Do-more Technical Training Instruction Set (Analog/Process)

Instruction Set THE BASICS ▫1▫181 instructions CContact (14) CCoil/Bit Output (11) AAnalog/Process (13) DDate/Time/Calendar (7) EEthernet (5) HHardware/Device (9) HHigh Speed/CTRIO (19) MMath (5) MMisc/Data Manipulation (23) PProgram Control (20) PProgram-Looping (8) PProtocol-Custom/ASCII (7) PProtocol-Standard (10) SString (14) TTimer/Counter/Drum (16)

Box Instruction Corner

Instruction Set (Analog/Process) Analog/Process ▫ALDEV ▫ALHILO ▫ALRATE ▫CLAMP ▫DEADBAND ▫FILTER ▫INTEGRAT ▫PID ▫PIDINIT ▫RAMPSOAK ▫SCALE ▫SLOPE ▫TIMEPROP

Instruction Set (Analog/Process) Utilizes Tinker-Toy™ approach ▫O▫Other things use common PID controls (Alarms, Ramp/Soak profiles, Filters, Clamping, Deadband, etc.) ▫M▫Modular, interchangeable, independent, & run- time configurable UUsing multiple Ramp/Soak profiles for same PID (recipes) ▫E▫Easier to troubleshoot FFilter issue? Deadband too tight? Too wide? Ramp rate in Ramp/Soak too steep? Too slow? RRight-click on instruction & select Trend Instruction

ALDEV “Deviation Alarm” ▫S▫Sets alarm bits if the input deviates from a set point by more than a limit value ▫P▫Parameters: IInput – location of the monitored value SSet Point – data value from which the deviation is compared DDeviation Limit – maximum allowable deviation from the Set Point before an alarm is set PPositive Alarm (optional) – bit that is set ON if Input > Set Point + Deviation Limit NNegative Alarm (optional) – bit that is set ON if Input < Set Point – Deviation Limit

ALHILO “High/Low Alarm” ▫S▫Sets various alarm bits based on values ▫P▫Parameters: IInput – location of the monitored value HHigh-High Limit – data value for high-high alarm HHigh-High Alarm – high-high alarm bit HHigh Limit – data value for high alarm HHigh Alarm – high alarm bit LLow Limit – data value for low alarm LLow Alarm – low alarm bit LLow-Low Limit – data value for low-low alarm LLow-Low Alarm – low-low alarm bit ▫N▫NOTES: AAll alarm pairs (value/bit) are optional AAlarms are inclusive AAlarm values must be consecutive order

ALRATE “Rate of Change Alarm” ▫S▫Sets alarm bits if the input changes at rate faster than a limit value ▫M▫Multiscan instruction (yellow triangle) ▫P▫Parameters: IInput – location of the monitored value SSample Time – the period (ms) between samples of the Input RRate Limit – maximum allowable change of the Input value from one sample time to the next PPositive Alarm (optional) – bit that is set ON if Input value has increased by more than the Rate Limit since last sample time NNegative Alarm (optional) – bit that is set ON if Input value has decreased by more than the Rate Limit since last sample time

CLAMP “Limit Range” ▫C▫Constrains a memory location’s highest/lowest value ▫P▫Parameters: IInput – location of the monitored value HHigh – maximum allowable value for Input LLow – minimum allowable value for Input OOutput – location to stored the clamped value

DEADBAND “Set Outside Deadband” ▫G▫Generates an output value only when the input value differs by the deadband value ▫P▫Parameters: IInput – location of the monitored value DDeadband – minimum change in Input before generating the Output OOutput – location of the new value ▫N▫NOTES: DDeadband value is applied equally above & below

PID “Closed Loop Controller” ▫P▫Proportional, integral & derivative control algorithm ▫M▫Multiscan instruction (yellow triangle) ▫P▫Parameters: PPID Struct LLoop Algorithm: PPosition VVelocity IInitialization Mode: SSet SP equal to PV BBumpless

PID “Closed Loop Controller” ▫P▫Parameters (cont’): SScale to.PV FFrom Raw PV, Raw Min, Raw Max EEng. Min, Eng. Max, Eng. Units CControl Loop FForward, Reverse OOther Options UUse Error-Squared – less responsive but responds faster with a large error EEnable Error Deadband – PV more immune to noise DDisable Bias Freeze – bias keeps changing even if Output go out of range SScale from.Output % SScaled Min (0%) SScaled Max (100%) TTo Scaled

PID “Closed Loop Controller” ▫Input Leg:  A/M – Automatic / Manual ▫Structure (PID)   : User PID Structure

Instruction Set (Analog/Process) PIDINIT “Set PID Tuning Constants” ▫Initializes the runtime parameters of a PID loop ▫Parameters:  PID Struct – which PID  Sample Time – milliseconds  Gain (P)  RESET (I)  Rate (D) – optional

Instruction Set (Analog/Process) RAMPSOAK “Ramp Soak Profile” ▫Moves a set point through sets of values at prescribed time intervals ▫Multiscan instruction (yellow triangle) ▫Parameters:  Ramp/Soak Struct  Set Point  Step Preset – which step to begin with  Action / Value / Time Period / Rate  INIT TO Value  SOAK for Constant (or Variable) Time Period  RAMP to Value ▫Over Constant (or Variable) Time Period ▫At Rate (per Second, Minute or Hour)  ADJUST BY Value ▫Over Constant (or Variable) Time Period ▫At Rate (per Second, Minute or Hour) ▫Editing buttons:  OK, Cancel, Insert, Remove, Move Up, Move Down

Instruction Set (Analog/Process) RAMPSOAK “Ramp Soak Profile” ▫I▫Input legs: EE/R – Enable/Reset JJOG – (edge triggered) moves to next step PPAU – freezes execution ▫S▫Structure (Ramp/Soak) <<RampSoakName>: User Ramp/Soak Structure ▫N▫NOTES: CCan have up to 50 rows

SCALE “Scale Value” ▫Converts value to engineering units ▫Parameters:  Input – location to be scaled  In Min – minimum value of Input  In Max – maximum value of Input  Out Min – minimum value of Output  Out Max – maximum value of Output  Output – location of scaled value

Instruction Set (Analog/Process)

Process Control Utilities A.PID Overview B.PID View C.Auto-tune Process D.PID Process Simulator

A.PID Overview ▫P▫PID ref ▫M▫Mode ▫R▫Ramp/Soak ▫C▫Colors GGGGreen – Auto NNNNormal – Manual YYYYellow – Auto-tune RRRRed – Alarm ▫P▫PV vertical graph ▫S▫SP marker ▫S▫SP, PV, Bias & Output values ▫O▫Output horizontal graph ▫A▫Alarm markers Instruction Set (Analog/Process)

B.PID View ▫C▫Configuration, tuning & monitoring ▫3▫3 panes DData form PPV / SP trend OOutput / Bias trend Instruction Set (Analog/Process)

C.Auto-tune Process ▫S▫Sets optimal values for P, I & D to get ideal response from control system ▫M▫Manipulates the PID’s output then measures the rate of change, overshoot and response of the process variable UUses Ziegler-Nichols methodology ▫P▫Press <Auto-Tune…> button  ▫N▫NOTE: 1 st make sure process is relatively stable ▫S▫Steps: 1.Choose which variables to tune 2.Choose tuning algorithm 3.Decide what to do with newly-tuned PID 4.Do something with new tuning constants

Instruction Set (Analog/Process) C.Auto-tune Process (cont’) 1.Choose which variables are to be Auto-Tuned (Control Type) 2.Choose which type of tuning algorithm to be used (Tuning Algorithm) a.Closed Loop – cycles Output from 0% to 100% & back as PV crosses SP (3 times) i.Choose Deadband around this crossing if necessary Press <Start Tuning> button… Auto-tune happens…

Instruction Set (Analog/Process) C.Auto-tune Process 2.Choose which type of tuning algorithm to be used (Tuning Algorithm) b.Open Loop – Output is bumped & response is measured by the change in PV i.Set Sample Time to 25% of loop’s sample time ii.Set Minimum PV Change iii.Set Output Bump size Press <Start Tuning>… Auto-tune happens…

Instruction Set (Analog/Process) C.Auto-tune Process (cont’) 3.Decide what to do with the newly-tuned PID  Return Control to the Ladder Program  Override Loop Mode as Auto  Override Loop Mode as Manual  Recent Tuning History

Instruction Set (Analog/Process) C.Auto-tune Process (cont’) 4.Do something with your newly calculated PID constants CCopy to Clipboard AAdd to PIDINIT Instruction RRecent Tuning History

Instruction Set (Analog/Process) D.PID Process Simulator ▫Do-more Designer has a Virtual PLC (SIM) ▫Sim  Setup PID Process Simulator