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s Preface, Contents SIMATIC PID Temperature Control Manual Introduction 1 Continuous Temperature Controller FB 58 "TCONT_CP" 2 Controller Tuning in FB 58 "TCONT_CP" 3 Temperature Step Controller FB59 "TCONT_S" 4 Getting Started 5 Examples for the Temperature Controllers 6 Appendix A Abbreviations and Acronyms B Index Edition 12/2003 A5E00125039-02 Safety Guidelines This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts: ! Danger ! Warning ! Caution indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken. indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken. indicates that minor personal injury can result if proper precautions are not taken. Caution indicates that property damage can result if proper precautions are not taken. Notice draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation. Qualified Personnel Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and systems in accordance with established safety practices and standards. Correct Usage Note the following: ! Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended. Trademarks SIMATIC®, SIMATIC HMI® and SIMATIC NET® are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners. Copyright © Siemens AG 2001-2003 All rights reserved Disclaimer of Liability The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. Siemens AG Bereich Automation and Drives Geschaeftsgebiet Industrial Automation Systems Postfach 4848, D- 90327 Nuernberg ©Siemens AG 2001-2003 Technical data subject to change. Siemens Aktiengesellschaft A5E00125039-02 Preface Purpose of the Manual This manual supports you when you work with the temperature controller block from the Standard Library > PID Control. It will familiarize you with the functions of the controller blocks and, in particular, with tuning the controller and working with the user interface in which you set the parameters for the blocks. There is an online help system for both the blocks and the user interface that supports you when setting the parameters of the blocks. This manual is intended for qualified personnel involved in programming, configuration, commissioning, and servicing of programmable controllers. We recommend that you spend some time studying the "Examples of Temperature Controllers" in Chapter 6. These examples will help you to understand the application of temperature controllers quickly and simply. Basic Knowledge Required To understand this manual, you should be familiar with automation engineering and know the basics of closed-loop control. You should also be familiar with using computers or similar tools (for example programming devices) with the Windows 95/98/NT/2000 or Me operating system. Since PID Temperature Control is used in conjunction with the STEP 7 basic software, you should be familiar with working with the basic software as described in the "Programming with STEP 7 V5.1" manual. Scope of the Manual This manual applies to the temperature controllers of the Standard Library > PID Control of the STEP 7 programming software, Version V5.1 Service Pack 3 and higher. PID Temperature Control A5E00125039-02 iii Preface STEP 7 Documentation Packages This manual is part of the STEP 7 Basic Information documentation package. Manuals Purpose STEP 7 Basic Information with Basic information for technical • Working with STEP 7 V5.1 personnel describing the methods of implementing Getting Started control tasks with STEP 7 and • Programming with STEP 7 S7-300/400. V5.1 • Configuring Hardware and Communication Connections, STEP 7 V5.1 • From S5 to S7, Convertor Manual STEP 7 Reference with • Ladder Logic (LAD) / Function Block Diagram (FBD) / Statement List (STL) for S7-300/400 manuals • Standard and System Functions for S7-300/400 Elect. manual • PID Temperature Control Order Number 6ES7810-4CA05-8BA0 Provides reference information 6ES7810-4CA05-8BR0 and describes the programming languages LAD, FBD, and STL and standard and system functions extending the scope of STEP 7 basic information. This manual describes the Part of the STEP 7 temperature controllers of the software package Standard Library > PID Control. Online Help Systems Purpose Order Number Help on STEP 7 Basic information on programming and configuring hardware with STEP 7 in the form of an online help. Part of the STEP 7 software package Reference help systems for Context-sensitive reference information Part of the STEP 7 software package • LAD/FBD/STL • SFBs/SFCs • Organization blocks • PID Temperature Control Further Closed-Loop Control Products in SIMATIC S7 • SIMATIC S7 User Manuals: Standard PID Control, Modular PID Control, PID Self-Tuner, FM355/455 PID Control • Jürgen Müller, "Regeln mit SIMATIC - Praxisbuch für Regelungen mit SIMATIC S7 und PCS7" published by MCI Publicis Verlag ISBN 3-89578-147-9 (German only) iv PID Temperature Control A5E00125039-02 Preface Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. You will find your contact person at: http://www.ad.siemens.de/partner Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7 automation system. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200. Internet: http://www.sitrain.com SIMATIC Documentation on the Internet Documentation is available free of charge on the Internet at: http://www.ad.siemens.de/support Here, you can use the Knowledge Manager to locate the documentation you require quickly. If you have questions or suggestions regarding the documentation, a "Documentation" conference is available in the Internet Forum. PID Temperature Control A5E00125039-02 v Preface A&D Technical Support Worldwide, available 24 hours a day: Nuernberg Beijing Peking Johnson City Worldwide (Nuernberg) Technical Support 24 hours a day, 365 days a year Phone: +49 (180) 5050-222 Fax: +49 (180) 5050-223 E-Mail: adsupport@ siemens.com GMT: +1:00 Europe / Africa (Nuernberg) United States (Johnson City) Asia / Australia (Beijing) Authorization Technical Support and Authorization Technical Support and Authorization Local time: Mon.-Fri. 8:00 to 5:00 PM Local time: Mon.-Fri. 8:00 to 5:00 PM Local time: Mon.-Fri. 8:00 to 5:00 PM Phone: +49 (180) 5050-222 Phone: +1 (423) 262 2522 Phone: +86 10 64 75 75 75 Fax: +49 (180) 5050-223 Fax: +1 (423) 262 2289 Fax: +86 10 64 74 74 74 E-Mail: adsupport@ siemens.com E-Mail: simatic.hotline@ E-Mail: +1:00 GMT: GMT: sea.siemens.com -5:00 adsupport.asia@ siemens.com GMT: +8:00 The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English. vi PID Temperature Control A5E00125039-02 Preface Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: http://www.siemens.com/automation/service&support where you will find the following: • The newsletter, which constantly provides you with up-to-date information on your products. • The right documents via our Search function in Service & Support. • A forum, where users and experts from all over the world exchange their experiences. • Your local representative for Automation & Drives. • Information on field service, repairs, spare parts and more under "Services". PID Temperature Control A5E00125039-02 vii Preface viii PID Temperature Control A5E00125039-02 Contents 1 Introduction 1.1 1.2 2 3 3.8 3.9 3.10 3.11 3.12 3.13 5 3-1 Introduction........................................................................................................3-1 Process Types ..................................................................................................3-2 Area of Application ............................................................................................3-3 The Phases of Controller Tuning ......................................................................3-4 Preparations ......................................................................................................3-6 Starting Tuning (Phase 1 -> 2)..........................................................................3-8 Searching for the Point of Inflection (Phase 2) and Calculating the Control Parameters (Phase 3, 4, 5) ................................3-10 Checking the Process Type (Phase 7) ...........................................................3-10 Result of the Tuning ........................................................................................3-11 Tuning Stopped by the Operator.....................................................................3-11 Error Situations and Remedies .......................................................................3-12 Manual Fine Tuning in Control Mode..............................................................3-16 Parallel Tuning of Control Channels ...............................................................3-19 Temperature Step Controller FB59 "TCONT_S" 4.1 4.1.1 4.1.2 4.2 4.3 4.3.1 4.3.2 4.3.3 2-1 Controller Section..............................................................................................2-1 Forming the Error ..............................................................................................2-1 PID Algorithm ....................................................................................................2-4 Calculating the Manipulated Variable ...............................................................2-6 Saving and Reloading Controller Parameters...................................................2-9 Pulse Generator PULSEGEN (PULSE_ON)...................................................2-11 Block Diagram .................................................................................................2-13 Including the Function Block in the User Program..........................................2-14 Calling the Controller Block.............................................................................2-14 Call without Pulse Generator (continuous controller) .....................................2-15 Call with Pulse Generator (pulse controller) ...................................................2-15 Initialization......................................................................................................2-18 Controller Tuning in FB 58 "TCONT_CP" 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 FB 58 "TCONT_CP"..........................................................................................1-3 FB59 "TCONT_S" .............................................................................................1-4 Continuous Temperature Controller FB 58 "TCONT_CP" 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.3 2.4 2.4.1 2.4.2 2.4.3 2.4.4 1-1 4-1 Controller Section..............................................................................................4-1 Forming the Error ..............................................................................................4-1 PI Step Controller Algorithm..............................................................................4-4 Block Diagram ...................................................................................................4-5 Including the Function Block in the User Program............................................4-6 Calling the Controller Block...............................................................................4-6 Sampling Time ..................................................................................................4-7 Initialization........................................................................................................4-7 Getting Started PID Temperature Control A5E00125039-02 5-1 ix Contents 6 Examples for the Temperature Controllers 6.1 6.2 6.3 6.4 6.5 A B Introduction........................................................................................................6-1 Example with FB 58 "TCONT_CP" (pulse control) ...........................................6-2 Samples for FB 58 "TCONT_CP" with Short Pulse Generator Sampling Time......................................................6-6 Sample for FB 58 "TCONT_CP" (Continuous) .................................................6-7 Sample for FB 59 "TCONT_S" (Step Controller) ............................................6-11 Appendix A.1 A.2 A.3 A.3.1 A.3.2 A.4 6-1 A-1 Technical Specifications................................................................................... A-1 Execution Times............................................................................................... A-1 DB Assignment ................................................................................................ A-2 Instance DB for FB 58 "TCONT_CP"............................................................... A-2 Instance DB for FB 59 "TCONT_S" ............................................................... A-13 List of Possible Messages during Tuning ...................................................... A-17 Abbreviations and Acronyms B-1 Index x PID Temperature Control A5E00125039-02