1730972894083 plc logic controller __.pdf

Date: Saturday, January 29, 2022
Control & Automation
Science Caravan Academy 2022. © All rights reserved. File: Industrial Control & Automation _ 1
Engineering Training for
Automation and Drives
Industrial Control
& Automation
‫واﻟﺗدرﯾب‬ ‫ﻟﻼﺳﺗﺷﺎرات‬ ‫اﻟﻌﻠوم‬ ‫ﻗﺎﻓﻠﺔ‬ ‫أﻛﺎدﯾﻣﯾﺔ‬
Science Caravan Academy
Eng. Rami El-Naqa
Amman - 2022
Part 2: Programmable Logic Control

Hardware components used in Programmable Automation

Siemens SIMATIC S7 Family

Performance Grades of SIMATIC PLCs
ET-200SP

Siemens SIMATIC S7-1200 PLC

SIMATIC S7-1200: Installation & Mounting Positions

SIMATIC S7-1200 Modules

Siemens SIMATIC S7-1200 PLC

Siemens SIMATIC S7-1200 PLC – CPU1212C

TIA Portal V16.0/V17.0 Software Package

TIA Portal Basic & Professional

Portal View & Project View

Project View

Menu Bar & Toolbar

Project Tree: 1st level

Project Tree: 2nd level

Connection to PLC

Manual PC Ethernet Settings
192.168.0.100

Online Access

Memory Concept & Memory Reset

Add New Device: Hardware Configuration

Inserting / Deleting H.W. Modules

Compiling and Downloading

Downloading to CPU
1
2
3
4

Addresses & Tags
%IB1
%I1.5
%M25.4
%Q0.2
%M26.4
{Size}

Register Size, Data Type & Address

Process Image (Input / Output Tables)

PLC Tags

Symbolic & Absolute Addressing

Watch Tables

Define Tag while programming

Program Structure

Types of Program Blocks (Functions/ Subroutines)

Cyclic Program Execution

Network / Rung / Segment

Program Editing

Block Call

Compile, Save & Download

Monitor program while running

Physical & Logical status

Normally Open & Normally Closed Signals

Data Types

Elementary Data Types
U- Unsigned
S-Short
D-Double
L-Long

Data Blocks

Binary Logic Operations: AND, OR

Binary Logic Operations: XOR

Binary Logic Operations: ASSIGNEMENT, SET, RESET, NOT

Binary Logic Operations: FLIP FLOP
LAD
FBD

Binary Logic Operations: Edge Trigger

Binary Logic Operations: RLO Edge Evaluation

Binary Logic Operations: SET/ RESET Bit Field (Range of Bits)

Binary Logic Operations: JUMP/ LABEL

Digital Operations: DATA Types

Digital Operations: TON – Timer On-Delay

Digital Operations: Counters

Digital Operations: Comparison

Digital Operations: MOVE

Digital Operations: MOVE Block

Digital Operations: IN_RANGE/ OUT_RANGE

Digital Operations: Date & Time of Day

Exercises
Exercise No: 1.a
Objective: Associate Input(s) to Output(s)
Language Elements: Contacts & Coils
Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED

Exercises
Exercise No: 1.a: Single Output
Start_PB: I0.0 Green_LED: Q0.0
-----| |----------------------------------------------------------( )
Exercise No: 1.b: Multiple Outputs … Lamp Test on Control Panel
-----| |----------------------------------------------------------( )
Red_LED: Q0.1
----------------------------( )
Blue_LED: Q0.2
----------------------------( )

Exercises
Exercise No: 2.a
Objective: Latch, Self Hold or Sealing Circuit
Language Elements: Contacts & Coils
Equipment:
Q0.1: Red LED
Q0.2: Blue LED

Exercises
Exercise No: 2.a: Latch
-----| |------------------------------------------------------------( )
Green_LED: Q0.0
-----| |--------------------
Exercise No: 2.b: Unlatch using physically NO Stop PB
Start_PB: I0.0 Stop_PB: I0.1 Green_LED: Q0.0
-----| |--------------------------| / |-----------------------------( )
Green_LED: Q0.0
-----| |--------------------
Exercise No: 2.c: Unlatch using physically NC Stop PB
Start_PB: I0.0 Stop_PB: I0.1 Green_LED: Q0.0
-----| |--------------------------| |-----------------------------( )
Green_LED: Q0.0
-----| |--------------------

Exercises
Exercise No: 3.a
Objective: On Delay Timer
Language Elements: Contacts, Coils & Box (Block)
Equipment:
Q0.1: Red LED
Q0.2: Blue LED

Exercises
Exercise No: 3.a: Delayed Start: TON without latch
-----| |------------------------------------------------------------( )
Exercise No: 3.b: Delayed Start: TON with latch using Memory bit
M0.0 Green_LED: Q0.0
-----| |------------------------------------------------------------( )
Start_PB: I0.0 Stop_PB: I0.1 M0.0
-----| |--------------------------| |-----------------------------( )
M0.0
-----| |-------------------- T1
T1

Exercises
Exercise No: 3.c: Run Load for Certain Time: TON with latch using Memory bit
Start_PB: I0.0 M0.0 Green_LED: Q0.0
-----| |--------------------------| / |--------------------------------( )
Green_LED: Q0.0
-----| |--------------------
Green_LED: Q0.0 M0.0
-----| |------------------------------------------------------------( )
T1

Exercises
Exercise No: 3.d: Run Load for Certain Time: TON with latch using Memory
bit (reduced circuit)
M0.0
--( )
-----| |--------------------------| / |--------------------------------( )
Green_LED: Q0.0
-----| |--------------------
T1

Exercises
Exercise No: 4.a
Objective: Time Sequencer of (n) loads ..e.g. 3 loads
Language Elements: Contacts, Coils & Box (Block)
Equipment:
Q0.1: Red LED
Q0.2: Blue LED

Exercises
Exercise No: 4.a: Time Sequencer using separate timer for each load
M0.0
------( )
-----| |--------------------------| / |--------------------------------( )
Green_LED: Q0.0
-----| |--------------------
M0.1
------( )
M0.0 M0.1 Red_LED: Q0.1
-----| |--------------------------| / |--------------------------------( )
Red_LED: Q0.1
-----| |--------------------
M0.2
------( )
M0.1 M0.2 Blue_LED: Q0.2
-----| |--------------------------| / |--------------------------------( )
Blue_LED: Q0.2
-----| |--------------------
T1
T2
T3

Exercises
Exercise No: 4.b: Time Sequencer using one timer for all load
M0.1
------( )
Start_PB: I0.0 M0.1 M0.0
-----| |--------------------------| / |--------------------------------( )
M0.0
-----| |--------------------
T1 T1 Q0.0
-----| > |-----------------------| < |--------------------------------( )
0 3
T1 T1 Q0.1
-----| > |-----------------------| < |--------------------------------( )
3 5
T1 T1 Q0.2
-----| > |-----------------------| < |--------------------------------( )
5 9
T1

Exercises
Exercise No: 5
Objective: Traffic Light Control
Language Elements: Contacts, Coils
& Box (Block)
Equipment:
Q0.1: Red LED
Q0.2: Blue LED

Exercises No. 5a: Traffic Light: Time Sequencer using one timer
M0.1
------( )
Start_PB: I0.0 M0.1 M0.0
-----| |-----------------| / |-------------------------( )
M0.0
-----| |----
T1 T1 RED: Q0.0
-----| > |--------------| < |-------------------------( )
0 2
T1 T1 AMBER: Q0.1
-----| > |--------------| < |-------------------------( )
2 3
-----| > |--------------| < |----
6 7
T1 T1 GREEN: Q0.2
-----| > |--------------| < |-------------------------( )
3 6
T1

Exercises No. 5b: Traffic Light: Flashing Signal

Exercises No. 5b: Traffic Light: Flashing Signal
M0.1
------( )
Start Signal M0.1 M0.0
-----| |-----------------| / |-------------------------( )
M0.0
-----| |----
T1 T1 RED: Q0.0
-----| > |--------------| < |-------------------------( )
0 2
T1 T1 AMBER: Q0.1
-----| > |--------------| < |-------------------------( )
2 3
-----| > |--------------| < |----
9 10
T1 T1 GREEN: Q0.2
-----| > |--------------| < |------------------------( )
3 6 Flasher
-----| > |--------------| < |----| |------
6 9
T1

Ladder Logic Elements

Transforming a Circuit Diagram into Ladder Logic Diagram

Exercise No. 6 : Car Park
Car Park
Full
Indicator
Lamp
Q0.2
Entrance
Actuator
Q0.0
Exit
Sensor 2
I0.3
Exit
Actuator
Q0.1
Exit
Sensor 1
I0.2
Entrance
Sensor 1
I0.0
Car
Counter
Entrance
Exit
Entrance
Sensor 2
I0.1

Exercise No. 7 : Mixing Tank
(1) Process Diagram

(2) Sequence Of Operation

(3) Tag List, Symbol Table, Variable Table

(4) PLC Program

(5) Download Program to PLC
(6) Switch PLC to RUN mode
(7) Monitor the Program while it is running
(8) Monitor the Tags in the watch table
(9) Modify program and repeat above steps

Analog Value Processing in PLC
 A/D Convertor
 D/A Convertor
 Resolution
 Conversion rate
0 - 10VDC
4 - 20mA
0 - 27648
1
2

Common Ranges of Analog Signals

Analog Sensor Connection to CPU Integrated Analog Inputs

Analog Values
HMI Operator
CPU
Analog Input
Sensor/
Transmitter
Process
Physical
Quantity
Display/
Control
Scaling
Converted
Digital
Quantity
Electrical
Analog
Quantity
Physical
Quantity
Engineering
Units
Display/
Control
Scaled
Value
0-27648
0-10VDC
4-20mA
-Temperature
-Pressure
-Level
-Flow
-Speed

Analog Values

Analog Value Scaling

Analog Value Processing
Analog Input Handling:
Analog Output Handling:

Analog Value Processing
 Use Conversion Operations
 Norm_X
 Scale_X

Exercise No.1 : Analog Signal Processing
Objective: Analog Input Reading & Scaling to 50m
Language Elements: Conversion Operations
Equipment: -PLC: S7-1200, CPU 1212C AC/DC/RLY
-Input: IW64: Potentiometer
24VDC
To
10VDC
230VAC
To
24VDC
Power
Supply
0 – 10VDC

HMI Selection

HMI: Wizard

HMI: Manual Configuration of IP

HMI: Manual Networking to PLC

HMI: Manual Connection to PLC

HMI Root Screen

HMI Objects

HMI Major Functions
• Display processes with a straight forward screen structures
• Communicate with processes
• Output alarms
• Archive process values and alarms
• Document process values and alarms as reports
• Manage process and machine parameters in recipes
• User management & administration

Exercise : HMI
1. Use the HMI Buttons to Start/ Stop a load with events.
2. Use the HMI I/O field to display a reading from the PLC.
3. Use the HMI I/O field to enter a setpoint to the PLC.
4. Use the HMI Bar to display an analog value reading.
5. Animation .. Color change
6. Create Several Screens and navigations.
7. Work with Template to create a header.
8. Display Trend.
9. Work with Alarms and Messages.
10.Users & Passwords

Design of the KTP700 Basic for PROFINET
① Connection for power supply
② USB interface for USB
mass storage device or USB mouse
③ PROFINET interface
④ Recesses for a mounting clip
⑤ Display/touch screen
⑥ Mounting gasket
⑦ Function keys
⑧ Rating plate
⑨ Connection for functional ground
⑩ Guide for labeling strip

Settings on Touch Panel KTP700 Basic/Start Center

Setting the transfer properties and assigning the IP address

WinCC user interface

Planning the screen structure

Program Structure

Types of Program Blocks (Functions/ Subroutines)

Reusable Functions: Tag Types

Exercise No.1: Reusable Function for Analog Scaling

Exercise No.2: Reusable Function for Alarms

Reusable Functions: Parameter Assignable Block

Reusable Functions: Declaration of Formal Parameters

Reusable Functions: Editing Parameter Assignable Block

Reusable Functions: Calling Parameter Assignable Block

Reusable Functions: Using FB and Multiple Instances DB

Reusable Functions: Block Interface for FB

VSD

VSD ‫اﺳﺗﺎﺗﯾﻛﻲ‬ ‫ﺳرﻋﺔ‬ ‫ر‬ِ‫ﯾ‬‫ﻣﻐ‬
1. VSD: Variable Speed Drive
2. VFD: Variable Frequency Drive
3. VVVF: Variable Voltage Variable Frequency Drive
4. ASD: Adjustable Speed Drive
5. VSI/CSI: Voltage/Current Source Inverter
6. Rectifier/ Convertor / Inverter/ PMW
5. Frequency Converter

VSD: Functions & Applications
Variable frequency drives are used in diverse industrial applications:
for example:
• Pumping, ventilating and compressing
• Positioning, processing, moving and machining
These functions are used in many industry sectors:
• Food & beverage industry
• Automotive industry
• Heating, ventilating and air conditioning (HVAC)
• Water and wastewater industry
• Paper industry
• Oil & gas
• Chemical industry
• Logistics
• Wind turbines, hydroelectric power
and photovoltaic systems
• Marine

VSD: Types
Types of Industrial Motor Drive Systems:
• Low Voltage Converters: from 0.12 kW up to 6840 kW
• Medium Voltage Converters: from 150 kW up to 85 MW
• Servo Converters: from 0.1 kW up to 6840 kW
• DC Converters: from 6.3 kW up to 30 MW

VFD: Definition
What is a frequency converter or variable frequency drive?
Frequency converters or also named variable frequency drives are electronic
devices that convert a (more or less) fixed frequency and voltage into a
variable frequency and voltage. This device allows electric motors to be
operated with a variable speed.
What are frequency converters / variable frequency drives used
for?
Today, frequency converters are used practically everywhere to operate
single-phase and three-phase electric motors with a variable speed. And not
just in industrial environments, but in everyday life. Starting from very low
power ratings to control washing machine drums up to medium power ratings
for pumps used in municipal water supplies.

VFD: Electrical Drive Chain

VFD: Building Blocks

VFD: Electrical Signal Manipulation

VFD: Power Circuit

VFD: Power Circuit
ELCB/
RCCB
Contactor

VFD: Additional External Components
A line reactor supports
the overvoltage
protection, smooths the
harmonics in the line
supply and buffers
commutation dips.
With a line filter,
the inverter can
achieve a
higher radio
interference
class.
The sine-wave filter at the inverter
output limits the voltage rate-of-rise
and the peak voltages at the motor
winding. The maximum permissible
length of motor feeder cables is
increased to 300 m.

VFD: Principle of Operation
Principle of Operation of Variable Frequency
Drive (VFD):
Speed of an induction motor is
proportional to the frequency
of the supply ( N = 120 f/p ) and by varying
the frequency we can obtain the variable
speed.
But, when the frequency is decreased, the
torque increases and thereby motor draw a
heavy current. This in turn increases the flux
in the motor. Also the magnetic field may
reach to the saturation level, if the voltage of
the supply is not reduced.
Therefore, both the voltage and frequency
have to be changed in a constant ratio in order
to maintain the flux within the working range.
Since the torque is proportional to the
magnetic flux, the torque remains constant
throughout the operating range of v/f.
The figure shows the torque and speed variation of an induction motor for voltage and frequency control.
Voltage and Frequency are changed at a constant ratio up to the base speed.
Thus the flux and thereby torque remain almost constant up to the base speed.
This region is called as a constant torque region.
Since the supply voltage can be changed up to the rated value only and hence the speed at rated voltage is the base
speed. If the frequency increased, beyond the base speed, the magnetic flux in the motor decreases and thereby torque
begins falling off. This is called flux weakening or constant power region.
This type of control is called constant v/f control method used in variable frequency drives (VFDs).
It is the most popular type of control in industries.

VFD: Speed vs. Frequency relation
N = Speed; Ns: Stator Speed (Electro-Magnetic),
Nr: Rotor Speed (Mechanical)
F = Frequency
P = Number of pole
VFD

VFD: Components
Operator
Panel
Control
Module
Power
Module

VFD: Motor Name Plate

VFD: Drive Control Sources
1.Operator Panel
2.Terminals
3.Communication

VFD: Drive Control Sources: Operator Panel
START
STOP
INCREASE
DECREASE
LCD DISPLAY

VFD: Drive Control Sources: Terminals: Push Button/Switch & Pot.

VFD: Drive Control Sources: Terminals: PLC & HMI
HMI

VFD: Drive Connection to PLC through I/O’s

VFD: Parametrizing & Commissioning
Commissioning and Parameters Programming in VFD
• Commissioning is needed for the proper functioning of VFD.
• Necessary (Quick Commissioning Parameters) from Motor Nameplate:
• Motor Power Rating
• Motor rated Voltage,
• Motor rated Current,
• Motor rated Speed,
• Motor rated Frequency,
• Motor Power Factor.
• Advanced commissioning: Give the details of all the digital and analog inputs
and outputs:
• Digital inputs: Start command and Speed Selection command
• Digital Outputs: Status of Drive Running and Drive in Fault etc.
• Analog Inputs: Speed setpoint Input 1 and/or Speed Input 2
• Analog Outputs: Current and Frequency of Motor

VFD: PLC Program
NETWORK 1: Checking whether the VFD is ready to start. This signal will come when all
the conditions are healthy as well as safety and power feedbacks are active.
NETWORK 2: When start button is pressed, VFD Drive_DO bit will be set, if
Ready_to_Start and No Error will be there.
NETWORK 3: When stop button is pressed it will reset the Drive_DO bit.

VFD: PLC Program
NETWORK 4: This logic is required for safety: as soon as Drive_DO bit is set and if for any reason the
VFD will not operate, then after predefined wait time, it will reset the Drive_DO bit and generate Error.
NETWORK 5: If the VFD is taking more current and gives overload error, then it will reset Drive_DO bit
and generate Error.
NETWORK 6: if you select speed input as a remote then it will activate Speed Selection bit resulting
Speed_DO present.

VFD: HMI Program
Normal State: Running State:
Error State:

VFD: Drive Connection to PLC through Communication

VFD: PLC Control of Multiple Drives

VFD: Practical Exercise
Model: AS2 - 15
In: Single Phase 220VAC, 50/60Hz
Out: Three Phase 220VAC, 1.5KW/2Hp
Rated Output Current: 8Amp
Model: AS2 - 15
Digital Inputs: 6
Digital Output: 1
Analog Inputs: 2
Analog Output: 1

VFD: Terminal Wiring Diagram

VFD: Power Connections

VFD: Control Connections: Analog Inputs

VFD: Control Connections: Digital Inputs/Outputs

VFD: Hardware Settings

VFD: Operator Panel

VFD: Example: Change Acceleration Time

VFD: Example: Change Maximum Frequency Limit

VFD: Example: Keypad/Display Control of Drive
Example 01: - Use the Up/Down Arrows to adjust speed
- Use the FWD/REV buttons to run the motor
- Use the STOP button to stop the motor
Parameters:
CD 10 = 0
CD 12 = 0

VFD: Example: Analog Pot. Control of Drive
Example 02 - Use the FWD/REV buttons to run the motor
- Use the STOP button to stop the motor
Parameters:
CD 10 = 1
CD 12 = 0

VFD: Example: Terminal Control of Drive
03 :

VFD: Example: PLC Control of Drive
04 :
AQ0 DQ0.0 DQ0.1
S7-1200 PLC

Encoder
Tacho Generator
Linear Encoder
Rotary Encoder
Analog device that
produces a voltage
proportional to speed.
Digital device that produces electrical pulses
based on mechanical rotational motion
Resolver

Encoder Function

Encoder Definition

Encoder Types
• Incremental Encoder
– Provides identical electronic pulses at each division of
shaft rotation.
– Used for position or speed/velocity measurements.
• Absolute Encoder
– Provides a unique electronic piece of information at
each division of shaft position.
– Used for position measurement.
• Resolver
– Provides sine wave and cosine wave to provide both
velocity and position feedback.
• Tacho generator
– Provides analog voltage proportional to speed.

Encoder Classification

Encoder Types

Linear Encoder

Incremental Encoder

Absolute Encoder

Encoder Technologies
Sensing Technologies:
 Magnetic (Magneto-resistive)
 Tough and simple
 Heavy Duty enough for Mills
 No Optics (no glass breakage)
 Limited to 2048 PPR
 Optical
 Higher Resolution (up to 10,000 PPR)
 Better signal quality
 Shafted and Hollow shaft designs

Rotary Encoder
Absolute Encoder
Incremental Encoder

Incremental Encoder
 Incremental encoders are usually supplied with two channels
(A & B) that are offset by 90 degrees.
 If complements are included (A, B ), the signal is
“quadrature”, providing speed of rotation AND direction of
rotation.
A
A
Encoder
B
B

Incremental Encoder
 Signal A leads B in one direction, B leads A in the reverse
direction
 Complement pulses, A and B are used to provide electrical
noise immunity for the signal as it travels through the cable.
A
A
Encoder
B
B

Incremental Encoder
B
A
Z
Marker
Although a “Marker” pulse is standard on some encoders, it is
additional feature (charge) on many encoders. Ask for one, if
you need one.
A marker pulse (reference, index or Z pulse) is a once per
revolution pulse that occurs at precisely the same
mechanical point in a 360º revolution of the encoder shaft.

Incremental Encoder

Incremental Encoder Output

Incremental Encoder Signals

Incremental Encoder Interface

Absolute Encoder

Incremental vs. Absolute Encoder

PLC & Encoder -> HSC
For S7-1200 PLC V4.x why to use HSC:
Hardware consideration:
The default digital input filter setting is: 6.4 ms,
which limits the maximum counting rate to: 78 Hz.
You can change the filter settings to count higher or lower frequencies
depending on the design of your system.
Software Consideration:
In normal scan cycle PLC updates digital inputs once per cycle based on
a variable program speed; which is usually greater than 1 ms.
 The basic counter instructions are limited to counting events that
occur at a rate slower than the scan cycle of the S7-1200 CPU.
 The High-speed counter (HSC) function provides the ability to count
pulses occurring at a higher rate than the PLC scan cycle.

PLC & Encoder -> Max. Frequency

PLC & Encoder –> Configuring the HSC
1. Configure HSC in
device configuration;
CPU properties
2. Configure Digital
Input Filters

PLC & Encoder -> Programming the HSC

High
Speed
Counter
(HSC)
Data
Type
Default
Address
HSC 1 DInt ID 1000
HSC 2 DInt ID 1004
HSC 3 DInt ID 1008
HSC 4 DInt ID 1012
HSC 5 DInt ID 1016
HSC 6 DInt ID 1020

PID Control
An everyday example is the cruise control of a car
Today the PID concept is used universally in applications
requiring accurate and optimized automatic control.
 . A Proportional – Integral – Derivative controller
 . PID controller
 . Three-Term controller
is a feedback control
loop mechanism that is widely used
in industrial control systems and a
variety of other applications requiring
continuously modulated control.

PID Control: Historical Development
Early PID theory was developed by
observing the actions of helmsmen in
keeping a vessel on course in the face of
varying influences such as wind and sea
state.
Pneumatic PID (three-term)
controller. The magnitudes of
the three terms (P, I and D) are
adjusted by the dials at the top.

Electronic Industrial PID Controllers (Process Controllers)

Software (PLC) based Industrial PID Controllers

PID Control
The PID control combines Proportional, Integral and Derivative actions to
create a control signal, where each action has a strong characteristic that
helps to control the output:
 The Proportional action makes the system respond to the present
error and enables immediate action in the face of variations or
disturbances;
 The Integral action eliminates errors such as jumps or steps in a
permanent and long term regime;
 The Derivative action anticipates the behavior of the process.

From Manual Control to Automatic PID Control

PID Control:
In theory, a controller can be used to control any process that has:
1. a measurable output (PV),
2. a known ideal value for that output (SP),
3. and an input to the process (MV) that will affect the relevant PV.
Controllers are used in industry to regulate:
temperature, pressure, force, feed rate, flow rate, level chemical
composition (component concentrations), weight, position, speed,
and practically every other variable for which a measurement exists.

PID Control: Principle

PID Control: Principle
Block diagram of a PID controller.
r (t ) is the desired process value or setpoint (SP),
e (t ) is the calculated error value,
y (t ) is the measured/actual process value (PV),
u (t ) is the calculated control variable (CV) or manipulated variable (MV).

PID Control: Mathematical
Another form:

PID Control
How Does PID Works?
A PID controller continuously calculates an error value = e(t);
which is the difference between adesired setpoint SP= r(t) and a
measured process variable PV = y(t): r(t) – y(t) , and applies a
correction based on proportional, integral, and derivative terms.
The controller attempts to minimize the error over time by
adjustment of a control variable u(t), such that the control
element is adjusted to a new value determined by a weighted
sum of the control terms.

PID Control: P Term
 Term P is proportional to the current value of the SP−PV; error e(t):
Kp . e(t) Kp : Proportional Gain
• The control output will be proportional to error value.
• Using proportional control alone will result in an error between the
setpoint and the actual process value called (Steady State error) because
it requires a non-zero error to generate the proportional response.
• If there is no error, or small error there is no corrective response (Dead
Band).
• Tuning theory and industrial practice indicate that the proportional term
should contribute the bulk of the output change.

PID Control: I Term

PID Control: D Term
 Term D is a best estimate of the future trend of the SP − PV error,
based on its current rate of change:
• It is sometimes called "anticipatory (predictive) control", as it is
effectively seeking to reduce the effect of the SP − PV error by
exerting a control influence generated by the rate of error change.
• The more rapid the change, the greater the controlling or damping
effect.
• Derivative action is seldom used in practice because of its
variable impact on system stability in real-world applications.

PID Control: Effect of Kp
Response of PV to step change of SP vs time, for three values of Kp (Ki and Kd held constant)
Oscillation: Unstable
Damped: Slow response,
less responsive or less
sensitive controller
Overshoot: Fast response

PID Control: Effect of Ki
Response of PV to step change of SP vs time, for three values of Ki (Kp and Kd held constant)
Faster
Response
Eliminates
the
residual
steady-
state error

PID Control: Effect of Kd
Response of PV to step change of SP vs time, for three values of Kd (Kp and Ki held constant)
Improves
settling
time and
stability

PID Control:
Setpoint
------
Actual Value
------

PID Control:
Effects of increasing a parameter independently
Parameter Rise time Overshoot Settling time
Steady-state
error
Stability
Kp Decrease Increase Small change Decrease Degrade
Ki Decrease Increase Increase Eliminate Degrade
Kd Minor change Decrease Decrease
No effect in
theory
Improve
if Kd small

PID Control:
Selective use of control terms:
Although a PID controller has three control terms, some
applications need only one or two terms to provide
appropriate control.
This is achieved by setting the unused parameters to zero
and is called a PI, PD, P or I controller in the absence of
the other control actions.
PI controllers are fairly common in applications where
derivative action would be sensitive to measurement
noise, but the integral term is often needed for the system
to reach its target value.

PID Control: Tuning
Control Loop tuning
 Tuning a control loop is the adjustment of its control
parameters (proportional band/gain, integral gain/reset,
derivative gain/rate) to the optimum values for the desired
control response.
• Stability (no unbounded oscillation) is a basic requirement
• Zero Steady State Error
• Fast Response to changes and disturbances
 PID tuning is a difficult problem, even though there are
only three parameters.
 There are several methods for tuning a PID loop.

PID Control: Tuning Methods
Choosing a tuning method
Method Advantages Disadvantages
Manual tuning No mathematics required; online. Requires experienced personnel.
Ziegler–Nichols Proven method; online.
Process upset, some trial-and-
error, very aggressive tuning.
Tyreus Luyben Proven method; online.
Process upset, some trial-and-
error, very aggressive tuning.
Software tools
Consistent tuning; online or offline - can employ
computer-automated control system design
(CAutoD) techniques; may include valve and
sensor analysis; allows simulation before
downloading; can support non-steady-state
(NSS) tuning.
Some cost or training involved.
Cohen–Coon Good process models.
Some mathematics; offline; only
good for first-order processes.
Åström-Hägglund
Can be used for auto tuning; amplitude is
minimum so this method has lowest process
upset
The process itself is inherently
oscillatory.

PID Control: Manual Tuning

PID Control: Ziegler-Nichols Method

PID Control: S7-1200 PLC & Auto Tuning Method (1)
1. Call PID_Compact controller in a cyclic
interrupt by adding new Organization block
2. Select cyclic interrupt OB35
3. Set Cycle Time to 50 ms
4. From Technology Instructions
Drag & Drop the PID_Compact
5. Assign a name for the
instance data block
and apply it with OK.
6. Expand the view of the
block by clicking the
up arrow.
Interconnect this block as
shown in figure:
setpoint, actual value,
manipulated variable
and Reset input for
deactivating the controller

7. Open the configuration mask of the controller and set the parameters

8. Save, compile & download the project to the PLC
9. Activate the monitoring function
10. Start the PID commissioning & tuning by clicking the icon

11. Press Start for measurement & after that Start for Pre-tuning

12. After successful tuning parameters obtained can be saved to project

PID Control: Exercise: Training Kit
PID Simulation Kit
The lamp (Q0.0) is to be used to control the temperature.
The controller is be started up using the Auto-tune functionality.

PID Control: Exercise: Create TAGs
Create Tags as in Table

PID Control: Exercise: Set PID Block Parameters as in Figure
• Select controller type "Temperature“
• Select "°C" as the unit
• Set the setpoint as constant e.g. "60“ or use Tag.
• Select "Input_PER" as the input and "temperature_sensor" (IW64) as the tag.
• Select "Output_PWM" as the output and "heating (bulb)" (O0.0) as the tag.

PID Control: Exercise

PID Control: Exercise: Prepare data to show on HMI
Parameterize the "Setpoint" input with the tag "Setpoint" (MD100)
Parameterize the "ScaledInput" output with the tag "Scaled_Input" (MD104).

PID Control: Exercise: HMI – I/O Field
Displaying actual value and setpoint on the HMI as I/O Fields

PID Control: Exercise: HMI - Trend
Displaying actual value and setpoint on the HMI as TREND

Introduction to SCADA System
SCADA stands for:
Supervisory Control And Data Acquisition.
 A SCADA system is an automation system which is used to gather
data from sensors and instruments located locally or at remote sites
and to transmit and display this data at a central site for control or
monitoring purposes.
 The collected data is usually viewed on one or more SCADA Host
computers located at the central or master site.
 A layer of equipment between the remote sensors/ instruments and the
central computer is used to digitize then packetize the sensor signals
so that they can be digitally transmitted via an industrial
communications protocol over long distances to the central site;
such devices include: RTU, PLC, IEDs, and Smart devices.
 These devices employ standard industrial data communication
protocols such as: Modbus, IEC, and DNP3.0.

Introduction to SCADA System: Major Components
There are Four essential composing parts of a SCADA system:
 Master System/ Central System/ Supervisory System: Human
Machine Interface (HMI)
 Communication Infrastructures
 Remote Terminal Units (RTUs) or Programmable Logic
Controllers (PLCs)
 Field Devices: Sensors/ Instruments and Actuators

Introduction to SCADA System: Typical SCADA HMI

Introduction to SCADA System: Architecture: Local/ Wired

Introduction to SCADA System: Architecture: Remote/ Wireless

Introduction to SCADA System: Major Functions
Major Functions of SCADA:
A SCADA system performs four major functions:
 Data acquisition
 Networked data communication
 Data presentation
 Control

Introduction to SCADA System: SCADA vs. HMI
HMI
SCADA HMI
• Small Scale
• Close to Process
• Usually stand alone
• Usually no Data Base
connectivity

SIMATIC WinCC (TIA Portal) Runtime Software
SIMATIC WinCC Runtime Advanced
(TIA Portal)
- PC-based HMI solution for
- single-user systems
- directly at the machine.
- The range of functions of WinCC
Runtime Advanced includes:
- Visualizing (graphics)
- Alarming (messaging)
- Trending (graphs & curves)
- Archiving (logging & history)
- Recipes
- Reporting
- Administration
What is WinCC RT advanced?
- It can be expanded to suit requirements and costs by using optional packages.

SIMATIC WinCC Advanced: Practical
1.Create a new project in the TIA
Portal.
2.In the Project View you double-
click "Add new device" and select
the S7 controller. Click the "OK"
button to add the controller.
3.Through the Hardware Catalog
you add more components to the
Device View (like power supply, IO
modules).
4.Click the PROFINET interface of
the S7 controller and assign a
unique IP address and the
associated subnet mask under
"Properties > General > Ethernet
Addresses".
5.Double-click "Add new device"
and select WinCC Runtime
Advanced from the PC System
sub folder.

6. In the Device View in the Hardware
Catalog you select the "IE General"
communication module and double-click to
add this to the PC station.

7. Click the "IE General" interface
just added. Under "Properties >
General > PROFINET interface [X1]
> Ethernet addresses" you enter the
IP address and subnet mask of the
Runtime station.
8. Switch to the Network View and
enable "Connections" to create an
HMI connection. Connect the
interfaces of the S7 controller and
the Runtime station by drag-and-
drop.

9. Click the HMI connection.
Under "Properties > General >
Access point" you enter the name
you are using in the PG/PC
interface of the Runtime station.
In this example we use the preset
name "S7ONLINE".
10. Open the PG/PC interface
on the Runtime station through
"Start > Control panel > Set
PG/PC interface".
11. Complete the configuration similar to
normal HMI and download the project to the
S7 controller and the PC Runtime station.

1730972894083 plc logic controller __.pdf

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