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TIA Training Manual Page 1 of 36 Module P01_06

Status: 12/2010 PCS 7 for Universities
LOOP CONTROL AND MORE CONTROL FUNCTIONS
OBJECTIVE
In this chapter, the students get to know the essential components and the demands on a
block for continuously controlling process variables; they will also learn to set up and
configure a temperature control by using the blocks CTRL_PID and PULSEGEN.
THEORY IN SHORT
In the process industry, certain process variables have to be kept to a certain value
(disturbance variable), or process variables have to be set stability-oriented to specified
setpoints (response to setpoint changes). To this end, control loops are used as
shown in Figure 1.

Figure 1: Control Loop
For our plant, the reactor temperature has to be set to a certain value for the reaction
control to be in accordance with the specification. The disturbance variables are the
ambient temperature and the materials that are used having different temperatures. For the
temperature to be regulated, we first have to ascertain it by measurement. This measured
value that corresponds to the actual value of the process variable is then compared with
the desired value (setpoint). The difference between theactual value and the setpoint is
called (system) deviation.
If the system deviation is known, counter-measures can be derived. Regarding
temperature regulation, the heater is switched on if the measured actual value is lower than
the specified setpoint. For the process to handle this autonomously, a controller is needed.
A controller that calculates the manipulated variable based only on the current deviation is
called a proportional controller (P-controller for short).
In practice, controllers prevailed that can, with the aid of a few parameters, be used for a
wide range of processes, the so-called PID controllers.
The PCS7 Standard Library V71 contains proven blocks that implement this function.
Below, the block CTRL_PID is used.
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TIA Training Manual Page 2 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
THEORY
INTRODUCTION
The P-controller mentioned above is the simplest one. It works according to the principle:
the larger the current deviation, that larger the manipulated value. That is, its behavior is
derived directly from the current system deviation which makes it fast and dynamically
relatively favorable. However, certain disturbances are not completely compensated; i.e., a
system deviation always remains.
Not every system tolerates a sustained system deviation. For that reason, additional steps
have to be taken. One option is adding an integral component, which changes the P-
controller into a PI controller. The effect of the integral component is this: a sustained
system deviation is totaled. Thus, the manipulated value increases although the system
deviation remains the same.
If abrupt disturbances occur in a system, they can be quickly counteracted with an
additional differentiating component. The D-component calculates the manipulated
variable using the time deviation of the system deviation. However, this behavior causes
stochastic disturbances (noise). Here, an effective compromise has to be found. .
A combination of P, I and D components is referred to as a PID controller. In the process
industry, 95% of applications are implemented with these controllers since the PID
controller is set with only three parameters (gain, TN (reset time, integral action time) and
TV (rate time, derivative time). These few parameters already allow for a good adaptation
to numerous different dynamic processes.
However, setting the parameter presupposes knowledge of the system to be controlled.
The knowledge about the system can be gained from experience, it can be ascertained
experimentally, or it can be calculated by modeling the process. For a wide range of
processes that are not dominated by delays and respond in a similar manner to positive as
well as negative changes of manipulated variable interventions, it was possible to come up
with different rules for controller adjustment suitable in practice. Examples are the rules for
controller adjustment according to Chien, Hrones and Reswick [1], the method by Ziegler
and Nichols [2] as well as the T-Sum Rule [3].
The process control system PCS7 supports setting the parameters using a PID tuner.
For the controller block CTRL_PID, the three parameters are GAIN, TN for the integral
component, and TV for the differential component. In addition, there is the parameter
TM_LAG that sets the delay time for the D-component. The time is specified in seconds.
The input variable of the controller is the system deviation ER, and the output variable is
the manipulated value LMN that is calculated according to the following formula:
ER
s LAG TM
s TV
s TN
GAIN LMN
|
|
.
|

\
|
+

+

+ =
_ 1
1
1 .
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TIA Training Manual Page 3 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
INDUSTRIAL SUITABILITY OF CONTROLLERS
For a controller to work day by day and meeting industrial demands, additional functions
have to be implemented. Primarily, these are:
Bumpless changeover
Anti reset windup (ARW)
Support of different controlled system structures
The bumpless changeover is to prevent an abrupt change of the manipulated variable
when switching between the manual and automatic mode, between internal and external
setpoint selection, or when parameters are changed. A bumpless changeover between the
manual and the automatic mode is required, for example, when a process in process
engineering runs semi-automatically; i.e., when we perform the startup manually and then
switch to the automatic mode for regular operation. In the manual mode, the operator
specifies the manipulated variable directly, while in the automatic mode, the control
algorithm calculates the manipulated variable.
The function anti-reset windup (ARW) is to prevent that the integral component (reset) of
the manipulated variable continues to increase (wind up), since it is not possible to adjust a
system deviation because of the manipulated variable restriction, for example.
Supporting the different control structures allows for optimizing the control system without
having to replace the controller. In the chapter 'Expanded Control Structures, some of
these control structures are explained in greater detail. With CTRL_PID from the PCS7
Standard Library V71, the following control structures can be implemented:
Fixed setpoint control
Cascade control (single/multiple cascades)
Ratio control
Synchro control
Blending control
Feed forward injection of disturbance variable
With this block, the majority of control structures common in the process industry can be
implemented. For connections going beyond thise -such as split range control, Smith-
Prdikator control and override control- the PCS7 Advanced Process Library V71
provides the continuous PID controller PIDConL.
EXPANDED CONTROL STRUCTURES
For some applications, single loop control loops are not sufficient so that expanded control
structures have to be used to attain the desired objective.
If for a process variable, the response to setpoint changes and to the disturbance variable
can not be optimized satisfactorily, a feed forward control /auxiliary variable control or a
cascade control can be used.
If the disturbance variable can be measured and its point of attack is known, a
compensation of the disturbance variable can be applied to the controller input or output.
With the feed forward control, the disturbance variable can be compensated
completely so the controller can be set to the optimum command behavior (response to
setpoint changes).
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Status: 12/2010 PCS 7 for Universities

Figure 2: Feed forward control at the input (1) or the output (2) of the loop controller
If it is not possible to set the disturbance variable but another variable in the system, this
auxiliary variable is connected with a controller to the controller input. Applying the
auxiliary variable reduces the influence of the disturbance variable, but does not
compensate it completely.

Figure 3: Compensation by auxiliary variables
If the injection is made at the controller input, compensation and controller are not
independent of each other. That means: if the controller parameters are adjusted, the
compensation has to be adjusted also.
If applying the disturbance and auxiliary variable is not sufficient, or if it is not possible to
determine the point of attack of the disturbance variables with sufficient accuracy, or model
the subsystems with sufficient accuracy, a two or multi-loop cascade control is used.
When designing the cascade control, it is assumed that the underlaid control loops
(Controller 2 in Figure 4 -a socalled slave controller) respond faster than the overlaid
control loops (Controller 1 in Figure 4 -a socalled master controller). Thus, the control is
always optimized from the inside toward the outside.
The cascade control reduces the influence of the disturbance variable and makes the
control faster. To use the cascade control, correspondingly measurable variable have to
exist.
w
1
Loop
controller 1
Subsystem
e1
+
- -
Subsytem
Loop
controller 2
e
2
y
2
x2 y
1
= w
2
x
1

Figure 4: Cascade control with two loops

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TIA Training Manual Page 5 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Ratio control is used if the process variable is determined in dependence of another
variable; for example, the ratio control of two liquid streams that are to be blended; i.e.,
controlling the composition of the blend; or the ratio control of combustion gas and fresh air
in a gas burner for optimum combustion. The setpoint of the process variable w
2
is
calculated from the ratio r
w
and the process variable x
1
.

Figure 5: Ratio control
CONNECTING TO PROCESSES
The continuous output signal of the controller is not always read out at the process. This is
particularly inadvisable for great forces or large streams. For that reason, binary
connections are used. To this end, the analog signal is changed into a binary signal by
means of pulse width modulation. The PCS7 provides the elementary block
PULSEGEN [4] for this.
By modulating the pulse width, the function PULSEGEN transforms the input variable INV
(= LMN manipulated value of the PID controller) into a pulse sequence of a constant
period. It corresponds to the cycle time with which the input variable is updated, and has to
be parameterized in PER_TM.
The pulse duration for each period is proportional to the input variable. Here, the cycle
parameterized with PER_TM is not identical with the processing (machining) cycle of the
function block PULSEGEN. As Figure 6 shows, a cycle PER_TM consists of several
processing cycles of the function block PULSEGEN. The number of PULSEGEN calls
for each PER_TM cycle represents here the measure for the accuracy of the pulse width
modulation.

Figure 6: Time curve of input INV to output QPOS_P with PULSEGEN [4]
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Status: 12/2010 PCS 7 for Universities
An input variable of 30% at 10 PULSEGEN calls for each PER_TM means the following:
1 at output QPOS for the initial three calls of the PULSEGEN (30% of 10 calls)
0 at output QPOS for seven additional calls of the PULSEGEN (70% of 10 calls)
At the start of each period, the pulse duration is recalculated. Through a sampling ratio of
1:10 (CTRL_PID calls to PULSEGEN calls), the manipulated value accuracy in this
example is limited to 10%. Specified input values INV can be mapped only in the raster of
10% to a pulse length at output QPOS. Correspondingly, accuracy increases with the
number of PULSEGEN calls for each CTRL PID call. If PULSEGEN is called 100 times and
CTRL PID only once, the resolution is 1% of the manipulated variable range.
Note: You have to program the down scaling of the call frequency yourself.
LITERATURE
[1] Chien, Kun Li; Hrones, J. A.; Reswick, J. B. (1952): On the Automatic Control of
Generalized Passive Systems. In: Transactions of the American Society of Mechanical
Engineers, Vol. 74, Cambridge (Mass.), S. 175-185.
[2] Ziegler, J. G. and Nichols, N. B. (1942): Optimum settings for automatic controllers. In:
Trans. ASME, 64, S. 759-768.
[3] Kuhn, U.: Eine praxisnahe Einstellregel fr PID-Regler: Die T-Summen-Regel.
Automatisierungstechnische Praxis, Nr. 5, 1995, S. 10-16.
(Practice-Oriented Controller Adjustment Rules for PID Controllers: The T-Sum
Rule.Automation Engineering Practice, No. 5, 1995, Pages 10 to 16).
[4] SIEMENS (2009): Process Control System PCS 7: CFC Elementary Blocks.
!
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TIA Training Manual Page 7 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
STEP BY STEP INSTRUCTIONS
TASK
Corresponding to the information provided in the chapter Process Description, we are
supplementing the CF charts in Chapter Functional Safety.
The following CFCs are created here:
A1T2H003: Manual operation Educt B003 to Reactor R001
A1T2H007: Manual operation Reactor R001 Stirring
A1T2H008: Manual operation Reactor R001 Heating
A1T1S003: Pump Discharge Educt Tank B003
A1T1X006: Open/Close Valve Inlet Reactor R001 from Educt Tank B003
A1T2X003: Open/Close inlet Reactor R001 from Educt Tank B003
A1T2S001: Stirrer Reactor R001
A1T2T001: Temperature Reactor R001

The following lock conditions have to be noted:
Actuators are to be switched only if the main switch of the plant is switched on and the
emergency OFF switch is unlocked.
No container must overflow; i.e., there is either an encoder that signals the maximum
level, or the maximum level (here: 1000ml) is known numerically and is evaluated by
means of the measured level.
No pump must draw in air; i.e., there is either an encoder that signals the minimum
level, or the minimum level (here: 50ml) is known numerically and is evaluated by
means of the measured level.
A pump must not attempt to draw in liquid from a closed valve, or press liquid against a
closed valve.
The temperature in both reactors must not exceed 60C.
The heaters in both reactors must be started only if they are covered with liquid (here: a
minimum of 200ml in the reactor).
The stirrers in both reactors should be started only if they come into contact with a
liquid (here: a minimum of 300ml in the reactor).
OBJECTIVE
In this chapter, the student gains:
Additional experience in programming with CFCs
Knowledge of programming a continuous controller with pulse output and locks.
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TIA Training Manual Page 8 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
PROGRAMMING
1. To program the manual operation for filling Reactor R001from Educt Tank B003, we
are setting up a new CFC in the SIMATIC Manager in the plant view for the EMSR
location A1T2H003. Follow the screen shots below and the entries:



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TIA Training Manual Page 9 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities


Table 1: New Blocks in Chart 'A1T2H003/Sheet1
Block Catalog/Folder
Number of
Connections
RS_FF / RS FlipFlop Blocks/FLIPFLOP
OR / Or function Blocks/BIT_LGC 6
CMP_R / Comparator
for REAL values
Libraries/PCS 7 Library V71/
Blocks+Templates\Blocks/COMPARE


Table 2: Input Connections in Chart 'A1T2H003/Sheet1
Input Connected to Inverted
RS_FF.1.S
A1.T2.A1T2H003.HS+.START / I4.4 / Start
Educt B003 to Reactor R001
no
OR.2.IN1
'A1.T2.A1T2H003.HS-.STOP / I4.5 / Stop
Educt B003 to Reactor R001
no
OR.2.IN2
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.2.IN3
A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
OR.2.IN4
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
yes
OR.2.IN5
A1.T1.A1T1L003.LSA-.SA- / I3.1 / Level
monitoring Educt Tank B003 Operating Point
L
yes
CMP_R.3.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.3.IN2 1000.0
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TIA Training Manual Page 10 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 3: Block Connections in Chart 'A1T2H003/Sheet1
Input Output Inverted
RS_FF.1.R OR.2.OUT no
OR.2.IN6 CMP_R.3.GT no

Table 4: Output Connections in Chart A1T2H0003/Sheet1
Output Connected to Inverted
RS_FF.1.Q
'A1.T2.A1T2H003.HO+-.O- / Q4.3 / Educt
B003 to Reactor R001 Status value
no
RS_FF.1.Q
The other connections that are visible here
are generated later from the charts
A1T2X003, A1T1X006 and A1T1S003.


2. To program the manual operation for the stirrer in Reactor R001, we are setting up a
new CFC in the SIMATIC Manager in the plant view for the EMSR location
A1T2H007. Follow the screen shots below and the entries:

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TIA Training Manual Page 12 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 5: New Blocks in Chart 'A1T2H007Sheet1
Block Catalog/Folder
Number of
Connections
RS_FF / RS-FlipFlop Blocks/FLIPFLOP
OR / Or function Blocks/BIT_LGC 5
CMP_R / Comparator
for REAL values
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE


Table 6: Input Connections in Chart 'A1T2H007Sheet1
Input Connected to Inverted
RS_FF.1.S
'A1.T2.A1T2H007.HS+.START / I4.6 / Start
stirring reactor R001
No
OR.2.IN1
'A1.T2.A1T2H007.HS-.STOP / I4.7 / Stop
stirring reactor R001
No
OR.2.IN2
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.2.IN3
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
OR.2.IN4
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
yes
CMP_R.3.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.3.IN2 300.0

Table 7: Block Connections in Chart 'A1T2H007Sheet1
Input Output Inverted
RS_FF.1.R OR.2.OUT no
OR.2.IN5 CMP_R.3.LT No

Table 8: Output Connections in Chart 'A1T2H0007Sheet1
Output Connection to Inverted
RS_FF.1.Q
A1.T2.A1T2H007.HO+-.O- / A4.7 / Reactor
R001 stirring Status value
nein
RS_FF.1.Q
The second connection visible here will be
generated later from chart A1T2S001.

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TIA Training Manual Page 13 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
3. To program manual operation for heating in Reactor R001 we are setting up a new
chart in the SIMATIC Manager in the plant view for the EMSR location A1T2H008.
Follow the screen shots below and the entries:



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TIA Training Manual Page 14 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities


Table 9: New Blocks in Chart 'A1T2H008Sheet1
Block Catalog/Folder
Number of
Connections
RS_FF / RS FlipFlop Blocks/FLIPFLOP
OR / Or function Blocks/BIT_LGC 5
CMP_R / Comparator
for REAL values
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE


Table 10: Input Connections in Chart 'A1T2H008Sheet1
Input Connection to Inverted
RS_FF.1.S
'A1.T2.A1T2H008.HS+.START / I5.0 / Start
heating Reactor R001
no
OR.2.IN1
'A1.T2.A1T2H008.HS-.STOP / I5.1 / Stop
heating Reactor R001
no
OR.2.IN2
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.2.IN3
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
OR.2.IN4
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
yes
CMP_R.3.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.3.IN2 200.0

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TIA Training Manual Page 15 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 11: Block Connections in Chart 'A1T2H008Sheet1
Input Output Inverted
RS_FF.1.R OR.2.OUT no
OR.2.IN5 CMP_R.3.LT no

Table 12: Output Connections in Chart 'A1T2H0008Sheet1
Output Connection to Inverted
RS_FF.1.Q
'A1.T2.A1T2H008.HO+-.O- / Q5.0 / Heat
Reactor R001 Status value
no
RS_FF.1.Q
The other two connections visible here are
generated later from chart A1T2S001.


4. Now we are gong to program the individual drive functions with locks for the 'Pump
Outlet Educt Tank B003 in a CF chart with two sheets.
To this end, in the SIMATIC Manager in the plant view in the folder 'MOTORS we
copy the process tag type 'MOTOR from the master data library to the hierarchy folder
for the EMSR location A1T1S003. Then, we make the other corrections and
expansions in the CFC. Follow the screen shots and the entries below:


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TIA Training Manual Page 16 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
5. First we program in the second sheet of chart A1T1S003 the locks for 'Pump outlet
Educt Tank B003.


6. Then the other connections for 'Pump Outlet Educt Tank B003 in the first sheet of
chart A1T1S003 follow.

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TIA Training Manual Page 18 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 13: New Blocks in Chart 'A1T1S003/Sheet2
Block Catalog/Folder
Number of
Connections
OR / Or function Blocks/BIT_LGC 6
AND / And function Blocks/BIT_LGC 2
AND / And function Blocks/BIT_LGC 2
CMP_R / Comparator
floating point numbers
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE


Table 14: Input Connections in Chart 'A1T1S003/Sheet2
Input Connection to Inverted
OR.8.IN1
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.8.IN2
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
OR.8.IN3
'A1.T1.A1T1L003.LSA-.SA- / I3.1 / Level
monitoring Educt Tank B003 operating point
L
yes
OR.8.IN6
'A1.T1.A1T1X006.GO+-.O+ / I3.4 /
Open/close valve outlet Educt Tank B003
Feedback Open
yes
AND.1.IN2
'A1.T2.A1T2X003.GO+-.O+ / I6.4 /
Open/close valve inlet Reactor R001 from
Educt Tank B003 Feedback Open
no
AND.7.IN1
'A1.T2.A1T2X003.GO+-.O+ / I6.4 /
Open/close valve inlet Reactor R001 from
Educt Tank B003 Feedback Open
yes
AND.7.IN2
'A1.T3.A1T2X006.GO+-.O+ / I10.4 /
Open/close valve inlet Reactor R002 from
Educt Tank B003 Feedback Open
yes
CMP_R.9.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.9.IN2 1000.0

Table 15: Block Connections in Chart 'A1T1S003/Sheet2
Input Output Inverted
AND.1.IN1 CMP_R.9.GT no
OR.8.IN4 AND.1.OUT no
OR.1.IN5 AND.7.OUT no

Table 16: New Blocks in Chart 'A1T1S003/Sheet1
Block Catalog/Folder
Number of
Connections
AND / And Function Block/BIT_LGC 2
AND / And function Block/BIT_LGC 2
OR / Or function Block/BIT_LGC 5
OR / Or function Block/BIT_LGC 2
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Status: 12/2010 PCS 7 for Universities
Table 17: Input Connections in Chart 'A1T1S003/Sheet1
Input Connection to Inverted
AND.3.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
AND.2.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
OR.4.IN1 A1T2H003(A,1) / RS_FF.1.Q no
OR.5.IN2 A1T1S003(A,2) / OR.8.OUT no
CH_DI.FB_RUN.VALUE
'A1.T1.A1T1S003.SO+.O+ / I3.2 / Pump
outlet Educt Tank B003 Feedback On
no
MOTOR.Pump_A1T2S003.
MONITOR.
On

MOTOR.Pump_A1T2S003.
TIME_MON
10.0


Table 18: Block Connections in Chart 'A1T1S003/Sheet1
Input Output Inverted
AND.3.IN1 OR.4.OUT yes
AND.2.IN1 OR.4.OUT no
OR.5.IN1 AND.3.OUT no
MOTOR.Pump_A1T1S003.
LOCK
OR.5.OUT
no
MOTOR.Pump_A1T1S003.
LOCK_ON
AND.2.OUT
no
MOTOR.Pump_A1T1S003.
FB_ON
CH_DI.FB_RUN.Q
no
CH_DO.OUTPUT.I MOTOR.Pump_A1T1S003.QSTART no
MOTOR.Pump_A1T1S003.
CSF
OR.ERROR.OUT
no
OR.ERROR.IN1 CH_DI.FB_RUN.QBAD no
OR.ERROR.IN2 CH_DO.OUTPUT.QBAD no

Table 19: Output Connections in Chart 'A1T1S003/Sheet1
Output Connection to Inverted
CH_DO.OUTPUT.VALUE
'A1.T1.A1T1S003.SV.C / Q0.3 / Pump outlet
Educt Tank B003 Actuating signal
no

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TIA Training Manual Page 20 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
7. Next, we program the individual drive function with locks for the 'Open/Close valve
outlet Educt Tank B003 in a CFC with 2 sheets.
To do this, we copy in the SIMATIC Manager in the plant view in the folder
'VALVES the process tag type 'VALVE from the master data library to the hierarchy
folder for the EMSR location A1T1X006. Then, we make the other corrections and
expansions in the CFC. Follow the screen shots below and the entries:


8. The lock for the 'Open/close valve outlet Educt Tank B003 is programmed in Sheet2
again.

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TIA Training Manual Page 21 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
9. All additional connections for the 'Open/close valve outlet Educt Tank B003 are made
in Sheet 1.



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Status: 12/2010 PCS 7 for Universities
Table 20: New Blocks in Chart 'A1T1X006/Sheet2
Block Catalog/Folder
Number of
Connections
OR / Or function Blocks/BIT_LGC 2

Table 21: Input Connections in Chart 'A1T1X006/Sheet2
Input Connection to Inverted
OR.9.IN1
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.9.IN2
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes

Table 22: Block Connections in Plan 'A1T1X006/Sheet2
Input Output Inverted
None None no

Table 23: New Blocks in Chart 'A1T1X006/Sheet1
Block Catalog/Folder
Number of
Connections
AND / And function Blocks/BIT_LGC 2
AND / And function Blocks/BIT_LGC 2
OR / Or function Blocks/BIT_LGC 5
OR / Or function Blocks/BIT_LGC 5

Table 24: Input Connections in Chart 'A1T1X006/Sheet1
Input Connection to Inverted
AND.1.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
AND.2.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
OR.7.IN1 A1T2H003(A,1) / RS_FF.1.Q no
OR.8.IN1 A1T2H003(A,1) / RS_FF.1.Q yes
CH_DI.FB_OPEN.VALUE
'A1.T1.A1T1X006.GO+.O+ / I3.4 /
Open/Close valve outlet Educt Tank B003
Feedback Open
no
CH_DI.FB_CLSD.VALUE
'A1.T1.A1T1X006.GO+.O+ / I3.6 /
Open/close valve Educt Tank B003 Feedback
Closed
no
VALVE.Ventil_A1T1X006.V
_LOCK
A1T1X006(A,2) / OR.9.OUT
no
VALVE.Ventil_A1T1X006.M
ONITOR
On

VALVE.Ventil_A1T1X006.TI
ME_MON
10.0

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TIA Training Manual Page 23 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 25: Block Connections in Chart 'A1T1X006/Sheet1
Input Output Inverted
AND.1.IN1 OR.7.OUT no
AND.2.IN1 OR.8.OUT no
VALVE.Ventil_A1T1X006.V
L_OPEN
AND.1.OUT
no
VALVE.Ventil_A1T1X006.V
L_CLOSE
AND.2.OUT
no
VALVE.Ventil_A1T1X006.F
B_OPEN
CH_DI.FB_OPEN.Q
no
VALVE.Ventil_A1T1X006.F
B_CLOSE
CH_DI.FB_CLSD.Q
no
CH_DO.OUTPUT.I VALVE.Ventil_A1T1X006.QCONTROL no
VALVE.Ventil_A1T1X006.C
SF
OR.ERROR.OUT
no
OR.ERROR.IN1 CH_DO.OUTPUT.QBAD no
OR.ERROR.IN2 CH_DI.FB_CLSD.QBAD no
OR.ERROR.IN3 CH_DI.FB_OPEN.QBAD no

Table 26: Output Connections in Chart 'A1T1X006/Sheet1
Output Connection to Inverted
CH_DO.OUTPUT.VALUE
'A1.T1.A1T1X006.XV.C / Q1.1 / Open/Close
valve outlet Educt Tank B003 Control signal
no

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TIA Training Manual Page 24 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
10. Now, we are going to also program in a CFC with 2 sheets the individual drive function
with locks for the 'Open/Close Valve Inlet Reactor R001 from Educt Tank B003.
To do this, we copy in the SIMATIC Manager in the plant view in the folder 'VALVES
the process tag type 'VALVE from the master data library to the hierarchy folder for
the EMSR location A1T2X003. We then make the other corrections and expansions in
the CFC. Follow the screen shots below and the entries:


11. The lock for the 'Open/close valve inlet reactor R001 from educt tank B003 is
programmed on Sheet2.


Industry Automation and Drive Technologies - SCE


TIA Training Manual Page 25 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
12. In Sheet1, the other connections for the 'Open/close valve inlet reactor R001 from
educt tank B003 are set up.



Industry Automation and Drive Technologies - SCE


TIA Training Manual Page 26 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 27: New Blocks in Chart 'A1T2X003/Sheet2
Block Catalog/Folder
Number of
Connections
OR / Or function Blocks/BIT_LGC 2

Table 28: Input Connections in Chart 'A1T2X003/Sheet2
Input Connection to Inverted
OR.9.IN1
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.9.IN2
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes

Table 29: Block Connections in Chart 'A1T2X003/Sheet2
Input Output Inverted
None None no

Table 30: New Blocks in Chart 'A1T2X003/Sheet1
Block Catalog/Folder
Number of
Connections
AND / And function Blocks/BIT_LGC 2
AND / And function Blocks/BIT_LGC 2
OR / Or function Blocks/BIT_LGC 5
OR / Or function Blocks/BIT_LGC 5

Table 31: Input Connections in Chart 'A1T2X003/Sheet1
Input Connection to Inverted
AND.1.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
AND.2.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
OR.7.IN1 A1T2H003(A,1) / RS_FF.1.Q no
OR.8.IN1 A1T2H003(A,1) / RS_FF.1.Q yes
CH_DI.FB_OPEN.VALUE
'A1.T2.A1T2X003.GO+.O+ / I6.4 /
Open/Close valve inlet reactor R001 from
educt tank B003 Feedback Open
no
CH_DI.FB_CLSD.VALUE
'A1.T2.A1T2X003.GO+.O+ / I7.0 /
Open/close valve inlet reactor R001 from
educt tank B003 Feedback closed
no
VALVE.Ventil_A1T2X003.V
_LOCK
A1T2X003(A,2) / OR.9.OUT
no
VALVE.Ventil_A1T2X003.M
ONITOR
On

VALVE.Ventil_A1T2X003.TI
ME_MON
10.0

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TIA Training Manual Page 27 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 32: Block Connections in Chart 'A1T2X003/Sheet1
Input Output Inverted
AND.1.IN1 OR.7.OUT yes
AND.2.IN1 OR.8.OUT no
VALVE.Ventil_A1T2X003.V
L_OPEN
AND.1.OUT
no
VALVE.Ventil_A1T2X003.V
L_OPEN
AND.2.OUT
no
VALVE.Ventil_A1T2X003.F
B_OPEN
CH_DI.FB_OPEN.Q
no
VALVE.Ventil_A1T2X003.F
B_CLOSE
CH_DI.FB_CLSD.Q
no
CH_DO.OUTPUT.I VALVE.Ventil_A1T2X003.QCONTROL no
VALVE.Ventil_A1T2X003.C
SF
OR.ERROR.OUT
no
OR.ERROR.IN1 CH_DO.OUTPUT.QBAD no
OR.ERROR.IN2 CH_DI.FB_CLSD.QBAD no
OR.ERROR.IN2 CH_DI.FB_OPEN.QBAD no

Table 33: Output Connections in Chart 'A1T2X003/Sheet1
Output Connection to Inverted
CH_DO.OUTPUT.VALUE
'A1.T2.A1T2X003.XV.C / Q7.0 / Open/close
valve inlet reactor R001 from educt tank B003
Controlling signal
no

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TIA Training Manual Page 28 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
13. Now, we are going to program in a CFC with two sheets the individual drive functions
for the stirrer 'Reactor R001
To this end, we copy in the SIMATIC Manager in the plant view in the folder
'MOTORS the process tag type 'MOTOR from the master data library to the hierarchy
folder for the EMSR location A1T2S001. Then, we make the other corrections and
expansions in the CFC. Follow the screen shots that follow and the entries:


14. The locks for the 'Stirrer Reactor R001 are programmed in Sheet 2.

Industry Automation and Drive Technologies - SCE


TIA Training Manual Page 29 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
15. Other connections for the 'Stirrer Reactor R001 are programmed in Sheet 1.



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TIA Training Manual Page 30 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 34: New Blocks in Chart 'A1T2S001/Sheet2
Block Catalog/Folder
Number of
Connections
OR / Or function Blocks/BIT_LGC 5
CMP_R / Comparator
Floating point numbers
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE


Table 35: Input Connections in Chart A1T2S001/Sheet2
Input Connection to Inverted
OR.1.IN1
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.1.IN2
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
CMP_R.11.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.11.IN2 300.0

Table 36: Block Connections in Chart 'A1T2S001/Sheet2
Input Output Inverted
OR.1.IN1 CMP_R.11.LT no

Table 37: New Blocks in Chart 'A1T2S001/Sheet1
Block Catalog/Folder
Number of
Connections
AND / And function Blocks/BIT_LGC 2
AND / And function Blocks/BIT_LGC 2
OR / Or function Blocks/BIT_LGC 5
OR / Or function Blocks/BIT_LGC 2

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TIA Training Manual Page 31 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 38: Input Connections in Chart 'A1T2S001/Sheet1
Input Connection to Inverted
AND.3.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
AND.2.IN2
'A1.A1H003.HS+-.LOC / I0.2 / Activate local
operation
no
OR.4.IN1 A1T2H007(A,1) / RS_FF.1.Q no
OR.5.IN2 A1T2S001(A,2) / OR.1.OUT no
CH_DI.FB_RUN.VALUE
'A1.T2.A1T2S002.SO+.O+ / I10.0 / Stirrer
reactor R001 Feedback On

MOTOR.Stirrer_A1T2S001.
MONITOR.
On

MOTOR.Stirrer_A1T2S001.
TIME_MON
10.0


Table 39: Block Connections in Plan 'A1T2S001/Sheet1
Input Output Inverted
AND.3.IN1 OR.4.OUT yes
AND.2.IN1 OR.4.OUT no
OR.5.IN1 AND.3.OUT no
MOTOR.Stirrer_A1T2S001.
LOCK
OR.5.OUT
no
MOTOR.Stirrer_A1T2S001.
LOCK_ON
AND.2.OUT
no
MOTOR.Stiier_A1T2S001.F
B_ON
CH_DI.FB_RUN.Q
no
CH_DO.OUTPUT.I MOTOR.Stirrer_A1T2S001.QSTART no
MOTOR.Stirrer_A1T2S001.
CSF
OR.ERROR.OUT
no
OR.ERROR.IN1 CH_DO.OUTPUT.QBAD no
OR.ERROR.IN2 CH_DI.FB_RUN.QBAD no

Table 40: Output Connections in Chart 'A1T2S001/Sheet1
Output Connection to Inverted
CH_DO.OUTPUT.VALUE
'A1.T2.A1T2S001.SV.C / Q6.1 / Stirrer
reactor R001 Control signal
no

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TIA Training Manual Page 32 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
16. Now we are going to program in a CFC with 2 sheets the individual drive function with
locks for 'Temperature Reactor R001. We are going to use a continuous PID controller
for this.
First, in the SIMATIC Manager in the plant view we are setting up a new CFC for the
EMSR location A1T2T001. Next, we make the other corrections and expansions in the
CFC. Follow the screen shots below and entries:


17. The locks for 'Temperature Reactor R001 are programmed in Sheet2.

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TIA Training Manual Page 33 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
18. In Sheet 1 of chart A1T2T001, the other connections of 'Temperature Reactor R001
are programmed.



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TIA Training Manual Page 34 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 41: New Blocks in Chart 'A1T2T001/Sheet2
Block Catalog/Folder
Number of
Connections
OR / Or function Blocks/BIT_LGC 4
CMP_R / Comparator
floating point numbers
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE

CMP_R / Comparator
floating point numbers
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/COMPARE


Table 42: Input Connections in Chart 'A1T2T001/Sheet2
Input Connection to Inverted
OR.22.IN1
'A1.A1H001.HS+-.START / I0.0 / Switch on
multi-purpose plant
yes
OR.22.IN2
'A1.A1H002.HS+-.OFF / I0.1 / Activate
emergency OFF
yes
CMP_R.20.IN1
A1T2L001(A,1) / CH_AI.LISA+_A1T2L001.V
Process value

CMP_R.20.IN2 200.0
CMP_R.21.IN1 A1T2T001(A,1) / CH_AI.10.V Process value
CMP_R.21.IN2 60.0

Table 43: Block Connections in Chart 'A1T2T001/Sheet2
Input Output Inverted
OR.22.IN3 CMP_R.20.LT no
OR.22.IN4 CMP_R.21.GT no

Table 44: New Blocks in Chart 'A1T2T001/Sheet1
Block Catalog/Folder
Number of
Connections
CTRL_PID /
Continuous PID
controller
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/CONTROL

PULSEGEN / Pulse
width modulation for
PID controller
Libraries/CFC Library
/ELEM_400\Blocks/CONTROL

CH_AI / Driver block
Analog value input
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/DRIVER

CH_DO / Driver block
Binary output
Libraries/PCS 7 Library
V71/Blocks+Templates\Blocks/DRIVER

AND / And function Blocks/BIT_LGC 2
OR / Or function Blocks/BIT_LGC 2
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TIA Training Manual Page 35 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
Table 45: Input Connections in Chart 'A1T2T001/Sheet1
Input Connection to Inverted
OR.1.IN1 A1T2H008(A,1) / RS_FF.1.Q no
OR.1.IN2 A1T2T001(A,2) / OR.22.OUT no
AND.2.IN1 A1T2H008(A,1) / RS_FF.1.Q no
AND.2.IN2 A1T2T001(A,2) / OR.22.OUT yes
CH_AI.10.VALUE
A1.T2.A1T2T001.TIC.M / IW516 /
Temperature actual value Reactor R001

CH_AI.10.VHRANGE 100
CH_AI.10.VLRANGE -100
PULSEGEN.8.STEP3_ON 0

Table 46: Block Connections in Chart 'A1T2T001/Sheet1
Input Output Inverted
CTRL_PID.PIDTemp_A1T2
T001.PV_IN
CH_AI.10.V

CTRL_PID.PIDTemp_A1T2
T001.LMNR_IN
CTRL_PID.PIDTemp_A1T2T001.LMN

PULSEGEN.8.INV CTRL_PID.PIDTemp_A1T2T001.LMN
PULSEGEN.8.MAN_ON OR.1.OUT no
PULSEGEN.8.POS_P_ON AND.2.OUT no
CH_DO.11.I PULSEGEN.8.QPOS_P no

Table 47: Output Connections in Chart 'A1T2T001/Sheet1
Output Connection to Inverted
CH_DO.11.VALUE
A1.T2.A1T2T001.TV.S / Q4.0 / Temperature
Reactor R001 Control signal
no
CH_AI.10.V A1T2T001(A,2) / CMP_R.21.IN1
Industry Automation and Drive Technologies - SCE


TIA Training Manual Page 36 of 36 Module P01_06
Status: 12/2010 PCS 7 for Universities
EXERCISES
We are going to apply what we learned in the theory chapters and the step by step
instructions to the exercises. We are using the already existing multi-project from the step
by step instructions (PCS7_SCE_0106_R1009.zip) and expand it.
The PID controller set up in the step by step instructions is to be expanded. First, we are
going to implement the required settings for a setpoint/actual value follow up.
TASKS
The tasks below are based on the step by step instructions. For each task, we can use the
corresponding steps of the instructions as an aid.
1. A few inputs of the controller function block have to be wired as described in Table 48
below for the setpoint/actual value follow-up when the manual mode of the plant is
activated.
2. The changeover from the automatic mode to the manual/follow-up mode takes place
by means of the input 'AUT_L. When this input is set to 0, it indicates the
manual/follow-up mode; when set to 1, correspondingly to the automatic mode. There
are two application cases where the follow-up mode is needed: Either the plant is in
the manual mode, or it is in the automatic mode. However, there is no setpoint for the
controller.
Implement a combinational circuit that takes input 'AUT_L to the correct state when
the plant is put into the manual mode. Also, the combinational circuit is to have an
additional unwired input that activates the follow up. This input is used later in the
automatic mode.

Table 48: Inputs of Controller Function Block
Input Value
LMN_SEL 0
LIOP_MAN_SEL 1
SPBUMPON 1
SPEXTSEL_OP 0