
when remote manual orders are given.

Over load and Surge protection:

A protection against external short circuits at the outputs SV and BE_P is
provided which trips the breakers on the module and isolates both the power
supplies. Surge protection provided against high voltage transients at power
supply inputs, all inputs and outputs relating to the field using surge
suppressor diodes.

AUTO command input:

The AUTO Input (P3A-3) puts the module into automatic mode and controls
the automatic relay K1, the real status of which is issued with a potential
free change-over contact output at ACO-1 (P3A-7) and ACO-2 (P3A-8).
The auto mode of operation is indicated by 'AUTO' LED on the front plate.
AUTO input cannot be blocked by MANUAL OPEN / CLOSE commands

BHEL / EDN / SAE / PROMAX Page 5 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Manual command input:

A number of logic are provided for manual remote control and auto to
manual transfer. The remote manual command can be issued for full-open
via Open Input Manual OPI_MAN (P3A-4) or for full-close via Close Input
Manual CLI_MAN (P3A-5). along with simultaneous Enable ENA command at
P3A-6.
Open Input manual OPI_MAN and Close Input Manual CLI_MAN are interlocked
internally to prevent any action when both open and close commands are
issued. The manual commands can be issued only after the AI signal has
been disabled.
OPI_MAN and CLI_MAN commands are valid only if issued simultaneously
with ENA command.
Simultaneous OPI_MAN and CLI_MAN commands will result in `No-command'

OPEN / CLOSE Outputs:

Outputs OPEN (P3A-13) and CLOSE (P3A-9) serve to echo-back the manual
control commands from the final output SV which drives the servo valve.
A logic high is issued when 'AUTO' Input is disabled, blocking element is
excited and a positive (for OPEN) or negative (for CLOSE) signal is given to
the output SV.

POWER SUPPLY:
Whenever the line current exceeds 1.2A, circuit breaker on the module
trips cutting off input power supply to the module. Once the fault is cleared,
the circuit breaker can be manually reset by pressing 'RESET' push button
on the front plate. The circuit breaker can be manually tripped by pressing
'MANUAL TRIP' push button on the front plate
DC-DC converter and voltage regulators in the module generates ± 15V, ± 24V
for internal power supply requirement.

BHEL / EDN / SAE / PROMAX Page 6 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

C. ELECTRICAL SPECIFICATIONS:
POWER SUPPLY (field) : PF (P1A-18 + P1A-19)
Ground : GF (P1A-21 + P1A-22)
Voltage range : +19.0V min, +24.0V typ, +28.0V max.
Current Consumption @ 24V : 300mA typ, 1A max during short circuit

Circuit Breakers Current rating : 1.2A @ 24V DC

INPUTS :
Position Demand Signal from
1. Any standard Current Transmitter: 4...20mA
(normal range corresponding
to 0...10V at PFI (P2A-6) output)
Connection between : P2A-3 and P2A-1+P2A-5

2. Sulzer SG10 voltage Transmitter: 5 ……. 15mA

Ranges of PFT input:
Connection +15V : +15V (P2A-3)
Signal : SGP (P2A-4) Ri =18K
Ground : SG1 (P2A-1)
'Line Zero' current : 3.7 to 5.4 mA
Input current for PFI (S)=10V : 7.5 to 16 mA
Input voltage for PFI (S)=10V : 3 to 10 V

Position Demand signal input (PI)

Summing amplifier
Number of inputs :5
Position Demand current Input: P1_P (P2A-12)
common : P1_G (P2A-11)
4 to 20 mA

BHEL / EDN / SAE / PROMAX Page 7 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Voltage inputs P2 : P2A-14, A=1, -10V to +10V

P3 : P2A-15, A=1, -10V to +10V

P4 : P2A-16, A=4, -10V to +10V
(A=gain of summing amplifier)
0... 10V @ 100K
Input cut-off frequency : with jumper S1= 4 Hz
without jumper S1=15 Hz

Control Desk Logic Inputs

Auto/Manual changeover 'AUTO' : P3A-3 indicated by 'AUTO' LED.
Open_manual OPI_MAN : P3A-4
Close_manual CLI_MAN : P3A-5
Enable ENA : P3A-6
Voltage Ranges Logic HIGH : 13.7 V... 28 V
Logic LOW : 0...1.5 V

OUTPUTS:
Module fault and PFT fault : SME_P (P3A-15)
: SME_N (P3A-14)
Relay ohmic contact rated 60V, 1A, 30VA
Open : module OK
Close : module FAULT

Buffered Voltage reference : Vref ( P2A-10)

Adjustable voltage range (pot P6) : 0...10V
Maximum source current : 10mA
Temperature drift of ref voltage : 0.1% per 10°C

BHEL / EDN / SAE / PROMAX Page 8 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

Position Feedback Current Output : I_PFI (P2A-8)

Common : GI (P2A-9)
: 4...20mA @ 500 ohms max.
Position Feedback Indication signal to meter
PFI : P2A-6
Ground for PFI G_PFI : P2A-2
0...10V, 10 mA max
Range of PD_Gain Amplifier
Adjustable by pot 'PD_GAIN' : +10V to -10V (gain= 6…120)
Position Deviation Signal PDS (Xw): P3A-1
(to meter) -10V to +10V, ±25mA max.
Servo Valve Output: SV : P3A-16
Ground for SV GF_SV : P3A-10
Square wave, Pulse-width modulated
-11.5V.… +11.5V, ± 120mA max.
Short circuit current protected,
Trip Current : 160mA ± 15%

Blocking Element output: BE_P : P3A-12

Common for BE_P BE_N (-24V): P3A-11
- Output voltage
1. Energized state : +24V (48V net across BE coil)
2. De-energized state : High impedance (floating)
- Load current max. : 500 mA, Short circuit current protected
Trip current : 600mA ±15%
AUTO Contact Output : ACO-1 (P3A-7)
ACO-2 (P3A-8)
Relay contact rated 60V,1A,30VA
Open : AUTO command - present
Close : AUTO command - absent

BHEL / EDN / SAE / PROMAX Page 9 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

OPEN Echo-back signal

Output OPEN command : P3A-13
Yes : +24V
No : 0V, sink current=10mA max.

CLOSE Echo-back signal output: P3A-9

Yes : +24V
No : 0V, sink current=10mA max.

D PIN DEAILS :
PCB EDGE FP TOP 16 PIN FP BOTTOM 16 PI N
CONNECTOR CONNECTOR CONNECTOR
P1A-18 PF P2A-1 SG1 P3A-1 PDS
P1A-19 PF P2A-2 G_PFI P3A-2 PDG
P1A-21 GF P2A-3 +15V P3A-3 AUTO
P1A-22 GF P2A-4 SGP P3A-6 ENABLE
P2A-5 SG2 P3A-5 CLOSE_MAN
P2A-6 PFI P3A-4 OPEN_MAN
P2A-7 Vp P3A-7 ACO-1
P2A-8 I_PFI P3A-8 ACO-2
P2A-9 G_I_PFI P3A-9 CLOSE
P2A-10 Vref P3A-10 GF_SV
P2A-11 P1_G P3A-11 BE_N
P2A-12 P1_P P3A-12 BE_P
P2A-13 V_P1 P3A-13 OPEN
P2A-14 P2 P3A-14 SME_N
P2A-15 P3 P3A-15 SME_P
P2A-16 P4 P3A-16 SV

BHEL / EDN / SAE / PROMAX Page 10 of 12

ANALOG DRIVE CONTROL MODULE (DSZA) OM69229S908A REV-00

E. MECHANICAL SPECIFICATIONS:
Weight : 800 grams.
PCB : Double sided, 298 x 254 mm, gold finger
edge connector,grounded metallic cover plate
Front Plate : Aluminum, 44.8 mm width ,
Max control Grey graphic panel,
with 5 LEDs, 3 trim-pots, circuit breaker.
Connector : Two 16 pin male WRP-151631 on the front
plate for field wiring.

F. ENVIRONMENTAL SPECIFICATIONS :
Operating Temperature : 0° C to +55° C
Storage Temperature : -10°C to +70°C
Climatic Class: : IEC 68-2-30 (55C) RH 90-95%
6 cycles (6 days) de-energized
Vibration: : IEC 68-2-6
(X,Y,Z axes 0.5g, 10-150 Hz, 30 mts)
ESD / EFT : as per IEC 16000-4-2
SWC : as per ANSI C37.90a
Maximum ambient temperature: +70°C

Ordering Information : ED69229S908A

Analog drive control module.

BHEL / EDN / SAE / PROMAX Page 11 of 12