BEGIN SETUP
TROUBLESHOOTING
Initial Setup
The following steps will guide you through the initial steps for setting up a PID loop in the PLC.
For best results, connect to your CPU and have it in Program mode.
Select PLC Select Setup Select PID
initial setup
You should now see the Set PID Table Address window.
Set the Table Start Address. Allow yourself 32 words for each complete PID table.
See table below for valid V-Memory ranges.
Assign the total Number of Loops. This will vary according to the CPU you are using.
See table below for max loops per CPU.
Once these are assigned you should select Update and Exit.
V-Memory Ranges
Minimum Requirements
These next steps will walk you through the setup for items that are required for a basic loop to operate.
We will cover the Setup PID window, tab by tab. Doc tab is optional. Configure tab: see Details for more in-depth information on each.
Algorithm: select the following
Position Sample rate: 0.05 (sec.) Forward acting
Transfer Mode:
Bumpless I or II is OK
Loop Mode:
Unselected
Configure Details
SP/PV Details
Output Details
Gain/Bias: Values can be set now or later. You can also Autotune from the PID window and let the process calculate the values.
Gain (Proportional): Will vary per process. This is a multiplier for the error. Reset (Integral): Will vary per process. This is a time constant that determines the frequency that the error is added to the bias. Freeze Bias: Selected. (good option) see Details for more information Rate (Derivative): Will vary per process. This is a compensation that reacts to sudden change. Derivative gain limiting: Not selected.
Tuning Details
Monitor Rate of Change: No values required Enable PV Deviation: No values required Alarm hysteresis: No value required
Alarm Details
System in Operation
With this view, you can see where the P-I-D values have been set and the process is controlling. In the data view window, you can see the current SP, PV& Output values, along with the rest of the PID table addresses. Make sure you reference page 8-8 of the USER manual for details on what each word of the PID loop table represents.
I
D
Configure Details
Select from the following data sheets for specific details on the area you are looking for.
Algorithm:
Transfer Modes:
Position -vsVelocity
Sample Rate
Forward -vsReverse
BMP I -vsBMP II
Loop Mode:
Common -vsIndepend.
Unipolar -vsBipolar
Independ. of CPU
Configure Tab
SP/PV Details
Output Details
Tuning Details
Alarms Details
SP/PV Details
Select from the following data sheets for specific details on the area you are looking for.
Set Point:
Remote SP Pointer
Process Variable:
Address
Enable Limiting
Address
Square root
Auto Transfer
SP/PV Format:
Common -vsIndepend. Unipolar -vsBipolar 12-bit 15-bit 16-bit
SP/PV Tab
Configure Details
Output Details
Tuning Details
Alarms Details
Output Details
Select from the following data sheets for specific details on the area you are looking for.
Output:
Address
Limits
Auto Transfer
Output Format:
Common -vsIndepend. Unipolar -vsBipolar 12-bit 15-bit 16-bit
Output Tab
Configure Details
SP/PV Details
Tuning Details
Alarms Details
Tuning Details
Select from the following data sheets for specific details on the area you are looking for.
-PProportional Gain
-IIntegral Gain
-DDerivative Gain
Bias
Freeze Bias
Error Sq.
Enable Deadband
Tuning Tab
Configure Details
SP/PV Details
Output Details
Alarms Details
Alarm Details
Select from the following data sheets for specific details on the area you are looking for.
Limit Alarms:
Rate of Change:
Limit Alarms
PV Deviation:
Alarm Hysteresis:
Enable PV Deviation
Alarm Hysteresis
Alarms Tab
Configure Details
SP/PV Details
Output Details
Tuning Details
Algorithm :
Position -vs- Velocity Profile
A high percentage of all applications are Position. This will include your standard heating and cooling loops and most position or level controls. A typical Velocity control would consist of a process variable like a flow totalizer. As the definition explains, it is working off of a rate of change.
Sample Rate:
Typically you will find that a faster sample rate will give you better results in your process. One of the only reasons for extending your sample time is if your PID process is not that critical and your CPU scan is a higher priority.
Forward/Reverse Acting:
You will find that everyone defines this part of the control differently. One systems Forward (direct) acting may be completely opposite from another. So it is very important to read this section to determine how you intend on your process to react. Forward or Direct acting is also known as a heating loop. The greater the error (SP-PV), the greater the output will be. If you manually increase the output, the PV will increase. (forward) Reverse acting is, of course, right the opposite. The greater the error the less the output. If you manually increase the output, the PV will decrease. (reverse)
12-15-16-Bit Resolution:
The resolution you select will be determined by the modules that are supplying the SP/PV and the module receiving the Control Output or the data value range that your process needs to control.
Most of our Analog modules are 12-bit resolution. The exception would be the THM & RTD temperature modules and isolated output modules which are 16-bit.
12-15-16-Bit Resolution:
The resolution you select will be determined by the modules that are supplying the SP/PV and the module receiving the Control Output or the data value range that your process needs to control.
Most of our Analog modules are 12-bit resolution. The exception would be the THM & RTD temperature modules and isolated output modules which are 16-bit.
12-15-16-Bit Resolution:
The resolution you select will be determined by the modules that are supplying the SP/PV and the module receiving the Control Output or the data value range that your process needs to control.
Most of our Analog modules are 12-bit resolution. The exception would be the THM & RTD temperature modules and isolated output modules which are 16-bit.
Limit Alarms:
The limit alarms give you a good way to monitor your system. If the process gets out of control, you can have the PLC let you know. You can have a visual alarm in the PID view as well as using the PID mode word to trigger bits and react upon those in the ladder.
PV Deviation:
The PV deviation alarms are a good way to monitor a stable process. With this you can determine if the process is going out of control.
Alarm Hysteresis:
This works in conjunction with other alarm settings to give you a way to omit nuisance alarms generated by erratic fluctuations in the process.
Proportional Gain:
The Proportional Gain is the most widely used factor of the three values in the algorithm. It is basically a multiplier. Take the error (SP-PV) and multiply it times the P value and that is your output.
Integral Gain:
The Integral Gain is calculated by the error (SP-PV). The value of time in this setting determines how often the current error is added to the Bias.
Derivative Gain:
The Derivative Gain is the least likely to be used of all the gains. This is basically a compensator. It compares the current error (SP-PV) with the previous error and adjust accordingly. The majority of all processes we find can be controlled with a P-I loop to required standards.
Freeze Bias:
Freeze Bias is an excellent option in processes that are slow to respond. In slower applications, the the Output will climb to the max value before the Process Variable reaches the Set Point. During this time the Bias term will continue to increment. Once the PV crosses the SP, the Bias must unwind before the output will start to drop.
Bias:
The Bias term, like the Control Output, is a calculated value that is determined by the algorithm. The Bias begins with the initial Output value and builds from there. On each Manual to Auto transition, you will see the Bias is set equal to the current output. The result of the integral term is then added to the Bias.
Error Squared:
You will find that this is typically not used. It has specific applications where it comes into play and that is only when you will see it used.
Error Deadband:
The Error Deadband is an area that is equally above and below the Set point. While the PV is within this area the error is equal to 0. Once beyond this area the error assumes its current value.
Output Address:
The Output address is determined by the starting PID loop table address. The address is V+05. (V = starting loop address) value is fixed and can not be changed.
Refer to the Loop Table Word Definitions chart on page 8-8 of your USER manual.
Output Limits:
These limits are important in the PID function. The upper limit is mandatory before an actual output will be generated. If there is an output upper limit of zero, as soon as the PID algorithm begins to calculate it thinks it has reached its max limit and shuts off. The values are not read on-the-fly. Meaning that if you try to write to these location it will not acknowledge the data until the next PLC mode change.
Refer to the Loop Table Word Definitions chart on page 8-8 of your USER manual.
Refer to the Loop Table Word Definitions chart on page 8-8 of your USER manual.
Refer to the Loop Table Word Definitions chart on page 8-8 of your USER manual.
Enable Limiting:
This allows you to put a Min. & Max. limit on the set point for applications that require this to remain within a certain spec. Refer to the Loop Table Word Definitions chart on page 8-8 of your USER manual.
Square Root:
You will find that this is typically not used. It has specific applications where it comes into play and that is only when you will see it used.
Terms:
What is PID control?
This will give you a brief overview of the PID operation and some of the commonly used terms.
Basically PID control is the cruise control on your car. It is the method of controlling a process around a specific point with the least amount of fluctuation as possible. A good example of what is not PID control is your household heating and cooling thermostat system. This is on full or completely off, very little precision control
Troubleshooting
Select from the following data sheets of commonly seen trouble areas in PID setup and operation.
Sample Rate
Output Limits
P-I-D Values
Algorithm
Auto Manual
Ladder Code
BCD to BIN
SP Limits
PV Auto X-fer
Ramp Soak
BEGIN SETUP
No Output
Output Limits
In the Output Tab of the PID setup, you will see an Upper and Lower Limit. Verify that the upper limit has been set to a value greater than zero.
An Upper Limit of zero will cause the PID to think it has reached its maximum value before it gets started. In cases where the output value needs to be restricted, it may be best to leave these limits at the output full range (ex. 0-4095 for 12-bit) and scale them in the ladder code.
No Output
P-I-D Values
In the Tuning Tab of the PID setup, you will see the Proportional, Integral & Derivative gains. To get an output from the PID algorithm, you must have a value in at least one of these variables.
You can also set these values from the PID View window. From here you can set and adjust the values while your process is running. This will allow you to manually tune the loop. In many cases you may only need one or two of the variables set to obtain the loop control that your process requires. P-I loops are among the more common process control configurations seen. What combination is best for your application? This can ONLY be determined by running the process to see how it will react.
No Output
PID Algorithm
In the Configure Tab of the PID setup, you have the option to select Position -vs- Velocity algorithm as well as Forward Acting -vsReverse Acting.
90% or more of the applications that we have encountered are Position Algorithm. If your process is designed for one and you have the other selected you can expect to get unpredictable results at best. Forward & Reverse Acting loops are defined differently by different people. Make sure you understand the meaning of each before selecting one for your process. Forward Acting is also referred to as a heating loop where Reverse acting may be referred to as a cooling loop.
No Output
CPU Mode
In the Configure Tab of the PID setup, you will see a selection for Independent of CPU mode. If this is not selected the CPU must be in RUN mode before the PID will function.
Typically this is not selected because you will need the processor in run to adequately filter the inputs from the process into the PID and allow the PID output to effect the process. There are cases where the PID does need to operate even if the rest of the process is not active. This is really the only reason for the Independent mode to be selected.
No Output
Auto, Manual
The mode of the PID loop can cause the Output not to function. You can set the PID mode through the PID View or in the Ladder code. The ladder code ALWAYS takes precedence over any manual changes you try to make.
In Manual mode the Output will hold its last state. This is the only mode which will allow you to actually write a value to the Output Vmemory location. Manual mode is set by V+00 bit 0. Auto mode is the common operating state of the PID loop. In this mode the Output is determined by the PID algorithm. Auto mode is set by V+00 bit 1
No Output
Ladder Code
The ladder code ALWAYS takes precedence over any manual changes you try to make.
Check the ladder code to verify that the PID Output, V+05, is being written to the correct output channels for your process.
No Output
Time-Proportioning Control
If you are using Time-Proportioning Control, also known as on/off control, then you will need to verify that the programming code has been entered into the ladder. You can find an example of this on page 8-52 of your USER manual. (pages may vary depending on manual and manual revision)
No Output
Auto Transfer to output module
In the Output tab of the PID set you will find the option to select the auto transfer to I/O module. If this has been selected you will need to removed any analog module setup in your current code AND CPU memory.
Auto transfer is one of many options for telling the CPU how to write data to the analog output modules. You can only use one method at a time. If you had previously been using the pointer method for setting up analogs in the 05, 06, 205 or 350 CPUs, the pointer setup may remain in the CPU memory even if you remove the setup code from the ladder. You will need to clear the corresponding V-memory ranges before the auto transfer will function. Take into consideration that if you select the auto transfer that you can NOT use these other programming methods for the analog cards and this may restrict the use of the remaining channels.
** Finished **
You have just successfully completed the setup of a DirectLOGIC PID loop. If you experience problems with the loop operation, see the Troubleshooting section of this trainer. If you have further setup or troubleshooting questions, feel free to contact us by e-mail support@automationdirect.com or call our tech support line @ 770-844-4200.
BEGIN SETUP
TROUBLESHOOTING
Valid Ranges:
Number of Loops: