RSLoop Optimizer

Technical Data

RS

Loop Optimizer uses an intuitive software environment to develop a process model of your control loop

automatically. With this process model, you can analyze and simulate current operating conditions with the most advanced PID optimization software available. After gathering information on the dynamics of the process model, RSLoop Optimizer applies advanced analysis tools to diagnose PID loop disturbances. It then suggests optimal proportional, integral, derivative, and filtering values. These new values can be tested before you download them to your process, allowing you to predict the new loop response and compare improvements with the current settings. RSLoop Optimizer provides powerful tools to optimize your PID loops to best fit your process type. For example, your process requirements may require that a loop reach setpoint as fast as possible or that the setpoint never be overshot. Either way, RSLoop Optimizer can optimize your control loop. RSLoop Optimizer includes advanced optimization tools for analyzing and tuning PID control loops in Allen-Bradley MicroLogix, PLC-5, SLC 500, FlexLogix, CompactLogix, ControlLogix, and ProcessLogix controllers. Optimizing your process and reducing process variability with RSLoop Optimizer improves productivity and plant efficiency. RSLoop Optimizer contains all of the functionality of RSTune , with

Features
Includes complete RSTune feature set with additional advanced analysis tools Characterization tools to correct non-linear and pH loops Valve analysis tools to determine stiction, hysteresis, and excessive valve movement Process variable and setpoint filter analysis capability Loop interaction analysis tools

Benefits
Optimize process efficiency Reduce maintenance costs Improve asset utilization Reduce time to optimize your loops from days to minutes

additional advanced analysis tools. For detail on functionality that is common to both products, see the RSTune Technical Data Sheet, Rockwell Automation document number TUNE-TD001C-EN-P, and the RSTune and RSLoop Optimizer Feature Comparison, document number TUNE-CP001A-EN-E.

Advanced Analysis Tools

Identify Potential Process Equipment Deficiencies The Power Spectral Density Analysis plot can help you troubleshoot product quality problems that are caused by process equipment.

This powerful frequency analysis tool graphically shows the relative power in the process signal at various frequencies. Power Spectral Density Analysis identifies the frequencies at which uncontrollable disturbances are present. Given this information, you can examine the process and relate the process dynamics to the frequency at which the disturbances are occurring. Power Spectral Density Analysis has proven to be extremely effective at identifying process equipment problems such as worn or improperly sized pumps and valves.

Reporting RSLoop Optimizer has extensive reporting capabilities to document loop analyses. The default report includes information such as current and new tuning values; loop notes; the PID Tuning Grid; and Process Model, Robustness, and Frequency Response Plots. Reports can also be customized to accommodate your specific needs. Customizable options include recording stiction, hysteresis, linearity, Process Model asymmetry, power spectrum, and auto- and cross-correlation data. Information is added through a simple menu option in RSLoop Optimizer. RSLoop Optimizer creates reports in Microsoft Word.-C

Tools to Identify and Defeat Nonlinearity in Your System

Most control loops experience non-linearity, but some control loops are so non-linear that they cannot be controlled effectively over the entire range. This results in oscillations and sluggishness at various points in the control range. The Characterizer examines the gain over the range of control and identifies the degree of non-linearity. It then guides you through a simple process for deriving the characterization parameters. The Auto Adjust feature
Power Spectral Density Analysis Plot

interpolates between the process data points and adjusts the height of the Characterizer plot.

Plot the Statistical Spread of Your Data The Histogram option in RSLoop Optimizer plots the statistical spread of your data. This feature displays a histogram of error, process variable, or controller output. This plot can identify a non-linear process or show if the loop is tuned properly. The Characterizer produces linear algorithms that you can use in Basic, C, structured text, or X-Y plots. Copy and paste the Characterizer code into any Microsoft Windows application for use as a characterizer on the output of your controller. This helps you get uniform performance across the entire range of your process. RSLoop Optimizer also supports other methods for correcting the effects of non-linearity, including gain scheduling and detuning the controller using the most sensitive running conditions. Improve pH Loop Performance pH loops can be difficult to tune because the process is inherently non-linear. RSLoop Optimizer contains a pH Linearizer that converts titration data into an algorithm that can be applied to the input of the process variable signal. This ensures that the control loop is linear over the entire range of control. This feature can also be applied to oxidation-reduction or distillation column temperature control or any other application where there is a steep slope at
Histogram Showing Controller Output

the desired point of control. The pH Linearizer produces linear algorithms that you can use in Basic, C, structured text, or X-Y plots.

Preventive Maintenance for Valves

RSLoop Optimizer includes valve wear indicators and a hysteresis check to help you maintain and improve performance of valves. Extend Valve Life and Reduce Valve Maintenance The valve wear indicators in RSLoop Optimizer help you predict and prevent valve failure. These indicators allow you to compare valve travel and direction changes to determine wear. They also compare current travel and reversal data with new values that have been optimized by RSLoop Optimizer, and they provide quantitative data indicating the improvements made to the loop. Prevent Valve Stiction Performance Degradation Performance degradation can occur from valve stiction because the controller has to overcompensate for the output. (Valve stiction is resistance to the start of motion and is usually measured as the difference between the driving values required to overcome static friction upscale and downscale.) The Stiction Wizard gives you a quantitative measure of stiction and determines if this resistance is reducing the efficiency of your process.

The RRT gives an indicator of the speed of the control loop. These indicators help you improve performance of a cascading loop by giving you RRT targets when you set up the inner and outer loops. To help you decouple interacting loops, you can adjust the safety factor or lambda value to achieve a specific RRT factor. Cross and Auto Correlation assist in checking loop interaction and hidden cycling on complex loops. Cross Correlation can determine if two loops are interacting with each other and causing control problems. Auto Correlation detects hidden cycling of the control loop. Monitor Multiple Trends and Loops Many processes include other analog values that can be affected by, or can affect, the PID loop. To monitor these values, you can add them to the RSLoop Optimizer faceplate as trend lines. Trend lines are displayed in real time so you can monitor, tune, and analyze multiple loops from the same trend interface. You can add as many additional trend lines as you like. You can also add more than one loop to the faceplate, making decoupling and controlling complex control strategies more convenient. You can then create loops from the trends for modeling, analysis, simulation, and tuning. Another tool that helps you monitor multiple trends and loops is the Loop Summary Table, which records and organizes the results of several loop tests.

Loop Interaction and Analysis Tools

Analyze Cascading, Feedforward, and Interacting Loops Cascading and interacting loops can be difficult to analyze. The Relative Response Time (RRT) and correlation tools in RSLoop Optimizer help improve the performance of these loops.

Loop Summary Table

Optimize Process Efficiency

Select the Best Tuning Values How do you pick the best tuning values for a loop that requires multiple sets of PID and filtering parameters for optimal performance? For example, if you have a temperature control application for an insulated vessel that heats up more quickly than it cools down, you may want separate PID and filtering values for each direction.
PID Tuning Grid showing Relative Response Time (RRT)

To help you pick the best values, the Loop Summary Table records and organizes the results of several loop tests. New and existing values are displayed with information about their effects on the control loop, so you can pick the best options. You can also archive loop history data for each direction. You can add notes to each test in the Loop Summary Table. Stored data include PID values, model parameters, the Relative Response Time (RRT), stability index, dead time values, and the quality of frequency data fit. The Loop Summary Table logs the PID value sets separately and automatically stores associated data, such as the RRT for each entry. Adjust Filters and Evaluate Performance RSLoop Optimizer includes the Robustness Plot, the PV filter analysis, setpoint filter analysis, performance evaluation, time-line analysis, and shrink-swell. These tools are in addition to the Process Model window, the Process Frequency Response Plot, and the Control Loop Simulation Plot, described in the RSTune PV Filter Analysis A common method for improving loop performance is to put a filter in the process variable input. You can use RSLoop Optimizer to experiment with different filters and settings, including First Order, Second Order, Second Order Butterworth, and Moving Average. RSLoop Optimizer will automatically calculate the maximum filter value for the selected filter without degrading your process.
Robustness Plot

Technical Data Sheet.

Process Frequency Response Plot

Quickly Change the Safety Margin The RSLoop Optimizer Dial-In Robustness Plot tool allows you to change the safety margin graphically automatically recalculating and applying the PID values you selected. Simply drag a line on the robustness plot to make adjustments.

Process Variable Filtering

Maintain Tight Control If changes to setpoint result in unstable control, you might consider using a setpoint filter, especially if you need to maintain tight, aggressive control. The Setpoint Filter Analysis optimizes responses to setpoint changes and load upsets by filtering the effect of a setpoint change.

Analyze Control Loop Time Components Use Time Line Analysis to help understand the relationships between the time elements of each component in your control loop. The time elements are charted in an easy-to-read chart that helps you visualize and improve the time relationships. The time elements that RSLoop Optimizer examines are: Sample interval compared to dead time Process variable filter time compared to the controller derivative time Controller derivative time compared to the controller integral time Process variable filter compared to dead time Equivalent dead time (only for second-order process) Relative response time (RRT) Tools for Tuning Re-Boil and Distillation Column Applications The Inverse Response (shrink-swell) helps you tune difficult level loops, such as those found in re-boil and distillation column applications. These loops can be hard to model because the introduction of more liquid briefly lowers the level. RSLoop Optimizer can optimize
Faceplate

and help you analyze these hard-to-tune applications.

Judge Performance and Robustness Trade-offs The Performance Evaluation Analysis shows the trade-offs between performance and robustness at a glance. The performance summary includes: Performance Increase: The probable improvement in reaction to control upsets with the new tuning value. Robustness Increase: The percentage of robustness improvement you can expect with the new tuning parameters. Valve Travel and Reversal Indices Current Relative Response Time: The existing speed of the control loop. New Relative Response Time: The new speed of the control loop.

Additional Features
PID tag browsing on set-up screen Remote connection to a PID loop through RSLinx Gateway Compare statistics between loops using normalization all values are normalized between 0% and 100% Remove the effects of a process variable filter so you can see the signal as if it were not filtered RSLoop Optimizer supports function block tuning in ProcessLogix and ControlLogix controllers

RSLoop Optimizer Integrates with Rockwell Automations Integrated Architecture

Until now, the control systems used for process, discrete, drive, and motion applications were separate. Now, Rockwell Automations Integrated Architecture allows manufacturers to integrate a plant, replacing isolated cells of activity with a single coordinated system that improves the flow of information from the simplest sensor on the plant floor to the companys intranet and extranet. RSLoop Optimizer integrates with this architecture, allowing you to optimize control loops regardless of the Rockwell Automation control strategy platform you choose. Rockwell Automations Integrated Architecture consists of Logix for control, the NetLinx Open Architecture for communication, and ViewAnyWare for visualization. The result is reduced complexity in an architecture that is easier to keep running.

System Recommendations
Intel Pentium processor or greater Microsoft Windows 98, Windows NT, Windows 2000, or Windows XP Minimum of 15MB of hard disk space 256-color or higher VGA graphics adapter, 1024 x 768 recommended Any Windows-compatible pointing device If reporting function will be used, Microsoft Word 2000 or higher Communications software: ProcessLogix 3.0.0 (or higher) or RSLinx 2.3 (or higher). RSLinx packages that can be used with RSLoop Optimizer include Single Node, OEM (OPC only), Professional, or Gateway. RSLinx Lite cannot be used with RSLoop Optimizer. OPC support: RSLoop Optimizer is an OPC client

Catalog Numbers
9323-LOOP01ENE RSLoop Optimizer PID Loop Tuner 9323-LOOP02ENE RSLoop Optimizer and RSLinx Bundle

Rockwell Software
For more information on the latest pricing or a demonstration of any Rockwell Software package, please contact your local Rockwell Automation sales office or Allen-Bradley distributor. For the very latest on Rockwell Software products, visit us at:

www.software.rockwell.com

Publication LOOP-TD001B-EN-D March 2005

Copyright 2005 Rockwell Automation, Inc. All rights reserved. Printed in USA.