12-2 INTRODUCTION have dealt with discrete PLC ‘operation; input and output statuses haye we det PLC operation. Analog PLC control can So far we rh ider analog Rees or off Inne chee fh varables ‘as a control consideration. Many medium. ste Is as having discrete functions, Fo to control any proces lnrge PLCs are able (0 deal with analog sigtal i C input signal is sense i ili to monitor such device: input capability enables you ren oil ee aaa ea Prectrical potentiometers, and many other day indi sssure transdi ices c: ioe Ss sg inal valves: OPO PLC analog control devices can be posto oat intermediate positions. This output control contrasts with discrete control, it extremes. ee, operates only at its two are divided into a number of: BCD PLC analog input and ouput value ranBe® : BCD analog input devices include thumbwheels, encoders, and the like. Analog o dleviges control such devices as digital numbers, seven-segment displays, and st, motors. PLC analog capabilities ‘on the input’s value. For examp «iby an analog input module, In allow many different actions for one single input, depey le, a process in which 20 lights are used to indicate ho tank is in 5 percent increments needs only one analog input and one sensor; a dis system needs 20 ‘on-off sensors and 20 inputs. Analog output programs have sit advantages; for example, a single analog output can position a valve in many diff positions. ‘Analog capal bility enables you to control continuous processes in such industi chemical and petroleum, Any number of variable input signals can be received by a modale and then processed mathematically by the CPU. The resulting analog val Values are then sent to an output module, The analog output module signal then cont variable process or processes. TYPES OF PLC ANALOG MODULES AND SYSTEMS Analog PLC systems are of two general types: BCD and straight numerical. log PLC system is sometimes called the multibit type. (Chapter 13 covers the B numbering system in detail.) Figure 22-1 shows the operation of a thumbwheel input t input BCD module. BCD codes are fed into the PLC input module from the thumbs output. Other possible BCD-type inputs are bar-code readers and encoders. A BCD 0M module is also shown in figure 22-1, In this ease, BCD codes are fed from the ou ‘module to numerical indicating device. BCD output devices include such tings number displays, variable position actuators, and stepper motors, "he other general PLC analog sytem the eraight mneerical type. Some VP ranges of the modules available for thesslsysiems are ¢hcurs in hguce 22-2. TH? numerical type of module is used fora large variety of input d in igure 22-2 Te of which is the electrical potentiometer, The Beers. the 08 re varying, electrical value to the input module, The Rene ster Cane es ia aConversion To CPUIFrom CPU —| FIGURE 22-1 temperature, pressure, distance, position, or electrical values. Other inputs include thermo- couplers, strain gauges, and straight electrical signals. The more complicated analog _ Note that the PLC handles continuous analog systems in discrete steps, The continu- ously varying input signal is not strictly continuous when it reaches the PLC CPU. As we livide up the input signal into more steps, it more nearly approaches the exact duplication “of the input signal, Figure 22-3 shows how the input signal is divided into more parts for increased accuracy, As the number of input divisions goes up from 8 to 16, the digital signal jore nearly describes the actual input signal. Some normally used PLC divisions are 1024 ind 4096, As the humber of divisions goes up, the PLC system cost also goes up. You must We enough steps to control your process with precision, but not so many that cost 240mA 4-20 mA 10-50 mA Oto + 5 Volts DC Oto + 10 Volts DC +25 Volts DC +5 Volts DC 10 Volts DO0 0 O+ Digital + 100% Step Steps © o= Dial Soting=> 100% ‘True Analog Signal FIGURE 22-3 | Analog Signal Conversion to Digital Steps PLC ANALOG SIGNAL PROCESSING The sensor or signaling device that feeds the input module electrical range as the input module. Its lower-limit electric Jower-limit electrical value of the input module, The input’s u also be matched to the upper-limit electrical value of intermediate signal conversion. Similarly, the output their signals appropriately matched by a converter. linearly matched by the converters for both input and output. The input signals available have to be converted module, For example, you have a signal that varies from 0 V to 100 percent input voltage. You decide to use a 0-5 VDC input convert 0-78 VAC to a linear 0-5 VDC, as shown in figure from the converter into the module is then converted to a number is sent from the analog module to an input register figure. How does the input conversion work? For illustration, analyzes the portion of 78 that 31 represents, This is 0.397. design and supply, puts out a DC voltage that is this proportion 1,987 Y, is sent to the input module, Assume that the input modul can hold a value up to 256 in decimal, The input module then 256, 102, and sends the value to a CPU input register. Which register: depends on the setting of DIP switches on the module.To CPU Input togistor 3) - 0907 x 5V = 1.087 v —> 195 «0,07 x 256 = 102 ——+ 19 PU 78 50 Path and Values Note that the input is stepped, in 256 steps, and is not perfectly linear when the CPU "receives data, The accuracy of this system is 1/256 = 0.0039, or about 0.4 percent. Other, more accurate, input modules of 10 and 12 bits can be obtained, at greater cost, if needed in your application. These would have 1024 and 4096 steps, respectively. How does the output signal get from the CPU to an output analog device? Figure 22-5 | shows an output system, For illustration it is assumed that the signal in figure 22-4 was " multiplied by 2 in the CPU. The output ratio is then 0.794, as shown in figure 22-5. This "would be 203 on the 256-step scale, Assume that there is an output module feeding an op amp device with a range of ~10 Y, to +10 V. The math shown indicates that the output _ would have a value of 5.9 VDC. ~ Toillustrate how an analog system might be used, an ADD application is shown in figure 22-6. An output meter is to indicate the sum of two analog inputs. The two input yalues go through conversion and then through the input module. ‘The digital values end up in IROJ and IRO2, as shown. An ADD function adds the two values when the ADD function. enabled, The sum can be updated very quickly by rapid enabling of the ADD function. The sum is put into OROI. The sum is then sent to an output module and then to the indicating meter. For illustration, 17 V and 42 VAC are added and converted, giving an output of 7.8 V to the meter. The meter full scale could be set at 2 times 78, or 156 VAG, to _ match input and output scales. "Figure 227 shows a block diagram of the conversion process, along with two "numerical examples. This module has 1024 steps, but it could have had 512, 4096, or some ‘other power of 2. These are typical values for the module's divisions. bh 256 +10VDC Output iy —+ | module |----b-- ov terminals —10V DC 0 From——+ 203 202 =o.794x20= 159V—> 59V—> > CPU oe)342 ANALOG PLC OPERATION l(t! 73V AC [J iro1 Value |5 VDC oa Roz |e ak M AD | 256 0-5 th Hort =| =| i IRO1 ov OVE eu 0 2 -f4|— module ! Pos 4 78V AC 5V0C/}terminals| 256 ! i jefe? Dest | | Value onot | | Sc lerleka ag ! 9 SEN oy o ono [_}? ov 17 Je = 0218 X5V=1.09V —> 56 194 Bera leso4ia—* oo TE 078 x 19744 42 7g = 0.598 X5V = 269V — 138 a FIGURE 22-6 Analog ADD Application Suppose you need to compare the input values with a fixed value, or wi input value for action. Say, for example, that if the sensor si must turn on output 6, Further, if the sensor signal is between tum on output 7, In this case you have an analog input and ad Processing of these electrical values is shown in figure 22-7, A more typical situation is analog in and analog out. Figure 22-8 shows anexm of an analog output system (input not shown). The upper and lower limits are shom | each block. Sixty-two percent of the total is traced through the analog output system. ignal exceeds 0.5 amper, 0.8 and 1.1 amperes, youn liscrete output. The signal ] dice Input fs Input re Signa) [~~ |Conversion-—-—} Ot, t+! cpu (could be analog) 1.1 Amp—> 100% Vv Eo ee Oup7 a | = Conversion —> | Binary Analysis | Ouaits OAmp — 0% wo ' — 1.1 Amp 100% 10.0V 256] 256 If between, OBAmp 72.7% Cece Des. tes output #7-ON O5Amp 45.4% 4 54V 116” 116 ip over, output 5-0 OAmp 0% ov 0 No Action FIGURE 22-7 Analog Input System5 ‘OR MULTIBIT DATA PROCESSING 343 Output | CPU ae ANS Conversion Device : (Value) 100% + 50V. 100% | —+x10 —> | | 0% —50V 0% om —> 159 —*> +1.2V—+ 62% —+ x 40+ + 12V Valve 62% Open ee 62% x 90° = 55.8° Mi |GURE 22-8 snalog Output System (CD OR MULTIBIT DATA PROCESSING CD data is handled like analog data. Figure 22-9 shows a block diagram of how BCD ices and data are used by the PLC. The input and output devices are mathematically natched directly by the input and output modules. No conversion of values is required jecause the input and output devices are built to match the modules directly. In this uThumbhee! J7368 | 16 Wires BCD 7368 0111 0011 0110 1000 i BCD to Binary Conv. ‘ ° u ye = Binary 7368 0901 1100 1100 1000 t ; p Multiply by 0.5 F Alt = Binary 2684 . 0000 1110 otto 0100 t Be Binary to BCD Conv. 1M oth " Lar i) |o = BCD 3684 0011 OO ood 0100 ° qd d ju. u i CPU Operations 1 je e 16 Wires 3684 ‘Output Display SURE 22-9 fultibit) Input and Output System o a22-5 EXAMPLE 22-1: ANALOG IN AND DISCRETE OUT ‘ANALOG PLC OPERATION. e ilusration, the input number is entered diretly from thumbwhcels The, sealed to half forthe out indicator The resulting half value is see rhe gg four-digit, seven-segment display. Since the CPU does math in binary, rela and binary conversions are carried out as shown. The illustration in figure 22-9 shou 4 Lipiying by 0.5 Alternatively, you could divide by 2 and obtain the same resyi, °™ PLC ANALOG OUTPUT APPLICATION EXAMPLE The inputs and outputs of analog systems cun be straight analog or BCD, 4, We shown, or they can be other types such as thermocouple, oad cells, humidity aye and electric motor drive input and feedback signals. In addition, discrete modus used in combination with analog modules. Furthermore, multiple inputs and guy be involved. To illustrate all of these combinations would require many s This section presents six examples, four of which have multiple inputs representative of analog PLC operations. These examples are Example 22-1 Analog in/discrete out Example 22-2 BCD in/discrete out Example 22~3 Analog in/analog or BCD out Example 22-4 BCD in/BCD or analog out Example 22-5 Two analog in/two analog, out Example 22-6 Two BCD in/two analog out ‘The example given in figure 22-7 was analog in and discrete out. The figure’s va further illustrate the example. The problem is to have one output go on when a c level, 0.5 ampere, is reached, and another output on when the amperage is between and 1.1 amperes. To accomplish this, use the input values with comparison functions. (1 comparison functions are covered in chapter 12.) For the first output, use a GE function, Since the second condition has two limits needs two comparison functions—in this case, greater than and less than. Figure 22- illustrates how to program the PLC to accomplish the required comparisons and ener appropriate outputs. EXAMPLE 22-2: BCD IN AND DISCRETE OUT A problem similar to example 22-1 is illustrated in figure 22-11. The input is a B thumbwheel that counts up to 9999. If the input is 3750 or above, output 6 is to go on. the input is between 6200 and 8542, output 7 is to go on. Assume that the input data is ceived in register IRO006 in the CPU. As stated previously, the CPU works in bina fore, you must first convert the IRO006 value to binary. Register HROO4S will converted value, Thereafter, the comparison functions are the same as in example 22- Figure 22-11 shows the PLC programming for this BCD comparison problem.Data from abe Input Module Noosa Pulses) E0006 — On for Amps 2 0.5 INoo3a oy pee On for Amps = 0.8 INoo33 ae Qn for Amps = 1.1 GEON1 GEONI2 Onoranes : earl Between oe 0.8 and 1.1 a ay ‘Converted Input Data from Thumbwheel via Input Module Fi é at Noosa t— 10006 BCD to Binary HR0045 10033 4 On i Count 5 9750 1Noos3 a On if Count 5 6200 INooss = et (On if Count 5 8542 GE0111 GEO112 On if Count is tH Between 6200 and 8542M6 ANALOG PLC OPERATION Ear Binary Volts Equivalent 1024 | | [/ cru 10V 1024) : Input 4 5 i M 4 Conversion Input} Ll Value fo Needed U t BCD 1 Binary/BCD 9999 eI t ov 0 Value A Data Flow Diagram 0 Data from Input Module INoo16 Dvo0o11 1 oP Divide by 5 i 1ROO17 Enables - or 3 may have to be pulsed Destination va OR0024 INOO16 E02 t— /}—|_ or0024 Binary to BCD B PLC Program [en Og0008) | FIGURE 22-12 Example 22-3: Analog In/Analog or BCD Out EXAMPLE 22-3: ANALOG INAND ANALOG OR BCD OUT For this example an analog signal of 0 to 10 volts comes in through a converter to an it module, The signal is to be scaled to 1/5 of its value by the CPU and then sent out tro an output module. The output is also to be sent to a BCD output display. Figure 22 illustrates how the PLC can be programmed intemally to accomplish one or both o¥ conditions. The analog signal goes out directly. The output signal to the analog outp first converted to BCD and then sent to the BCD display. EXAMPLE 22-4: BCD IN AND BCD OR ANALOG OUT In this example a BCD input, 0 to 9999, is received by an input module, which places} value received into register IROOO4. A fixed value of 180 is to be subtracted from the ¥ received, and the result is to be sent out to a 0-9999 BCD output display. Additional ‘output value is to be placed in a 0- to 20-milliampere analog output module. Figure 22 illustrates the PLC programming necessary to accomplish the transfer of the original it value, less 180. Appropriate BCD-to-binary conversions are included in the progr™™PLC ANALOG OUTPUT APPLICATION EXAMPLES 41 1024 ——— 20mA, 9999 Input Sin (Output Device via Conversion it Needed BCDIBIN 4 BCD pe ~ 180 Input Value — e@-ca0t BCD 9999 BoD Display A Data Flow Diagram BcD Data 1N0037 pico ‘080172 [4 See o 10004 Dest HR0207 BCD to Binary INoos7 $B0173, ; OP.1 HRO27 op.2 118 Dest. ‘OR0067 Value Minus 118 iN0O37 BDOI74 ‘OR0067 0G0007 Binary to BCD B PLC Program FIGURE 22-13 Example 22-4: BCD In/BCD or Analog Out Examples 22-5 and 22-6 both have multiple inputs and outputs. They could have had more than two inputs and a single output, but in this illustration both examples use two inputs and two outputs. The example shown in figure 22-14 has two analog inputs whose values are manip- ulated in the CPU. For illustration, the values are both added and subtracted. The sum is output to one analog output, and the difference is sent out to another. ‘The internal programming to perform the mathematical manipulations is also shown.ANALOG PLC OPERATION a A— 1R0101 B 1R0102 Ae rar leaesl cPU Analog 4 —+ Sensor dha 1Ro101 Converter 4 ete -wvLe ‘Add pee BY Linput Fike “ Subtract —+| Sensor 4 Converter % 1 -svL& A Data Flow Diagram Input Data aD0207 INOO51 pe, L4 10101 HOH ‘Adds Values of 1R0101 and iRot02 IRo102 orot07 |__| eum INoos1 yee [1 -—— ro101 HOH Subtracts Value of 1R0102 from 1Ro102 Value of 1RO101 B PLC Program ORo108 |__| Difference FIGURE 22-14 Example 22-5: Two Analog In, Add and Subtract, Two Analog Out EXAMPLE Example 22-6, shown in figure 22-15, is similar to example 22-5. It has two BCD in 22-6:TWO —_and two numerical analog outputs. You could also mix and match analog and BCD in BCD IN, and outputs with little difficulty. In example 22-6, the first output is the product of MATHE- inputs and the second output is the sum, minus 155. The product is read on readout X MATICAL the sum, minus 155, on readout Y. Again, the PLC program to perform the math funct MANIPULA- __ is shown. TION, TWO ANALOG OUT—+[ 10006 —+[in0007 Output M CPU M ° Readout ud 0 ofetbtibes 1R0006 —* Binary A’ ’ 10007 —* Binary B a f (Ax B) —+ Output A+B=c qt Hentoll +B= ° eadout (eee c-155=p u 6 DB0031 LYE (Pus rocos HY ‘Converted eae BCD to Binary DB0032 INOO72 ae | + iro007 HOH converted HROO82 BCD to Binary MP0033 INOO72 . Ly} roe LOH (axa) HROO82 Allin Binary HROO91 800034 + /— HR0091 KY (Ax B) Converted ati! Outputted to X in BCD ‘AD0035 HRO081 KO A+B=C non Allin Binary HRO092 ‘$B0036 HA HEH Roo KY c-155=D a Alin Binary HR0093 800037 H-—_ { }+} DComverted in pe Outputted to Y in BCD 349,350 ANALOG PLC OPERATION EXERCISES -bit) output similar to those shown 1, Draw an output graph for a32-step (5-bit) ou epee is 100 percent. The input configuration isthe same as figure 22-3. Determine yy me M4 step-indicated voltage (range) for: rN ee of fi ee cs ri 185 Percent, Pic 2. If the input graph curve in figure 22-7 were nonlinear, as shown in figure 29 output Be linear ith respect to dial setting? Explain. 16, yeu 3 Refer to figure 22-4, Trace 61.5 volts through the system, 4, Refer to figure 22-5. Suppose that multiplication were by 0.5 instead of 2 would be 51, Trace 51 through the system. §. Refer to figure 22-6, Trace for inputs of22 VAC for valve A and 31 VAC fr valve For exercises 6 through 8, assume © Input volts 0 10 80. © Input module volts 0 t0 5. © Binary has'128 steps. For exercises 6 through 8, include the following in each answer. © Draw a block flow diagram as in figure 227. © Draw the required PLC ladder program as in the chapter example. © Trace a number, if requested, through the computational system simila carried out in figure 22-7. 6. The linear input of 0 to 80 volts is to be displayed on a 9999-maximum-count The digit ung (0 theta BCD output 32 volts through the system. 7, Repeat exercise 6, changing the output toa linear Oto 21 vols, Trace 53 vot inpt tu system, 8. Two linear input signals of 0 to 4 volts are to be multiplied and the result put out on iy Output of O to 150 volts. Trace the numbers if the inputs are 2.85 and 3.45 volt 9. Two BCD numbers are to be inputted. The first is to be divided by the second, The resus shown on an output BCD display. Trace the computation if A is 458 and B is 35, 10. There are three BCD inputs, A, B, and C. The output is to be A plus B minus Con a BCD ds ‘Trace the computation for an A, B, and C of 425, 283, and 63, respectively. 11. There are two BCD inputs. IFA exceeds 355, output F is to go on; if B exceeds 187, utp Gi £0 on; if both exceed their listed numbers, output H is to go on; otherwise, no outputs ae toed 1 NR ENS aR FIGURE 22-16 120 Diagram for Exercise 2‘OUTLINE 1 Introduction 9 23-2 PID Principles 9 23-3 Typical Continuous Process Control Curves PID Modules 9 23-5 PID Tuning 23-6 Typical PID Functions the end of this chapter, you will be able to iefly describe proportional, integral, and derivative control. Describe how the above three control systems are combined for effective process cuntrol. List and sketch the response curves of ineffective process control. ‘Show and sketch the response curve of a good process control system. Explain the characteristics of a PID module. “Describe PID Tuning function and methods. Generally describe the PID function.23-1 23-2 “Pid CONTROL OF CONTINUOUS PROCESSES. a INTRODUCTION All of the processes shown in the book 80 far have not been of the continugy, : is, these process examples either are on oF off or travel linearly between ra pt continua process, wernean one in which the Out is continuous oy POM «chemical proces, arefning process fr gatline, oF a paper machine yin sO output of paper onto rolls, Process control for these continuous Processes Rate accomplished fast enough by PLC on-off contro. Furthermore, analog py also not effective or fast enough. The control system Most often used jn cont processes is PID (proportional-integral-derivative) control PID contol can plished by mechanical, pneumatic, hydraulic, or electronic control syst PLCs Many medium-size PLCs and all large PLCs have PID contro! functo, able to accomplish process control effectively. In tis chapter, we discuss the by of PID control, We then explain the effectiveness of PID control by using response curves and show some typical loop control and PID functions Loop and PID control are designations used interchangeably by differ turers, Actually, some loop controls are not strictly the PID type. However, assy the same. 8, Which Sic Princip YPIeal proc Mt manuf ume they 4 PID PRINCIPLES PID (proportional-integral-derivative) is an effective control system for continun processes that performs two control tasks. First, PID control keeps the output ar level even though varying process parameters may tend to cause the output to vary fn the desired set point, Second, PID promptly and accurately changes the process le from one set point level to another set point level, For background, we briefly disc the characteristics of each of the PID control components: proportional, integral, derivative, Proportional control, also known as ratio control, is a control system that cored the deviation of a process from the set level back toward the set point. The correction Proportional to the amount of error. For example, suppose that we have a set point 975 cubic feet per minute (CFM) in an airflow system. If the flow rises to 580 CFM, corrective signal is applied to the controlling air vent damper to reduce the flow back 575 CEM. If the flow somehow rises to $85 CFM, twice the deviation from setpoint corrective signal of four times the magnitude would be applied for correction. T larger corrective signal theoretically gives a faster return to S75 CFM. In actuality! fast correction is not precise, You return to a new set point at the end of the correct for example, 576.5 CFM, not 575 CFM. Proportional control does not usually work fectively by itself, resulting in an offset error. To return the flow to the original set point, integral control, also known as control, is added. Note that integral control cannot be used by itself. Remember, ¥! Proportional control only, We had an output error from our original set point. We endedProportional block Integral ‘Summing Controller block amplifier © “output Derivative block (5 CFM, not 375 CFM. Integral control senses the product ofthe error, 1.5 CFM, ithe time the error has persisted. A signal is developed from this product. Integral then uses this product signal to return to the original setpoint. An integral con- smal can be used in conjunction with the proportional corrective signal. In the con- lr the added integral signal reduces the error signal that caused the output deviation e set point. Therefore, over a period of time, the process deviation from our orig- CFM is reduced to minimum. However, this correction takes a relatively long lustration of a system using PID control is shown in figure 23-2. In this system, precise oil output flow rate, The flow rate is controlled by pump motor speed. pe speed is controlled through a control panel consisting ofa cores the actual flow. If they differ for some reason, a corrective signal change is sent of controller. The motor controller changes motor speed accordingly by chang- ltage applied to the motor. For example, if the output oil flow rate goes below the a signal to speed up the motor is sent. The controller then uses PID control to correction promptly and accurately to return to the set point flow. If the dial is to a new setting, the function of the PID system is to reach the new set point as ekly and accurately as possible.34 23-3 INUOUS PROCESSES PID CONTROL OF CONTI! Sra | Control pane! 1 Control devices 1 t i Control diagrams Motor contro} Electronic controller OP amps Rectifier Programmable controller Solid-state devices ' f Incoming 1 power Poe FIGURE 23-2 General Control System Diagram—Hydraulic Pump TYPICAL CONTINUOUS PROCESS CONTROL CURVES To illustrate some of the possible system response curves for process control systems, will use the electromechanical system shown in figure 23-3. By response curves it example, We mean output position versus time. The curves to be shown are for v= types of control, including PID. Figure 23-3 shows a control system with a feedback loop, which can be PID. dial is set to a position in degrees, and the output device is to take the position s# °° dial. The output is to follow quickly and accurately any change from one cialElectrical Power to Rotate: Output Device Electrical Signal \ sen se in Indicating Output Indicating Input Position Position “another. Furthermore, the output position should not drift out of position over a period of "time, Another factor is that the indicator can have two different weights, depending on the pplication. These are 5 pounds and 20 pounds. Obviously, the output drive will tend to ‘operate more slowly for 20 pounds than for 5 pounds, unless a proper PID control is set up "to compensate for weight differences. For illustration we very quickly turn the dial from 0 degrees to 108 degrees at 3 sec- ~ onds after time base 0. Ideally, the position indicator should instantaneously reach 108 degrees, as shown in figure 23-4. Obviously, this does not happen in actual practice. | __ Figure 23-5 shows five possible curves for different types of control, Figure 23-Sais 4n idealized movement but takes 4 seconds. Figure 23-5b undershoots or overshoots the "mark, Figure 23-Sc shows cyclic response and reaches an angular point near the set posi- tion but oscillates for a few seconds before reaching the proper position. Figure 23-5d " shows damped response and reaches the new position exponentially but takes a long time. " Figure 23-Se reaches the new position but continually oscillates about the final setting. "None of these curves shows an acceptable control characteristic for accurate and prompt By comparison, PID control obtains the most ideal response possible—not perfect, Dut the best we can do. A curve for this control is showp in figure 23-6. (Tat Cc ee Elapsed Time in SecondsDesired Final Position —+ | - ~~ Postion | Initial ial Position sec. Time —> n come equipped with PID modules, used to process data obtained by feedback ‘Most such modules contain their own microprocessor. Since the algorithms fo generate the PID functions are rather complex, the PID microprocessor relieves having to carry out these time-consuming operations. understand the PID module, refer to figure 23-7. The PLC sends a set-point signal y module. The module is made up of three elements: the proportional, integral, ive circuits. The proportional circuit creates an output signal proportional to the Process Input Being Transducer Controlled Measured Value Proportional Correcting Circuit ee iraagral Error Circuit ‘Signal Derivative Circuit23-5 23-6 PID CONTROL OF CONTINUOUS PROCESSES difference between the measurement taken and the set point entered in the p integral circuit produces an output proportional to the length and amount of time the, signal is present. The derivative circuit creates an output signal proportional 0 the ray error signal. aot fea He generates an output signal from the process beng conta feeds the measured value to the PID module, The difference between the set goin from the PLC and the measured value coming from the input transducer isthe yrs Some sort of correcting device, such as a motor control, valve control, or amplifey ia error signal and uses it to control the correction sent to the process being contre, PID TUNING PID tuning refers to the adjustment of the systems modes. Such tuning must by online, that is, while the process is running. Three tuning methods are involved: open, transient response, ultimate cycle, and frequency response. Essentially, the of the control system are estimated and then the three modes are “fine-tuned of which is to reach the optimum control settings. In the open-loop method, control parameters are determined while the system is manual mode of operation. Fist, the process control loop is opened so that no feedback oa Second, the tuning is begun by operating the process on manual control until the me variable stays constant. Third, a step change in the manipulating device is introduced response of the controlled variable is recorded. Fourth, the controlled variable responds manipulated variable change. As a result, parameters used in the tuning equations are mined, Finally, the resulting parameters will include the process lag and process rate. With the ultimate cycle method, a loop is adjusted until steady oscillations Two measurements obtained from this method are known as the minimum controller and the period of the oscillation. The former is the amount of gain required to caus system to oscillate. The latter, also known as the ultimate period, represents the peti these oscillations. In the frequency response method, Bode plots are used to obtain a straight approximation of the magnitude and phase angle response to frequency. The Bode p obtained by opening the loop and providing a variable frequency disturbance o controlling variable, TYPICAL PID FUNCTIONS ire 23-8 is a representative loop control PID function. This function controls a PID tion that is not shown. A loop identifying number is specified in the block. Updat ti the block is also specified. This time in seconds (i.., 15 seconds) is the interval com the update procedure frequency. Coil P goes on when the function is enabled. Coll ‘on when the update time is reached for one scan, A typical PID function of intermediate complexity is shown in figure 23-9 PLCs combine the previously shown loop control function with the PID function example is for the PID function alone.— N pr KA AT MANUAL/ auto. |inpur [==--] A oureur Es] um no. fenron [===]PID CONTROL OF CONTINUOUS PROCESSES Manual Reference Number Type — T Calculate Output Loop Table End A To activate manual/automatic cascade modes, itis to close the appropri for at least one scan. necessary iate contact The calculate input must be closed to cause the k FIGURE 23-10 PID PLC Function loop to operate. OP Code +} @- 94 Auto eee an a| Sot Point | Casi Process Variable ea ee Coll Status = Alarm Low Alarm Limit High Alarm Limit Low Deviation High Deviation OP Code 94. Defines the itor (17) function as being alogg controller (LC) function, ‘Set Point. This value is the desired value oF the process variable. This can be a Constant value or be stored in a specilied: + Holding Register (HR) * Input Register (iA) + Output Register (OR) + Input Group (iG) * Output Group (0a) Process Variable. This is the measured value of the independent variable invoived in the process under contro, This can be stored in a specified: + Holding Register (HR) + Input Register (IR) * Output Register (OR) * Input Group ((G) * Output Group (0G) Output. This is the output of the process controller used to drive the final correcting device to ‘adjust the process under Ccontrol. This can be stored in. a specified: + Holding Register (HR) + Output Register (OR) * Output Group (0G) Loop Table End. This specifies the last holding register in the table containing data required for loop control operations. This may not be less than HROO32 or greater than the highest holding register available in the given processor. This table is always 32 holding registers lord (In figure 21-10, HRXXXX-31 is the beginning of the table and HAXXXX is the end ofthe table)Quantity Proportional Term (232,767) Value/Remarks Intearal Term (+:32,767) Derivative Term (=:32,767) SPq— Sot Point This Sample PVn— Process Variable This Sample Time Counter — Elapsed Sample Time ‘SPn= 1 — Sol Point Previous Samplo PVn= 1 — Process Varlable Previous Sample En=1— Error Previous Sample Bias (0 to Maximum Output) RESERVED. FUTURE — DO NOT USE lc} jololelajejalejelojo Configuration Input Word (Sea Below) RESERVED. RESERVED, FUTURE — 00 NOT USE Integral Sum (32,767) FUTURE — DO NOT USE _ Eq— Error This Sample Ta — Derivative Time (0 — $27.67 Min) Ti= Integral Time (0 — 327.67 Min.) Tz — Sample Time (0— 3276.7 Sec) Ke= Proportional Gain (.01 — 99.99) Innet Loop Pointer (Loop Table End) Outer Loop Pointer (Loop Table End) ‘Alarm Deadband (0 — Max PV) Batch Unit Preload (0— Max Output) Batch Unit Hi Limit (0 — Max Output) Neg. Slew Limit (Max — A Output/Sampie) Pos. Slew Limit (Max + A Output/Sample) Low Deviation Alarm Limit (0— Max PV) High Deviation Alarm Limit (O— Max PV) Low Alarm Limit (0 — Max PV) High Alarm Limit (0— Max PV) Output Status Word lolefelelelefefe|c}elelele|elele|cjo} (=Caleulated by Processor U=User-Entered Configuration input Word (HAXXXX-20) 16151413 12 11 108) aa Ss ee unt Definition Status_| Number Definition Status 1 = Proportional Mode Selected 9 1 = Derivative on PV Selected 0 = Derivative on Error Selected 1 = Integral Mode Selected 10 1 = Batch Unit Selected 1 = Derivative Mode Selected 1" RESERVED FOR CONTROLLER USE 1 = Deviation Alarms Selected 12 (0 = Anti Reset Windup When. Slew Limit Ocours 1 = Error Deadband Selected 13 RESERVED FOR FUTURE USE ‘1 = Error Squared Control Selected 14 RESERVED FOR FUTURE USE 1 = Slew Limiting Selected & RESERVED FOR FUTURE USE 1 = Reverse Action Selected |__| 0= Direct Action Selected 16 RESERVED FOR FUTURE USEFunctional Descriptions and Values D block identification number Fall in which the process variable is stored OUTPUT: the register in which the output algorithm is stored SETPT: the register in which the set point is stored ERROR‘ the register in which the value of ERROR = (SETPT — ypiy DB: the register for the deadband value is CHGMX: the register in which the maximum allowable Fate of cha the register in which proportional gain is stored cer in which the integral term is stored the register in which the proportional term is stored ‘Most of the functions in the block are written as a percentage of the set Point, values may be programmed as constants or moved in from other registers. DB, dea effectively the tolerance you can live with forthe process (in percent). The last three fy block inputs are adjusted for tuning the system in operation for optimum process ‘Contr ‘A more complex PID function is shown in figure 2310. A worksheet (instruct for this function is shown in figure 23-11. The PID function is designated Loop con| this format. This function, when properly enabled by input contacts, performs PID ay and control, The enabled function compares the set point with the process variable, differ by more than a preset value, an appropriate correcting signal is sent from the fu output to the controlling device’s controller, The input parameters are put into 32 cof tive registers ending with the register specified as “loop table end,” The number of reg required will vary by model and manufacturer. On the worksheet, not all register functions are used for all processes. Key resist 13 through 16 for system tuning, 27 and 28 for set point and allowable variance, and 29. for time sets. Register 20 is for “configuration word,” as specified in detail in the love INGE is stoy EXERCISES 1. The chapter does not discuss on-off discrete control. Would on-off control be effective ‘control of rapid, continuous processes? Why or why not? 2. A paper mill process is run by proportional control. The process involves paper being wut 4 roll ata speed of 62 feet/second (fUsec). At 64 flsec, the correction signal to the drive ~1.75 volts. What would be the correction signal for 66 fUsec, 68 fusec, and 60 fusec? 3. How does proportional—integral process control improve control compared to proportion only? 4. How does proportional-integral—derivative control improve process control compared portional-integral control? 5. Discuss the curves of figures 23-4, 23-5, and 23-6 in terms of a heater control control system is used to maintain a constant temperature of 105°F for an oil tank 6 What is meant by tuning a PID system? 7. Obtain manuals from a number of PLC manufacturers, Determine the similarities and i in their PID functions,