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MAQ20 PID Controller User Manual

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1. I MAO 20 Industrial Data Acguisition and Control System MA1056 MAQ20 COM4 MAQ20 COM2 PID Controller User Manual MAQ20 Tank 3 MAO20 Tank 4 Controller Controller Controller 100 MAO20 Tank 1 Controller 100 100 lo 20 4 6 80 Pee ee ee eee a 120 40 80 1 Controller 100 100 bp EU SP EU 60 70 pve fee EEN Eu _ 50 50 s P o 0 MODE MODE aU AUTO lt 4 nan 4 co 0 0 S Settings Settings Edit Unlocked Communication NO connection Scan intervak 100ms Running activity Control Loop Alarm Output activity None D2 DATAFORTH MA1056 MA 20 PID Controller User Manual MAQ20 PID Controller User Manual MA1056 Rev B March 2014 2014 Dataforth Corporation All Rights Reserved ISO9001 2008 Registered QMS The information in this manual has been checked carefully and is believed to be accurate however Dataforth assumes no responsibility for possible inaccuracies or omissions Specifications are subject to change without notice The information tables diagrams and photographs contained herein are the property of Dataforth Corporation No part of this manual may be reproduced or distributed by any means electronic mechanical or otherwise for any purpose other than the purchaser s personal use without the express written consent of Dataforth Corporation MAQ 20 is a registered trademark
2. 1390 R W 1 Output Type EN eee Oto 2 INT16 2 Discrete Output Setpoint Integer part at Address 1396 R W 2 Setpoint 1396 fractional part at 0 to 65 535 INT16 Address 1397 Process Variable Process Integer part at Address 12 PA 2 Variable 1398 fractional part at PO Pan uve Address 1399 Control Output Integer part at Address 1400 R W 2 Control Output 1400 fractional part at 0 to 65 535 INT16 Address 1401 CDATA ne 370143 MA1056 MA 20 PID Controller User Manual Start Address Read Write 1402 1404 1406 1408 1410 1412 1414 1416 1418 Page 38 of 43 Address Range 1300 1499 PID Loop Controllers Registers ee Data pond mee CO High Clamp Process Variable maximum value Integer part at Address 1402 fractional part at Address 1403 Process Variable minimum value Integer part at Address 1404 fractional part at Address 1405 Control Output maximum value Integer part at Address 1406 fractional part at Address 1407 Control Output minimum value Integer part at Address 1408 fractional part at Address 1409 Controller Gain Integer part at Address 1410 fractional part at Address 1411 Integral Time minutes Integer part at Address 1412 fractional part at Address 1413 Fractional part is in 10 000ths of a second Derivative Time minutes Integer part at Address 1414 fractional part at Address 1415 Fractional part is in 1
3. 0883 Integral time 0 0086 0 00525 minutes Derivative time 0 0 minutes Activate New Values Figure 18 MAQ 20 PID Controller Auto Tune Interface Ij MAO20 1 Auto Tune Details Dead time td 0 02345 minutes Average td eror 78 61 Half cycle amplitudes 13 13 01 13 03 13 01 13 03 PV amplitude 13 02 EU Noise adjusted PV amplitude 12 98 EU PV amplitude 12 98 of full scale Average PV amplitude error 0 1 CO amplitude 5 Ku 0 4905 2 21 2014 4 03 22 PM Step 8 Tuning sequence completed successfully Close Auto Tune Sequence Ended i Tuning sequence completed successfully The Current and New values for the controller parameters are displayed in the lower right part of the Auto Tuner window To apply these optimized values to the controller press the Activate New Values button The new controller parameters can be tested by closing the Auto Tuner windows adjusting the Setpoint and observing the controller response Default values for some Auto Tuner parameters such as PV deviation limits and CO step limits may need to be adjusted in order for the tuning process to converge Start with the default values tune the controller and observe the messages in the Auto Tune details window for recommendations on parameter changes Section 8 0 has complete details on the Auto Tune function P DATAFORTH Page 17 of 43 MA1056 MA 20 PID Controller User Manu
4. 1 Low 2 None 3 High High 4 High Deadband or Hysteresis Adds to low limits subtracts from high limits Integer part at Address 1442 fractional part at Address 1443 High High Alarm Limit Engineering Units Integer part at Address 1444 fractional part at Address 1445 High Alarm Limit Engineering Units Integer part at Address 1446 fractional part at Address 1447 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 n 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 Page 39 of 43 MA1056 MA 20 PID Controller User Manual Address Range 1300 1499 PID Loop Controllers Start Data Read Write Contents Description Data type Low Alarm Limit Low Engineering Units 1448 R W 2 Limi Integer part at Address 0 to 65 535 INT16 Imit l 1448 fractional part at Address 1449 Low Low Alarm Limit Loen Engineering Units 1450 R W 2 AT Integer part at Address 0 to 65 535 INT16 Alarm Limit 1450 fractional part at Address 1451 10 0 Recommended Reading Introduction to PID Control Dataforth Application Notes www dataforth com app notes aspx AN123 Tuning Control Loops for Fast Response AN124 Tuning Control Loops with the IMC Tuning Method AN125 Tuning Level Control Loops AN126 Tuning Surge Tank Control Loops Process Control for Practitioners Jacgues F Smuts copyright 2011 www OptiControls com Controller Tuning and Control
5. 3 IN NO EVENT WILL THE COLLECTIVE LIABILITY OF DATAFORTH AND ITS SUPPLIERS LICENSORS SERVICE PROVIDERS EMPLOYEES AGENTS OFFICERS AND DIRECTORS TO ANY PARTY REGARDLESS OF THE FORM OF ACTION WHETHER BASED UPON WARRANTY CONTRACT TORT OR OTHERWISE EXCEED THE GREATER OF EITHER US 1000 00 ONE THOUSAND DOLLARS U S A CURRENCY OR THE AMOUNT PAID TO DATAFORTH FOR THE APPLICABLE PRODUCT OR SERVICE OUT OF WHICH LIABILITY AROSE 4 DATAFORT H S LIABILITY ARISING OUT OF THE PRODUCTION SALE OR SUPPLY OF PRODUCTS OR THEIR USE OR DISPOSITION WHETHER BASED UPON WARRANTY CONTRACT TORT OR OTHERWISE SHALL NOT EXCEED THE GREATER OF EITHER US 1000 00 ONE THOUSAND DOLLARS U S A CURRENCY OR THE ACTUAL Page 41 of 43 MA1056 MA 20 PID Controller User Manual PURCHASE PRICE PAID BY BUYER FOR DATAFORTH S PRODUCTS DATAFORTH S LIABILITY FOR ANY CLAIM OF ANY KIND SHALL IN NO CASE EXCEED THE OBLIGATION OR LIABILITY SPECIFIED IN THIS WARRANTY d Technical Assistance Dataforth s Warranty as hereinabove set forth shall not be enlarged diminished or affected by and no obligation or liability shall arise or grow out of Dataforth s rendering of technical advice facilities or service in connection with buyer s order of the products furnished hereunder e Warranty Procedures Buyer shall notify Dataforth of any products which it believes to be defective during the applicable warranty period and which are covered by the Warranty set for
6. MA1056 MA 20 PID Controller User Manual 4 6 PID Controller Settings Click on the Settings button in the lower left corner of the PID Controller Faceplate to open the Settings window as shown in Figure 13 From here the Basic Settings Advanced Settings and Process Alarms tabs give the user access to the many powerful features of the PID Controller Default values for these parameters are set to establish a starting point for loop tuning but may need to be adjusted based on specific applications For this example start by reviewing the settings in the Basic Settings tab File Edit View Run Help AB 4DBAXGKAS l gt Acquire Analyze Present 1 Controller 100 100 Controller name MAG20 1 Description Controller SP Tuning Settings A Controller gain 0 1114 Integral time 0 008619 minutes Derivative time 0 minutes Auto Tune Control Direction Reverse acting Direct acting Measurement Range Upper calibration limit 100 Lower calibration limit 0 Engineering unit ly Settings ok JI Cancel Apply Figure 13 PID Controller Settings Basic Settings Tab When a Faceplate is added to the Present panel it is automatically named MA 20 1 and when more are added the number auto increments so they can be uniquely identified The Controller name and Description can be changed using the top two fields o
7. Mix Tank Liquid Level PID Input Output Select Input PV Unit Enter the unit of measure for the Process Variable This must be the same as the unit chosen in the Scale Data tab when the input channel was configured The default unit and standard unit for PID control is Yo For this example enter PID Input Output Select Output The Output drop down box lists all available output channels in the selected MAQ 20 system than can be used for the Control Output Select the output channel that will be used for the CO For this example select Mix Tank Valve PID Input Output Select Output CO Unit Enter the unit of measure for the Control Output This must be the same as the unit chosen in the Scale Data tab when the output channel was configured The default unit is This scale setting must be 0 to 100 for proper controller operation For this example enter File Edit View Run Help DE kaaos a gt Acquire Analyze Present 1 MAO20 1 ID P1D properties om Controller 100 100 PID Enabled MAQ20 System Select PID Save to EE Enabled v Not Save SP EU P 68 PID Input Output Select Must Select channel in same system Input Input PV Unit PV EU Mix Tank Liquid Level 7 50 SP Output_CO Unit CO 0 MODE AUTO CO Setti 0 ettings Figure 12 Setting PID Controller PV and CO O DATAFOR ne 130143
8. Oescrtiption at 10000 109 sr A J i e o No Kian SP EU 68 PV EU 50 CO 0 MODE AUTO Settings Figure 11 Placing a PID Controller Faceplate Page12ot48 S ODAAT MA1056 PID Controller User Manual 4 5 Selecting the PID Controller Input PV and Output CO in ReDAQ Shape Double click anywhere on the PID Faceplate to open the PID Properties window as shown in Figure 12 Configure the following properties as required by the application PID Enable Disable Enables or Disables the PID Controller Default Enabled For this example select Enabled MAQ20 System Select The MAQ20 940 software can monitor and control up to ten MAQ 20 systems Connect to all systems in the Acquire panel then select the number of the MAQ 20 system which the PID Controller is associated with For this example select system 1 PID Save to EE Selecting Save saves all PID parameters to the MAQ20 COM4 or MAQ20 COM2 non volatile memory when the PID Controller run is initiated Once the save operation is complete the setting will revert to Not Save Default Not Save PID Input Output Select Input The Input drop down box lists all available input channels in the selected MAQ 20 system that can be used for the Process Variable Select the input channel that will be used for the PV For this example select
9. Stabilize the process if possible i e by putting other loops in manual e Increase PV deviation limits and CO step limits A control valve or process problem could also have affected the process model created by the auto tuner These include e Control valve deadband e Control valve stiction e A nonlinear process or nonlinear final control element In all cases the problem needs to be resolved first before auto tuning will be accurate and control will be good Getting Help from Dataforth When contacting Dataforth for assistance with an auto tuning problem please capture a screenshot of the auto tune sequence copy all the text from the log in the Details window and email these to our support staff at sales dataforth com Page3gota3g S EDan MA1056 PID Controller User Manual 9 0 MAQ20 COM2 and MAQ20 COM4 Address Map Tables in this section outline the MAQ20 COMx address space Data in these registers contains all permanent and user settable information for module configuration status operation of all functions data read write and data storage Table columns list the following information Start Address Start address for the specified quantity of addresses The start address is offset by 2000 R where R is the module Registration Number The Registration Number for the MAQ20 COM2 and MAQ20 COM4 is always 0 Read Write Indicates whether data at the address is Read Write or both Number of Registers The number of 16 bit regi
10. Woman 32 Genio mode To U en eee 32 2 2 Wie Auto Tune Segel 32 8 4 Typical Auto Tune Seguence ooW Wo Wa 33 8 5 Auto Tune Process Troubleshooting oooooW WWW 33 The Auto Tune Sequence Did Not Complete ooo Wo Wo Wo mma 33 The Auto Tune Sequence Completed but the Tuning Settings Do Not WofK oooom 34 Getting Asesor DatarOnA ea asma ama aan ena Ma Aa Aa AE 34 9 0 MAQ20 COM2 and MAQ20 COM4 Address Map ooooWoWoWoWoWo WoW oom maan 35 10 0 Recommended RING an aa 40 y gt DATAFORTH MA1056 PID Controller User Manual About Dataforth Corporation Our passion at Dataforth Corporation is designing manufacturing and marketing the best possible signal conditioning data acguisition and data communication products Our mission is to set new standards of product guality performance and customer service Dataforth Corporation with more than a guarter century of experience is the worldwide leader in Instrument Class Industrial Electronics rugged high performance signal conditioning data acguisition and data communication products that play a vital role in maintaining the integrity of industrial automation data acguisition and guality assurance systems Our products directly connect to most industrial sensors and protect valuable measurement and control signals and eguipment from the dangerous and degrading effects of noise transient power surges internal gro
11. an input scale setting of Oto 100 Input data can be scaled to any engineering unit but when using a channel for PID control the scale setting must be matched to the same scale used by the PID faceplate Press the Return button to return to the main screen File Edit View Run Help DEH s a_eax ou sia Acquire Analyze Present 1 Device MAQ20 IDN Serial Number 0080518 02 MAQ20 IDN Retum Setup Scale Data Control Loop Alarm Channel Name Full Scale Scale To Offset Unit Input 0 762 to 4000 Count a an g Input 1 0 to 4000 Count n 2 4 ma Input 2 0 to 4000 Count a mA Input 3 0 to 4000 Count a 2 Q mA Input 4 0 to 4000 Count a 20 0 mA Input 5 0 to 4000 Count a a 4 mA Input 6 0 to 4000 Count a m a mA Input 7 0 to 4000 Count a 2 a mA Figure 6 Setting the MAQ20 IDN PV Signal Scale CDATA ye 9 0f 43 MA1056 MA 20 PID Controller User Manual 4 3 Selecting and Scaling the Control Output CO in ReDAQ Shape PID control output signals can be process voltage through the MAQ20 VO module process current through the MAQ20 IO module discrete output through the MAQ20 DIOL or MAQ20 DIOH module or a pulse width modulated signal through the MAQ20 DIOL or MAQ20 DIOH module To configure a module output channel as a control output locate the module graphic on the Acquire panel that corresponds to the MAQ20 output module which provides the output signal Click on the module graphic to open the Setup tab For thi
12. connected to it Click on the module graphic to open the Setup tab For this example from the Acquire panel click on the MAQ20 IDN module in Slot 1 next to the MAQ20 COMx module to open the screen shown in Figure 5 Assign the User Tag Name Mix Tank Liquid Level to Input Channel 0 and set the Input Range to 4 20mA File Edit View Run Help AG DAXOYAS l Acguire Analyze Present 1 MAQ20IDN Device MAQ20 IDN Serial Number 0080518 02 Retum Setup Scale Data Control Loop Alam Channel Name User Tag Name Data Display Input Select Avg Weight Max Min Input Range Control Loop Alarm Input 0 Mix Tank Liquid Level ne Raw 3 Reset hie Zien None Input 1 LIDN 11 Raw 3 El Reset Oto2imA None Input 2 1IDN1 2 naa r zl B Reset Oto 21mA None Input 3 1_IDN_1 3 aw al B Reset Oto 2imA None Input 4 1IDN_14 Raw B Reset Oto2imA None Input 5 LIDN15 Raw zl 3 Rest Oto21mA None Input 6 LIDN 1 6 na r 13 El Reset Oto 21ma None Input 7 LIDN 17 nan r al B Reset Oto 2imA None Figure 5 MAQ20 IDN Process Variable Channel Setup Next select the Scale Data tab and specify the scale for the PID process variable input as shown in Figure 6 By default the PID controller expects
13. on process variable changes This option eliminates controller output spikes under derivative control but will still bump under proportional control when the setpoint is changed e Proportional and derivative on PV proportional and derivative modes will act only on process variable changes This option eliminates derivative mode spikes and proportional mode bumps when the setpoint is changed However under this option the controller will take longer to get the process variable to the new setpoint With all three options above the controller s integral mode always works on error and will act on changes in both setpoint and process variable Integral mode will not cause any sudden changes in controller output The Proportional on error and derivative on PV setting the middle option is recommended for general purpose control loops while Proportional and derivative on PV third option is recommended for loops that do not have to rapidly get to a changed setpoint but where the process is very sensitive to sudden changes in controller output i e boiler drum level control Control Algorithms Two control algorithms are offered noninteractive also called standard or ideal shown in Figure 29 and parallel also called independent gains shown in Figure 30 The noninteractive control algorithm is far more common than the parallel algorithm and most tuning rules have been developed for it Fine tuning is difficult on the parallel control alg
14. setting can be used to prevent alarm chatter if the process variable is very close to the alarm level and the noise drives the signal into and out of alarm The Alarm hysteresis should be set greater than the amplitude of the noise on the process variable 2 FIC 100 Settings Process Varable Alam Settings High High alam 383 4 GPM High alam 366 6 GPM Low alarm 2394 GPM Low Low alam 116 5 GPM Alarm hysteresis 0 5 GPM Com 5 Figure 31 Process Alarm Settings 0 0 PY Low Low Figure 32 PV Below Low Low Alarm Level CODATA ne 290143 MA1056 MA 20 PID Controller User Manual 8 0 PID Auto Tuner The Dataforth PID Controller comes with an integrated Auto Tuner to simplify the often complex task of controller tuning The Auto Tuner interface is shown in Figure 33 PID controllers have to be individually tuned because the different processes they control behave differently each process has its own dynamic characteristics Every controller must be tuned to work in harmony with its process s dynamics Controller tuning should be done before the controller is put in automatic mode for the first time lu MAQ20 PID 1 PID Controller DataForth PID Tuner Process Variable and Set Point 13 25 21 13 26 36 13 26 51 1327 Controller Output 13 25 51 13 26 21 13 26 36 13 26 51 13 27 06 13 27 21 Tuning Sequencer Step Test Results Controller Tuning PV deviation limit
15. the Toolbox icon as shown in Figure 10 File Edit View Run Help 4 fee a Present Panel gt EES Acquire Panel gt PES Analyze Panel gt E Toolbox gt Ove Close Figure 10 Opening the REDAQ Shape Toolbox Scroll right to the Toolbox PID Controller tab select the PID controller Faceplate tool Click anywhere in the Present panel workspace to place the Faceplate as shown in Figure 11 Select anywhere within the Faceplate tool using the left mouse button and drag to reposition the Faceplate Place the mouse in the lower right corner of the tool then press and hold the right mouse button while dragging the mouse to resize the Faceplate For applications with multiple control loops repeat these operations to add multiple Faceplates to a project Each Faceplate is the user interface to one PID controller When a Faceplate is added to the Present panel it is automatically named MAQ20_1 and when more are added the number auto increments so they can be uniquely identified To change the Faceplate name and description refer to the Faceplate Basic Settings tab parameters described in Section 4 6 Refer to Section 5 0 for complete details on the parameters displayed on the Faceplate and the control features of the Faceplate File Edit View Run Help DE kLaBXOKAR Acquire Analyze Present 1 I gt Toolbox 7 PID Controller MAO20 1 Controller 100 100 Controller Name Cormotier
16. will be the process value producing 20 mA e Lower calibration limit the value in engineering units reflecting the zero calibration value of the measurement device i e On a 4 20 mA signal this will be the process value producing 4 mA e Engineering unit Engineering unit for the measurement i e m hr C GPM etc Caution The measurement range must be set correctly before the controller is put in automatic control mode Do not change the measurement range while the controller is in automatic control mode CODATA ng 25 of 43 MA1056 MA 20 PID Controller User Manual 7 2 Advanced Settings FIC 100 Settings aa an aan aan SSS DEEP EEE EEE EEE CEE Controller Output Limits Controller output upper limit 100 ps Controller output lower limit 0 x Setpoint Action Proportional and derivative on eror Proportional on eror derivative on PV 3 Proportional and derivative on PV Track process variable in manual mode Control Algorithm and Options Noninteractive standard ideal algorithm 3 Parallel independent gains algonthm Gap around setpoint 0 GPM Gain multiplier inside gap 0 5 PY filter time constant 0 minutes Significant digits to display 4 Ceme eo Figure 28 Advanced Settings The Advanced Settings tab shown in Figure 28 contains advanced settings that do not have to be adjusted unle
17. 0 000ths of a second PID Controller Update Rate seconds Integer part at Address 1416 fractional part at Address 1418 This value is fixed at 1s Controller Output upper limit Integer part at Address 1418 fractional part at Address 1419 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 0 to 65 535 INT16 P DATAFORTH MA1056 PID Controller User Manual Start Address Read Write 1420 JJ 1422 JJ 1423 1425 1427 1441 1442 1444 1446 P DATAFORTH Address Range 1300 1499 PID Loop Controllers Data Controller Output lower limit Ye Integer part at Address 1420 fractional Number of Registers CO Low Clamp PV Tracking Gap Width Gap Multiplier Filter Time Constant Active Alarm Alarm Deadband High High Alarm Limit High Alarm Limit part at Address 1421 Track Process Variable in Manual Mode 0 Do Not Track PV 1 Track PV Gap around setpoint Engineering Units Integer part at Address 1423 fractional part at Address 1424 Gain multiplier inside Gap Integer part at Address 1425 fractional part at Address 1426 PV Filter Time Constant minutes Integer part at Address 1427 fractional part at Address 1428 Fractional part is in 10 000ths of a second Indicates which alarm condition Is active 0 Low Low
18. 0 ReDAQ Shape Software for MAQ 20 provides easy steps for Communication Module and I O Module configuration when running PID loops and a PID faceplate within the software enables an engineer or operator to quickly configure the many parameters required for loop control and to monitor processes For details on installation configuration and system operation refer to the manuals and software available for download from www dataforth com This includes but is not limited to MA1036 MAQ 20 Quick Start Guide MA1040 MAQ 20 Communications Module Hardware User Manual MA1041 MAQ 20 milliVolt Volt and Current Input Module Hardware User Manual MA1037 MAQ 20 Configuration Software Tool User Manual MA1038 MAQ 20 ReDAQ Shape for MAQ 20 User Manual MAQ20 940 941 ReDAQ Shape Software for MAQ 20 Developer Version User Version MAQ20 945 MAQ 20 Configuration Software Tool MAA20 952 IPEMotion Software for MAQ 20 Page2ora3 OXSDATAFORTH MA1056 PID Controller User Manual 3 0 General Description The Dataforth PID Controller is a digital proportional integral derivative PID controller for real time closed loop control of industrial processes and equipment It is one of several data acquisition and control tools integrated into the MAQ 20 modules and MAQ20 940 ReDA S Shape Software for MAQ 20 The PID Controller is built into the MAQ 20 Communications Modules and will run autonomously after being configured using the ReDA S Sha
19. 1043 MAQ20 DIOL Discrete IO Module HW User Manual for full details on configuring and operating the MAQ 20 Discrete Input Output Modules File Edit View Run Help OD d s aeax oes a gt Acquire Analyze Present 1 MAQ20 DIOL Device MAQ20 DIOL Serial Number 0088313 01 Retum Setup Special functions Timer1 Input DIO Input 0 Input2 DIO Input 1 Timer2 Input1 DIO Input 2 Input2 DIO Input 3 Timer1 Output DIO Output 0 Output2 DIO Output 1 Save Selected Ti and T2 Settings to EEPROM Timer2 Output1 DIO Output 2 Output DIO Output 3 Pulse Freguency Counter Counter With Debounce Wavefom Measurement Time Between Events Freguency Generator PWM Generation One Shot Pulse Timer Time Base Output 1 PWM Period PWM Output 0 Low Time PWM Output 1 Low Time MS Obat 100 10 10 me IMS Enabled gt Pulse Freguency Counter Counter With Debounce Wavefom Measurement Time Between Events Freguency Generator PWM Generation One Shot Pulse Timer2 Time Base Output 1 PWM Period PWM Output 0 Low Time PWM Output 1 Low Time Enabled MS x Enabled 500 10 10 Figure 9 Configuring PWM Outputs gt DATAFORTH Page 11 of 43 MA1056 MA 20 PID Controller User Manual 4 4 Creating a PID Controller in ReDAQ Shape From the main ReDAQ screen select the Present panel and open the Toolbox by selecting Open from the View pull down menu or by clicking on
20. AQ20 PWR3 Power Supply module is used to provide additional power When a MAQ 20 I O module is inserted into a system module registration occurs automatically data acquisition starts and data is stored locally in the module The system is based on a Modbus compatible memory map for easy access to acquired data configuration settings and alarm limits Information is stored in consistent locations from module to module for ease of use and system design MAQ 20 modules are designed for installation in Class I Division 2 hazardous locations and have a high level of immunity to environmental noise commonly present in heavy industrial environments MAQ 20 communications modules provide connection between a host computer and a MAQ 20 Data Acquisition System over Ethernet USB RS 485 or RS 232 Ethernet communications use the Modbus TCP protocol USB communications are based on the Modbus RTU protocol and RS 485 and RS 232 communications use the Modbus RTU protocol Serial communications over RS 485 can be either 2 wire or 4 wire Each MAQ20 COMx module can interface to up to 24 MAQ 20 I O modules in any combination allowing high channel counts and great flexibility in system configuration A removable microSD card can be used by the MAQ20 COMx module to log data acquired from the MA S20 I O modules PID control algorithms are implemented in the MAQ20 COM2 and MAQ20 COM4 Communications Modules for complete autonomous system operation The MAQ20 94
21. Details 8 31 2012 11 44 33 AM Auto tuning sequence started 0 54 45 PV 351 1 8131 2012 11 44 33 AM Step 1 Determining average CO and PV values Average CO 54 72 Average PV 350 8 31 2012 11 44 51 AM Step 2 Putting controller in manual at average CD 0 54 72 PV 349 3 8131 2012 11 44 52 AM Step 3 Collecting data for PV noise analysis Pk Pk PV noise estimate 3 241 GPM 6 31 2012 11 45 09 AM Step 4 Monitoring PV response after CO step change CO 59 72 PV 351 4 8 31 2012 11 45 14 AM Step 5 Steptesting to determine process characteristics Dead band 1 642 GPM 6 31 2012 11 45 14 AM Step 1 of 5 CO 49 72 PV 354 Figure 34 Auto Tuner Details Window Page32ot43 o EDAR MA1056 PID Controller User Manual 8 4 Typical Auto Tune Seguence Below are the steps that the auto tuner executes during a typical tuning seguence 1 Monitor the process to determine average controller output and process variable values 2 Put controller in manual at the average controller output level 3 Collect data for process variable noise analysis a Check if process variable deviation limits are more than 2 x noise level and abort sequence if not 4 Make a controller output step change and monitor the process variable response a Wait until process variable moves outside noise band 5 Step controller output up and down to determine process characteristics a Controller output will change direction every time the process variable cro
22. E ee ie LSB at Address 1373 Control Output minimum CO Count count value MSB at Minimum Address 1374 LSB at 0 t0 2732 1 INT32 Address 1375 Process Variable Range PV Range maximum value Maa Integer part at Address 0 to 65 535 INT16 1376 fractional part at Address 1377 gt DATAFORTH ASCII PID Description noo PID ASCII Engineering Units ASCII ASCII MA1056 PID Controller User Manual Address Range 1300 1499 PID Loop Controllers Start Data Read Write Contents Description Data type Process Variable Range PV Range minimum value 1378 R W 2 Mini Integer part at Address 0 to 65 535 INT16 inimum 1378 fractional part at Address 1379 Control Output Range CO Range maximum value 1380 R W 2 T a Integer part at Address 0 to 65 535 INT16 1380 fractional part at Address 1381 Control Output Range CO Range minimum value 1382 R W Mini Integer part at Address 0 to 65 535 INT16 inimum 1382 fractional part at Address 1383 EZE R W Algorithm 0 Noninteractive 0 or 1 INT16 1 Parallel Coritrol Control Direction 1387 R W 1 Direction 0 Reverse Acting 0 or 1 INT16 1 Direct Acting Setpoint Action 0 Proportional amp i Derivative on Error 1388 R W 1 ral 1 Proportional on Error Oto 2 INT16 Derivative on PV 2 Proportional amp Derivative on PV Operational Mode 1389 R W 1 Mode 0 Manual O or 1 INT16 1 Automatic Control Output Signal Type 0 Voltage
23. Loop Performance PID Without the Math second edition copyright 1993 David W St Clair Straight Line Control Co Inc New Directions in Bioprocess Modeling and Control Baudreau and McMillan copyright 2007 ISA Wikipedia PID Control Page0ota3 S Aan MA1056 PID Controller User Manual DATAFORTH WARRANTY Applying to Products Sold by Dataforth Corporation a General Dataforth Corporation Dataforth warrants that its products furnished under this Agreement will at the time of delivery be free from defects in material and workmanship and will conform to Dataforth s applicable specifications or if appropriate to buyer s specifications accepted in writing by Dataforth DATAFORTH S OBLIGATION OR LIABILITY TO BUYER FOR PRODUCTS WHICH DO NOT CONFORM TO THE ABOVE STATED WARRANTY SHALL BE LIMITED TO DATAFORTH AT DATAFORTH S SOLE DISCRETION EITHER REPAIRING REPLACING OR REFUNDING THE PURCHASE PRICE OF THE DEFECTIVE PRODUCT S PROVIDED THAT WRITTEN NOTICE OF SAID DEFECT IS RECEIVED BY DATAFORTH WITHIN THE TIME PERIODS SET FORTH BELOW i for all software products including licensed programs thirty 80 days from date of initial delivery ii for all hardware products including complete systems one 1 year from date of initial delivery iii for all special products sixty 60 days from date of initial delivery and further all products warranted hereunder for which Dataforth has received timely notice of nonco
24. Manual Address Range 1300 1499 PID Loop Controllers Number Read Write of Registers Address 1300 JJ 1301 h 1310 JJ 1330 JJ 1350 JJ 1355 JJ 1360 1366 1 1367 1 1368 JJ 1370 JJ 1372 JJ 1374 z 1376 z Page 36 of 43 Data Unique instance ID of 0 to 31 INT16 Controller Enable Disable Controller PID Enable 0 Disable 0or 1 INT16 1 Enable Characters PID Controller Name 10 Numbers PID Name characters max and Space PID Controller Characters heen Numbers Description 10 and characters max Space Engineering Units EU Characters chosen for the Numbers Controller and 5 characters max Space Units chosen for Characters PV Range Unit Process Variable Numbers 5 characters max and Standard unit Space Units chosen for Control Characters CO Range Output Numbers Unit 5 characters max and Standard unit Space System Address where Rd US Process Variable is 0 to 65 535 INT16 obtained from CO Modbus System Address where Control Output is sent to AA ponte Process Variable PV Count maximum count value A Maximum MSB at Address 1368 9102 321 INT32 LSB at Address 1369 Process Variable PV Count minimum count value Minimum MSB at Address 1370 9102321 INT32 LSB at Address 1371 Control Output CO Count maximum count value Maximum MSB at Address 1372 OI
25. al 4 9 Saving a PID Controller Configuration After the PID Controller has been configured run and optimized using the Auto Tuner save the PID Controller parameters to make them permanent Save parameters optimized by the Auto Tuner to the MAQ20 COM2 or MAQ20 COM4 non volatile memory using the following steps e Stop the active project running in REDAQ Shape e Double click the PID Controller faceplate to open the PID_properties window e Select PID Save to EE Save e Click OK e Ensure PID Enabled Enabled e Run the project again in ReDA S Shape Save the PID Controller configuration and the project built within ReDAQ Shape to a REDAQ Shape project file using the following steps e Stop the active project running in REDAQ Shape NOTE The PID Controller will continue to run as long as Enable is selected in the PID_properties window and the system is powered e Click on the Save icon on the toolbar or select Save Project from the File pulldown menu Choose an appropriate filename and directory location then click Save e Resume PID Controller monitoring and control by running the project again or terminate monitoring through ReDAQ Shape by closing the program NOTE The PID Controller will continue to run as long as Enable is selected in the PID_properties window and the system is powered The project can be opened the next time ReDAQ Shape is started by clicking on
26. ase order number for out of warranty repairs The product should be carefully packaged making sure the RMA number appears on the outside of the package and ship prepaid to Dataforth Corporation 3331 E Hemisphere Loop Tucson AZ 85706 USA An RMA Request Form and instructions for processing are also found at www dataforth com The information provided herein is believed to be reliable however DATAFORTH assumes no responsibility for inaccuracies or omissions DATAFORTH assumes no responsibility for the use of this information and all use of such information shall be entirely at the user s own risk Application information is intended as suggestions for possible use of the products and not as explicit performance in a specific application Prices and specifications are subject to change without notice No patent rights or licenses to any of the circuits described herein are implied or granted to any third party DATAFORTH does not authorize or warrant any DATAFORTH product for use in life support devices and or systems MAQ20 PID Controller User Manual MA1056 Rev B March 2014 2014 Dataforth Corporation All Rights Reserved ISO9001 2008 Registered QMS DATAR ee 43 of 43
27. ces e Integral gain specified in 1 minutes a higher integral gain makes the controller respond faster to long term deviations from setpoint e Derivative gain specified in minutes a higher derivative gain makes the controller more responsive to changes in the process variable Caution A controller needs to be tuned before putting it in automatic control mode Making the controller too responsive can cause control loop instability Auto Tune The Auto Tune button launches the controller s auto tuner The Auto Tune feature is described in detail in Section 8 0 Control Direction The Control Direction setting changes the direction in which the controller s output will change in response to a change in the process variable e Reverse acting if the process variable increases the controller output will be decreased to compensate This is used on most control loops i e water flow and furnace temperature e Direct acting if the process variable increases the controller output will be increased to compensate This is used on control loops such as refrigeration temperature and the level controller shown in Section 3 1 Figure 1 Caution The control direction must be set correctly before the controller is put in automatic control mode Measurement Range e Upper calibration limit the value in engineering units reflecting the full scale calibration value of the measurement device i e On a 4 20 mA signal this
28. ch or threatened breach by buyer or by any of its employees or agents of any term condition or provision of this Warranty or iii from any warranty representation covenant or obligation given by buyer to any third party and not expressly provided for in this Warranty or iv for any non compliance in any form of the products with any necessary or mandatory applicable laws regulations procedures government or industry policies or requirements related to the use sale or importation of the products Such indemnification shall include the payment of all reasonable attorneys fees and other costs incurred by Dataforth in defending such claim c Limitation on Damages 1 IN NO EVENT SHALL DATAFORTH ITS SUPPLIERS LICENSORS SERVICE PROVIDERS EMPLOYEES AGENTS OFFICERS AND DIRECTORS BE LIABLE FOR INDIRECT SPECIAL INCIDENTAL COVER ECONOMIC PUNITIVE ACTUAL EXEMPLARY CONSEQUENTIAL OR OTHER DAMAGES OF ANY NATURE INCLUDING WITHOUT LIMITATION LOST PROFITS OR REVENUES COSTS OF REPLACEMENT PRODUCTS LOSS OR DAMAGE TO DATA ARISING OUT OF THE USE OR INABILITY TO USE ANY DATAFORTH PRODUCT 2 IN NO EVENT SHALL DATAFORTH BE LIABLE FOR DIRECT SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE RESULTING FROM BUYER S NONCOMPLIANCE IN ANY FORM WITH ALL NECESSARY OR MANDATORY APPLICABLE LAWS REGULATIONS PROCEDURES GOVERNMENT POLICIES OR REQUIREMENTS RELATED TO THE USE SALE OR IMPORTATION OF PRODUCTS
29. de the gap A multiplier of 1 0 will have no effect and a multiplier of 0 0 will effectively turn off control when the process variable is inside the gap The latter provides a deadband e PV filter time constant a first order lag filter also called a low pass filter is provided to reduce the noise content on the process variable signal Large amplitude noise may cause substantial random movement in controller output which may damage the final control element or affect the downstream process A time constant of 0 minutes has no effect The longer the filter time constant the more filtering will be done Caution Filtering negatively affects the control loop s dynamic performance and should be used only when absolutely necessary If filtering has to be used the shortest acceptable time constant should be used The controller should be retuned after a filter has been added or adjusted e Significant digits to display This setting specifies the number of significant digits to display on the faceplate and in the controller settings window Page28ota3g S QXSDATAFORTH MA1056 PID Controller User Manual 7 3 Process Alarms The Process Alarms tab shown in Figure 31 allows the user to configure four different alarm levels If the process variable is above the high or high high alarm levels or below the low or low low alarm levels the controller faceplate indicates the active alarm as shown in Figure 32 The Alarm hysteresis
30. e 3 Features of the PID Controller Faceplate Entity Description Adjustment Controller Short name or tag name for the In controller settings window Name controller Description Friendly descriptive name for the In controller settings window controller Engineering Engineering unit for the measurement is In controller settings window Unit indicated in parentheses i e m hr C GPM etc Setpoint SP Numeric indicator of the setpoint target Adjustable from faceplate value for the process Controller will attempt to keep the process at this setpoint Process Numeric indicator of the process variable Value is generated by the Variable PV measured value of the process measurement device Controller Numeric indicator of the controller s output Value is generated by controller in Output CO to the process as calculated by the internal automatic mode or adjustable from control algorithm in automatic mode oras faceplate in manual mode set on the faceplate in manual mode Settings When clicked the Settings button opens Not applicable Button the controller s settings window in which configuration items can be changed Controller Determines if the controller is Toggled from faceplate Mode MODE automatically controlling the process MODE AUTO or if its output is manually adjustable from the faceplate MODE MANUAL Upper Upper calibration limits of the process Upper calibration limit for the process Calibration va
31. e Scale To Offset Unit Output 0 763 3810 Count 0 100 0 z Output 1 0 3810 Count 0 20 0 m U Output 2 0 3810 Count 0 20 0 mA Output 3 0 3810 Count 0 20 0 mA Output 4 0 3810 Count 0 20 0 mA Output 5 0 3810 Count 0 20 0 mA Output 6 0 3810 Count 0 20 0 mA Output 7 0 3810 Count 0 20 0 mA Figure 8 Setting the MAQ20 IO Output Module CO Signal Scale Page 10 of 43 DATAFORTH MA1056 PID Controller User Manual Applications which use a pulse width modulated signal for the Control Output reguire an additional step in the setup process In these situations the MA 20 DIOL or DIOH module must first be configured for PWM output The discrete output modules have two timers dedicated to Special Functions like PWM Output and each timer can have two PWM outputs for a total of four PWM outputs To configure the timers select the Special Functions tab then select the PWM Generation tab as shown in Figure 9 Set the Time Base Output 1 Status and PWM Period to the values reguired by the application Timer Enable and PWM Output Low Time will be updated by the PID controller during operation In the example below PWM Output 0 and PWM Output 1 each with a period of 100ms are enabled on Timer 0 and these signals will be output on channels DOO and DO1 respectively In addition PWM Output 0 with a period of 500ms is enabled on Timer 1 and this signal will be output on channel DO2 Press the Return button to return to the main screen Refer to MA
32. e after power reset Controllers receive process data from any MAQ 20 analog input module or any discrete input module i e Voltage Current Thermocouple RTD Strain Gage Frequency Controllers provide process control outputs through any MA S20 analog output or discrete output module i e Voltage Current PWM Non interacting and parallel PID control algorithms allow users to work with their choice of algorithm Proportional and derivative modes can act on error or process variable to eliminate bumps to the process resulting from setpoint changes Gap control is available to improve control loop stability near the setpoint but retain high speed of response when needed Built in process variable filtering smoothes out noisy measurement signals Transfer from manual to automatic control mode is completely bumpless Tuning settings can be changed with the controller in automatic control without disturbing the process The setpoint can optionally track the process variable during manual operation to further facilitate a smooth transition to automatic control mode The controller output range can be limited to protect sensitive equipment Anti reset windup minimizes overshoot and improves stability after output saturation conditions Four process alarms are available for warning operators of abnormal process conditions A full featured faceplate provides numeric and visual feedback of key control loop parameters and simplifies operator interact
33. er output steps from its starting value The auto tuner will step the controller output up and down from its starting value by the amount specified by the CO step limits value For example if the controller output at the start of the auto tune sequence is 40 and the CO step limits value is set to 5 the controller output will be stepped between 35 and 45 This value can be set to 0 1 or larger It should be set large enough that the controller output changes will drive the process variable clear outside its noise band Larger controller output steps generally improves auto tuning accuracy Number of CO steps The Number of CO steps value specifies the number of full size steps that the auto tuner will do to determine the average response of the process It can be set from 4 to 12 More steps will increase tuning accuracy but take longer to complete Max PV response time The Max PV response time value is used as a time limit for the process to respond to changes in controller output The value is specified in minutes The Max PV response time should be set long enough for the process to respond significantly to changes in controller output This could be a very long time on slow processes such as kiln or reactor temperature control loops CO DATAFOR ce 310143 MA1056 MA 20 PID Controller User Manual This is a liguid level controller This option should be checked if the process being controlled is an integrating process such as lig
34. eration Soo oo o oWoooo oo mo o ioa0 kas baaiana ani en ndn nan BBS ena 21 6T MeN te Mode EE EE ROERNE 21 6 2 CANIN S yt ON a 21 6 3 Changing the Controller Output WooW WWW Wo 22 7g 0 GOnroller Segan nan ere eee ee tte 23 11 BASIC SCTINGSisiccn cccsenexencersanexcie lt extiexenswaivewsencievenceues wasn sensneieseoe sedebisenbesenbonse pe senebisenbeeeebersepeseorseenboncd 24 SOMEONE FING C cscsnc5asenstenssstetetstatesscedeccesescsdececacecsgecacacecadecacaeacedacccscecedecaascecedecesaaecscecaascecese 24 BS SCHILD AN anto 24 TONO CUNO cic dees ana BA naa aa Sa 24 AUO TUNG AAA EE en anakan ena AN en Mam asas 25 CONTO Die CON none en an eee eee 25 Measurement Range oooooW W oo Wo WWW mana 25 Ie PRM ANC CO SOU NDS caste 26 Controller Quiput BN 26 EPON AO 26 Control FIO UMN ee ESEE EEEE EEEE na 27 CONTO DO On ben na 28 113 PIOCESS ALAIN S oasataoetaatmab ea EER Mini an inna oli 29 E DATAFORTH y MA1056 MA 20 PID Controller User Manual 2 0 Tb AMO TING aa 30 8 1 Accessing the Auto TUNET o WWoWo W om WWW mm an 31 8 2 Gonliguning me Auto FUN en SA E A a E on ane 31 ea Ik 31 Ne cng ss me 31 Number of CO Step cccccccceeccceeeeceeecee cess eeese sees eeeeeeesseeeeseeeeseeeeseeeesaeeesaeeesaeesseeeeseeeeseeeess 31 Max PY response M bea baba elu Banana Kon 31 TAS IS aA liguld level COntrOllet seenen a e DRA N 32 Desired speed of response ooo W W Wo Woo
35. he SP box the box also displays Up Arrow and Down Arrow buttons Clicking these buttons will increase or decrease the setpoint by 1 of its span For example if the calibration range of the process variable shared by the setpoint is 150 C to 450 C clicking the Up button in the SP box will increase the setpoint by 3 C The Up Arrow and Down QDDATAFORTH oe 21 of 43 MA1056 MA 20 PID Controller User Manual Arrow keys on the keyboard can be pressed with the same effect as clicking the Up Arrow and Down Arrow buttons in the SP box Figure 22 Numeric entry field with Up Arrow and Down Arrow buttons for changing the Setpoint If a value is entered that exceeds the setpoint range the out of range value will be ignored If clicking the Up Arrow or Down Arrow buttons or pressing the Up Arrow or Down Arrow keys will place the setpoint out of range the attempted change will be ignored 6 3 Changing the Controller Output The controller output can be changed only if the controller is in manual mode If the mouse is clicked in the CO box the controller output becomes changeable as shown in Figure 23 Anew value for the controller output can then be entered and pressing the Enter key will activate the new value in the controller Pressing the Escape key or clicking anywhere outside the CO box on the controller faceplate before pressing the Enter key will discard the change and restore the original value MANUAL Figure 23 Numeric e
36. igure 14 PID Controller Settings Advanced Settings Tab The extents to which the controller output can go when the controller operates in automatic control mode can be limited with the Controller output upper limit and Controller output lower limit to protect eguipment In manual control mode these limits do not restrict the controller output For this example set the upper limit to 100 and the lower limit to 0 Refer to Section 7 2 for further details on parameters in the Advanced Settings tab 4 7 Running a PID Controller Once the PID Controller has been fully configured two steps remain before the controller is run e Enter the Process Setpoint in the SP box The Setpoint units EU Engineering Units must match the units chosen during input channel configuration and PV selection e Click on the MODE button to select AUTO or MANUAL based on the type of control to be used in the application To run the PID Controller click the Start button on the toolbar at the top of the screen or click Run gt Start as shown in Figure 15 Figure 15 Starting the PID Controller ReDAQ Shape will download all PID Controller settings to the MAQ20 COM4 or MAQ20 COM2 Communications Module and the controllers will run if they have been enabled during the configuration process PID Controller settings downloaded to the MAQ 20 system will overwrite any existing settings in the MAQ 20 Communications Module DATAR ne 150143 MA1056 MA 20 PID C
37. ion An integrated Auto Tuner simplifies the complex task of control loop tuning with separate methods for integrating and self regulating processes CDATA ee 5 of 43 MA1056 MA 20 PID Controller User Manual 4 0 Connecting Configuring and Running a PID Controller The MAQ20 940 ReDAQ Shape Software for MAQ 20 provides a simple interface to the MAQ 20 Data Acquisition and Control System An extensive toolbox in the software has a specialized PID Controller Faceplate as well as numerous buttons switches graphs indicators and other devices for controlling and monitoring a process This section outlines how to connect a MAQ 20 system for PID control of a process and then how to configure and run a PID controller using ReDAQ Shape software For details on individual MAQ 20 Communications Modules I O Modules and system setup refer to the hardware and software user manuals and software available for download from www dataforth com The PID Controller provides real time closed loop control of industrial processes and equipment by comparing process output and setpoint values The chosen PID algorithm then minimizes this error by adjusting the proportional P Integral 1 and Derivative D terms over time until the desired operating point is reached The controller then maintains stable process operation over setpoint changes and process variations The Noninteractive Control Algorithm is shown in Figure 2 and control algorithms are detai
38. led in Section 7 2 Controller Set point output Process variable Figure 2 PID Control Using the Noninteractive Control Algorithm A typical Level Control application which uses the MAQ 20 hardware and ReDA S Shape software is shown in Figure 3 In this example a MAQ20 IDN process current input module monitors the liquid level in the tank and provides the Process Variable while the MA 20 IO process current output module provides the Controller Output Dataforth ReDAQ Shape with PID Controller Feed flows Level measurement Dataforth MAQ 20 Level control valve Figure 3 Level Control with MAQ 20 Pageso43 SS DATAFORTH MA1056 PID Controller User Manual 4 1 Connecting to a MAQ 20 System using ReDAQ Shape Install the MAQ 20 Communications and I O Modules Connect the level measurement signal to the MAQ20 IDN module using the input connections listed in Table 1 For the purposes of this example Input Channel 0 will be used for level measurement Table 1 MAQ20 IDN Input Terminal Block Connections TERMINAL BLOCK MAQ20 IDN POSITION INPUT TOP TO BOTTOM CONNECTIONS IN Connect the level control valve signal to the MAQ20 IO module using the output connections listed in Table 2 For the purposes of this example Output Channel 0 will be used for valve control Table 2 MAQ20 IO Output Terminal Block Connections TERMINAL BLOCK MAQ20 I0 POSITION OUTPUT TOP TO BOTTOM CONNECTIONS CHO OUT p
39. ller and process The faceplate supports the following key operations e Toggle the controllers mode between automatic and manual e Change the setpoint to a new value e Change the controller output to a new value only possible if the mode is manual When the mouse is moved over the SP CO or MODE box on the faceplate the cursor changes from an arrow to a pointing hand and the background color of the box changes from gray to steel blue indicating that the contents of the box can be changed as shown in Figure 20 Note that the CO box becomes changeable only if the controller is in manual mode The PV box never becomes changeable because its value comes from the process SP GPM Figure 20 Mouse cursor and box background change when mouse is moved over a changeable box 6 1 Changing the Mode The controller mode is toggled between automatic mode AUTO and manual mode MANUAL by clicking the mouse inside the MODE box as shown in Figure 21 Figure 21 Changing the Controller Mode 6 2 Changing the Setpoint If the mouse is clicked in the SP box the setpoint becomes changeable as shown in Figure 22 A new value for the setpoint can then be entered and pressing the Enter key will activate the new value in the controller Pressing the Escape key or clicking anywhere outside the SP box on the controller faceplate before pressing Enter will discard the change and restore the original value Once the mouse has been clicked in t
40. n the Basic Settings tab Because the 4 to 20mA signal used for the Process Variable in this example was scaled to 0 to 100 enter Yo in the Engineering unit box The Upper calibration limit is the value in engineering units reflecting the full scale calibration value of the measurement device For this example the value is 100 The Lower calibration unit is the value in engineering units reflecting the zero calibration value of the measurement device For this example the value is 0 Refer to Section 7 1 for further details on parameters in the Basic Settings tab Page 14 of 43 DO DATAFORTH MA1056 PID Controller User Manual Next review the settings in the Advanced Settings tab as shown in Figure 14 File Edit View Run Help DEH DAXSUAs Acguire Analyze Present 1 MAQ20_ 1 4 MAQ20_1 Settings Controller 100 100 Controller Output Limits Controller output upper limit 100 Controller output lower limit 0 Setpoint Action ly Proportional and derivative on error Proportional on error derivative on PV Proportional and derivative on PV v Track process variable in manual mode Control Algorithm and Options Noninteractive standard ideal algorithm Parallel independent gains algorithm Gap around setpoint Gain multiplier inside gap PV filter time constant minutes Significant digits to display 0 Settings a Cancel Apply F
41. nformance must be returned FOB to Dataforth s plant in Tucson Arizona USA within thirty 30 days after the expiration of the warranty periods set forth above The foregoing warranties shall not apply to any products which Dataforth determines have by buyer or otherwise been subjected to operating and or environmental conditions in excess of the maximum value established therefore in the applicable specifications or any products that have been the subject of mishandling misuse misapplication neglect improper testing repair alteration or damage THE PROVISIONS OF THE FOREGOING WARRANTIES EXTEND TO BUYER ONLY AND NOT TO BUYER S CUSTOMERS OR USERS OF BUYER S PRODUCTS THE DATAFORTH STANDARD WARRANTY IS IN LIEU OF ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR USE AND ALL OTHER WARRANTIES WHETHER EXPRESS IMPLIED OR STATUTORY EXCEPT AS TO TITLE THE DATAFORTH STANDARD WARRANTY MAY BE CHANGED BY DATAFORTH WITHOUT NOTICE b Buyer Indemnity Buyer agrees to indemnify and hold Dataforth harmless from and against any and all claims damages and liabilities whatsoever asserted by any person entity industry organization government or governmental agency of any country resulting directly or indirectly i from any acts not authorized by Dataforth in writing or any statements regarding the P DATAFORTH products inconsistent with Dataforth s product documentation or standard warranty or ii from any brea
42. ntry field with Up Arrow and Down Arrow buttons for changing the Controller Output Once the mouse has been clicked in the CO box the box also displays Up Arrow and Down Arrow buttons Clicking these buttons will increase or decrease the controller output by 1 The Up Arrow and Down Arrow keys on the keyboard can be pressed with the same effect as clicking the Up Arrow and Down Arrow buttons in the SP box If a value is entered that exceeds the controller output s range of 0 to 100 the out of range value will be ignored If clicking the Up Arrow or Down Arrow buttons or pressing the Up Arrow or Down Arrow keys will place the controller output out of range the attempted change will be ignored Page22ot48 S ODAAT MA1056 PID Controller User Manual 7 0 Controller Settings The Dataforth PID controller has many settings that users can adjust to change the way the controller behaves The settings are accessed by clicking the Settings box on the faceplate as shown in Figure 24 Figure 24 Access Controller Settings by Clicking the Settings Box The settings window displays the controller name in the title bar This is important because more than one settings window could be open simultaneously The settings are separated onto three tabs as shown in Figure 25 1 FIC 100 Settings Basic Settings Per Settings Process Alams Controller name FIC 100 Figure 25 Settings Wind
43. o CHO OUT DATAR ge 7 of 43 MA1056 MA 20 PID Controller User Manual Run the ReDAQ Shape software and connect to the MA S20 hardware by clicking on the Connect button in the Acquire panel as shown in Figure 4 The software will display the input and output modules discovered in the system File Edit View Run Help D W saeaxseaia gt Acquire Analyze Present 1 Connect To MAQ20 er Scan Interval ns 100 Time Out ms 2000 gemy System 1 Enabled SP IP Addres 168 128 1 USB Port 1 COM3 Target ID 16 31 16 Baud Rate 115200 Party Even Click on Connect button to start ID Edit Unlockec Communication Connected Scan interval 100ms Running activity Control Loop Alarm Output activity None Figure 4 Connecting to the MAQ 20 System Page 8 of 43 0 DATAFORTH MA1056 PID Controller User Manual 4 2 Selecting and Scaling the Process Variable PV in ReDA Shape PID process variable input signals can be process voltage through the MAQ20 VDN or VSN module process current through the MAQ20 IDN or ISN module discrete input through the MAQ20 DIOL or MAQ20 DIOH module or any other signal from an industrial process or test and measurement application measured through a MAQ 20 input module To configure an input channel as a process variable locate the module graphic on the Acquire panel that corresponds to the MAQ20 input module which has the input signal
44. of Dataforth Corporation ReDAQ is a registered trademark of Dataforth Corporation Modbus is a registered trademark of the Modbus Organization Inc LabVIEW is a trademark of National Instruments Corporation E DATAFORTH MA1056 PID Controller User Manual Table of Contents EO Oy Stem RERE Aa 1 2 0 System Description and Documentation o oo o Woo 2 20 General Dee ON oa ana aa Ana Naas anon AKA ana aa San bana Sab 3 Sel YC LAPIGA Senen NA NN NK MAN Rn ta 4 a SY Pen nm aan san an ani An aan Gema 5 4 0 Connecting Configuring and Running a PID Controller ooomoooooWoWoWoW WWW Wak 6 4 1 Connecting to a MAQ 20 System using ReDA S Shape oooooooooooooo 7 4 2 Selecting and Scaling the Process Variable PV in REDAQ Shape ooooooo 9 4 3 Selecting and Scaling the Control Output CO in REDAQ Shape oooooooooo 10 4 4 Creating a PID Controller in REDAQ Shape ooooocoooooo oo oo oo oom 12 4 5 Selecting the PID Controller Input PV and Output CO in ReDAQ Shape 13 4 6 PID Gontroller STING So an on aa aan 14 as RUNO A PID Ono Eee enam maa nona osn aan Rana Nana Ana aan ai Ann 15 4 8 Tuning a PID Controller oo oo ooo ooo o ooooo co Wo o bm b bbs 16 4 9 Saving a PID Controller ConfiguratiOn ooWooWo om Wo Wae 18 5 0 The Controller Faceplate Woooooo Woo oo WWW Wo W mma 19 6 0 Basic PID Op
45. ontroller User Manual Tools such as Gauge Chart Recorder and Scope which are found in the ReDA S Shape Toolbox can be used to display the PV CO and other process variables as shown in Figure 16 These can be put on the project Present panel when a project is first built as well as added and removed at any time For full details on ReDAQ Shape Toolbox Tools refer to MA1038 ReDAQ Shape for MAQ20 User Manual File Edit View Run Help Acquire Analyze Present 1 u a MAQ20 1 Mix Tank Liquid Level Controller 100 100 1 50 7 F 60 N 30 70 SP EU 67 20 80 vd A PV EU 67 33 0 100 SP CO 61 57 Mix Tank Valve ee MODE AUTO Settings 0 Figure 16 Displaying PV and CO During PID Controller Run Using Toolbox Tools 4 8 Tuning a PID Controller A powerful function integrated in the MAQ20 940 ReDA Shape Software for MAQ 20 is an Auto Tuner which is used to simplify the complex task of control loop tuning To run the Auto Tuner first configure the system and the PID Controller Next Run the system and click the Settings button in the lower left corner of the PID Controller Faceplate From the Basic Settings tab click the Auto Tune button in the middle of this window as shown in Figure 17 Acquire Analyze Present 1 MAQ20 1 Controller a
46. orithm Controller Error Set point Process variable Figure 29 The Noninteractive Control Algorithm The equation of the noninteractive controller algorithm is as follows CO K E f Edt 7 a T P dt Where CO is the controller output E is the error between process variable and setpoint Kc is the controller gain Tiis the integral time Tp is the derivative time CODATA ng 270143 MA1056 MA 20 PID Controller User Manual Proportional Controller Set point Error output Process variable Figure 30 The Parallel Controller Algorithm The eguation of the parallel PID controller algorithm is as follows dE Where CO is the controller output E is the error between process variable and setpoint Kp is the proportional gain K is the integral gain Kp is the derivative gain Using the noninteractive algorithm is recommended unless there is a good reason to use the parallel algorithm Control Options e Gap around setpoint with gap control a lower controller gain can be used when the process variable is close to setpoint This will reduce the extent of controller output movements when the process variable in this area The Gap around setpoint setting specifies the width of the gap above and below the setpoint It is specified in the process variable s engineering units e Gain multiplier inside gap the controller gain is multiplied by this factor when the process variable is insi
47. ow with Three Tabs e The Basic Settings tab contains basic settings that need to be adjusted for every PID controller e The Advanced Settings tab contains advanced settings that do not need to be adjusted unless there is a specific need to do so e The Process Alarms tab contains process alarm settings that need adjustment only if the controller faceplate should display alarm conditions The controller settings available on these three tabs are described in detail in Sections 7 1 7 2 and 7 3 Below the tabs are three buttons shown in Figure 26 e OK applies all changes and closes the window e Cancel closes the window without applying any changes e Apply applies all changes and leaves the window open ee AE Cancel Figure 26 Buttons in the Settings Window gt DATAFORTH Page 23 of 43 MA1056 MA 20 PID Controller User Manual 71 Basic Settings 6 FIC 100 Settings Basic Settings Advanced Settings Process Alarms Controller name FIC 100 Description Steam How Controller Tuning Settings Controller gain 0 8 FT Integral time 0 1 minutes Derivative time 0 minutes Auto Tune Control Direction Reverse acting Direct acting Measurement Range Upper calibration limit 400 GPM Lower calibration limit 0 GPM Engineering unit GPM OK Cancel Apply Figure 27 Basic Settings The settings on the Basic Settings tab shown in Figure 27 need to be adj
48. pe software or Modbus commands The controller will automatically restart and resume control after power reset Up to 32 controllers can be configured to run on a single MAQ 20 Communications Module Each will receive process data from any MA S20 analog input or discrete input module installed in a system and will provide process control outputs through any MAQ 20 analog output or discrete output module in a system The controllers operate with a fixed update rate of 1 second The MAQ20 940 ReDAQ Shape Software for MAQ 20 software has a specialized faceplate through which an engineer or operator can interact with the controllers It also provides time trends for monitoring the controller and process over time One of the outstanding features of the Dataforth PID Controller is an Auto Tune function which is used to simplify the complex task of control loop tuning For users with limited or no experience in PID loop tuning Dataforth has published several highly recommended in depth application notes on this topic These provide a basic overview of what is to be accomplished and considerations for different types of control This manual describes how to use the MAQ20 system to run control loops The auto tuner can be very useful however no auto tuner can be expected to find solutions to all control loops A basic understanding of the overall control problem may be needed to achieve a stable feedback loop Most loops do not need or use the Derivati
49. plications DATAFORTH S PRODUCTS ARE NOT DESIGNED INTENDED AUTHORIZED OR WARRANTED TO BE SUITABLE FOR USE IN LIFE SUPPORT DEVICES OR SYSTEMS SAFETY EQUIPMENT NUCLEAR FACILITY APPLICATIONS OR OTHER CRITICAL APPLICATIONS WHERE MALFUNCTION OF THE PRODUCT CAN BE EXPECTED TO RESULT IN PERSONAL INJURY DEATH OR SEVERE PROPERTY DAMAGE BUYER USES OR SELLS SUCH PRODUCTS FOR USE IN SUCH CRITICAL APPLICATIONS AT BUYER S OWN RISK AND AGREES TO DEFEND INDEMNIFY AND HOLD HARMLESS DATAFORTH FROM ANY AND ALL DAMAGES CLAIMS PROCEEDINGS SUITS OR EXPENSE RESULTING FROM SUCH USE h Static Sensitive Dataforth ships all product in anti static packages Dataforth s Warranty as hereinabove set forth shall not cover warranty repair replacement or refund on product or devices damaged by static due to buyer s failure to properly ground gt DATAFORTH MA1056 PID Controller User Manual Application Support Dataforth provides timely high guality product support Call 1 800 444 7644 TOLL FREE Returns Repair Policy All warranty and repair reguests should be directed to the Dataforth Customer Service Department at 520 741 1404 If a product return is required request a Return Material Authorization RMA number You should be ready to provide the following information 1 Complete product model number 2 Product serial number 3 Name address and telephone number of person returning product 4 Special repair instructions 5 Purch
50. riable and controller output variable is adjustable in controller Limits settings window The upper calibration limit for the controller output is always 100 Alarm Point Levels on process variable scale In controller settings window Indicators above below which alarms are initiated Setpoint Indicator on process variable scale at the Adjustable from faceplate Indicator level of the setpoint Process Bar chart type indication of the current Level of the bar is determined by the Variable Scale value of the process variable feedback value from the measurement measurement relative to its upper and device lower calibration limits Controller Bar chart type indication of the current Level of the bar is determined by value Output Scale value of the controller output relative to its of the controller output upper and lower calibration limits of 0 and 100 respectively Lower Lower calibration limits of the Lower calibration limit for the process Calibration measurement device and controller output variable is adjustable in controller Limits settings window The lower calibration limit for the controller output is always 0 Process Indicates the currently active process Generated by controller based on level Alarm alarm if any of PV relative to alarm levels Indicator Page20ota3 o OXSDATAFORTH MA1056 PID Controller User Manual 6 0 Basic PID Operations The PID controller s faceplate is the primary interface to the contro
51. rocessing Enables Even More Functionality e Output modules are programmable for user defined waveforms e Discrete I O modules have seven high level functions gt Pulse Counter Frequency Counter Waveform Measurement Time Between Events Frequency Generator PWM Generator gt One Shot Pulse Generator VV VV Y Multiple Software Options e Free Configuration Software e Intuitive Graphical Control Software gt ReDAQ Shape Graphical HMI Design amp Runtime Solution gt IPEmotion Muli Vendor and Multi Language Solution gt Programming examples and LabVIEW Vis gt DATAFORTH Page 1 of 43 MA1056 MA 20 PID Controller User Manual 2 0 System Description and Documentation A MAQ 20 Data Acquisition System must have as a minimum a Communications Module a Backbone and one I O Module Examples include MAQ20 COMx Communications Module with Ethernet USB and RS 232 or RS 485 Interface MAQ20 DIOx Discrete Input Output Module MAQ20 xTC Type x Thermocouple Input Module MAQ20 mVxN VxN Voltage Input Module MAQ20 IxN Process Current Input Module MAQ20 IO VO Process Current Output and Process Voltage Output Module MAQ20 BKPLx x Channel System Backbone Refer to www dataforth com for a complete listing of available modules and accessories System power is connected to the Communications Module which in turn powers the I O modules For systems with power supply requirements exceeding what the Communications Module can provide the M
52. s 10 Percent Ultimate period 0 2667 minutes Control modes to use P PI PID Ultimate gain 10 52 X Curent New Controller gain 1 645 1 893 2 2 CO step limits 5 from starting value Number of CO steps 5 Tuning Criteria ton Integral time 0 5654 02771 minutes Max PV response time 3 minutes This is a liguid4evel controller Derivative time 0 0 minutes Desired speed of response Ensure process is stable before starting Regular r Activate New Values oem Tuning seguence completed successfully Figure 33 The Dataforth PID Auto Tuner and trends indicating a typical auto tune sequence The Dataforth Auto Tuner executes a simple test to determine the dynamic characteristics of the process that the controller has to control The Auto Tuner then calculates tuning settings according to the identified dynamic characteristics The Auto Tuner has various settings that the user should adjust prior to starting it to ensure the process remains within safe boundaries during testing The Auto Tuner displays a set of trends on a real time chart and logs all changes and calculation results during the entire auto tune sequence After the auto tune sequence has completed the user can change the desired speed of response for the control loop if needed and load the new settings into the controller Page 30 of 43 DO DATAFORTH MA1056 PID Controller User Manual 8 1 Accessing the Auto Tuner To access the a
53. s example from the Acquire panel click on the MAQ20 IO module in Slot 2 to open the screen shown in Figure 7 Assign the User Tag Name Mix Tank Valve to Output Channel 0 and set the Output Range to 4 20mA File Edit View Run Help IG kaana Acguire Analyze Present 1 MAQ20 I0 Device MAQ20 IO Serial Number 0000000 13 Retum Setup Scale Data Continuous Scan Mode Buffer Scan Mode Buffer Mode Interval Range 10 65535ms 100 Channel Name User Tag Name Output Data Default Output Output Range Buffer Mode Output Data Output 0 Mix Tank Valve 4 4 4 20mA X 1152 25 3394 45 R Output 1 11021 0 0 0 20 mA z j4 Output 2 1022 0 0 0 20 mA X Output 3 1023 0 0 0 20 mA X Output 4 11024 0 0 0 20 mA se Output 5 11025 0 0 0 20mA 4 5 4 3 5 3 2 5 2 1 5 1 R Output 6 11026 0 0 0 20 mA l 11 1 5 2 2 5 3 3 5 4 4 5 S Output 7 11027 0 0 0 20mA 4 54 3 5 3 2 5 21 5 1 5 Figure 7 MAQ20 IO Control Output Channel Setup Next select the Scale Data tab and specify the scale for the PID control output as shown in Figure 8 The PID control output scale setting must be 0 to 100 for proper controller operation Press the Return button to return to the main screen File Edit View Run Help Dedi 4 BX Tas gt Acquire Analyze Present 1 MAQ20 I0 Device MAG20 IO Serial Number 0000000 13 Retum Setup Scale Data Data Name Full Scal
54. sic Settings vanced Settings Process Alarms 400 100 o er name SP EU if SAE i n 01114 4 1 67 F 0 008619 minutes PV EU 67 02 H SP CO 61 36 MODE AUTO ag E Figure 17 Starting Auto Tune Page t6043 S CDan MA1056 PID Controller User Manual The PID Controller Auto Tune interface will open as shown in Figure 18 The tuning process is initiated by clicking the Start button in the lower left corner of the window When the tuning process runs the Auto Tune Details window opens and lists the tuning process steps as they occur displaying measured results lf the process is stable and can be tuned the Auto Tuner will converge and a message box will indicate success iy MAO20 1 Controller DataForth PID vw ng oo v j sSsukKwww B 16 02 44 16 03 14 16 03 29 Controller Output 16 02 29 16 03 14 Tuning Sequencer Step Test Results PV deviation limits 20 EU Ultimate gain 0 4905 CO step limits 5 from starting value N Number of CO steps 5 Tuning Criteria Max PV response time 3 minutes Desired speed of response Ensure process is stable before starting Regular X Daan Tuning sequence completed successfully l as Process Variable and Set Point Ultimate period 0 06689 minutes This is a liquid4evel controller 16 03 59 16 03 44 16 03 59 Controller Tuning Control modes to use P PI PID Curent New Controller gain 0 1114 0
55. ss there is a specific need to do so However these settings are important features of a PID controller when needed Controller Output Limits The extents to which the controller output can go when the controller operates in automatic control mode can be limited with the Controller output upper limit and Controller output lower limit to protect equipment In manual control mode these limits do not restrict the controller output Setpoint Action The output of a standard PID controller can spike significantly because of the derivative mode acting on a setpoint change Even without derivative control the output of a high gain controller can still produce a large bump because of the proportional mode acting on a setpoint change To eliminate these spikes and bumps the controller provides a group of settings where the user can specify which control modes respond to setpoint changes e Proportional and derivative on error this is the standard arrangement in which both proportional and derivative modes act on setpoint changes and on process variable changes but that is beside the point here This option will cause the controller output to spike under derivative control and to bump under proportional control when the setpoint is changed Page 260f43 o DnR MA1056 PID Controller User Manual e Proportional on error and derivative on PV proportional mode will act on setpoint and process variable changes while derivative mode will act only
56. sses over its average value from Step 1 Restore controller output to original level and put controller in original mode 7 Calculate process characteristics a Display various calculated values and the average error deviations from the average value 8 End the tuning sequence gt Throughout the sequence the auto tuner checks to ensure the process variable remains within specified limits from the setpoint 8 5 Auto Tune Process Troubleshooting The Auto Tune Sequence Did Not Complete If the auto tune sequence was aborted for any reason the auto tuner will log the reason in the Details window Depending on the abort message the problem and its solution could be one of the following e Process was not steady enough to do tuning o Stabilize the process if possible i e by putting other loops in manual o Increase PV deviation limits and CO step limits e Process has too much noise disturbances for tuning o Stabilize the process if possible i e by putting other loops in manual o Increase PV deviation limits and CO step limits e PV deviation limit is set too small o Increase PV deviation limits e CO step limit is set too small o Increase CO step limits e PV response time is set too short o Increase the Max PV response time e PV moved in the wrong direction compared to the controller s control direction setting o Make sure the Control Direction in the Basic Settings is set correctly o Stabilize the process if possible i e b
57. sters reserved for the specified contents Contents Parameter stored at the specified address Description Details examples limits and default values for the parameter stored at the specified address Data Range Valid data read from or written to an address range Data not in this range which is written to an address may return a Modus Exception 3 Illegal Data or may be ignored Data Type The type of data stored at the specified address ASCII 0123456789ABCDEFGHIJKLMNOPQRSTUVW XYZabcdefghijklmnoparstuvwxyz INT16 16 bit integer value 0 to 65535 unless otherwise indicated Stored at a single address INT32 32 bit integer value 0 to 4294967295 unless otherwise indicated Stored at two 16 bit addresses MSB is stored at address N LSB is stored at address N 1 Table 4 MAQ20 COM2 COM4 Address Map NOTE When a module is registered in a system addresses are offset by 2000 R where R is the Registration Number MAQ20 COMx Communication Module addresses always start at zero and are not offset by the Registration Number Refer to MA1040 MAQ20 Communications Module Hardware User Manual for further details on Registration Number Address Range 0 99 Module Information Start Number Address Read Write of Contents Description Registers See MA1040 MAQ 20 Communications Module Hardware User Manual for the Communications Module complete Address Map CDATA eg 35 of 43 MA1056 MA 20 PID Controller User
58. th above Buyer shall not return any products for any reason without the prior authorization of Dataforth and issuance of a Return Material Authorization RMA number After issuance of a RMA number such products shall be promptly returned by buyer and in no event later than thirty 30 days after the Warranty expiration date transportation and insurance prepaid to Dataforth s designated facility for examination and testing Dataforth shall either repair or replace any such products found to be so defective and prompily return such products to buyer transportation and insurance prepaid Should Dataforth s examination and testing not disclose any defect covered by the foregoing Warranty Dataforth shall so advise buyer and dispose of or return the products in accordance with buyer s instructions and at buyer s sole expense and buyer shall reimburse Dataforth for testing expenses incurred at Dataforth s then current repair rates Page 42 of 43 f Repair Warranty Dataforth warrants its repair work and or replacement parts for a period of ninety 90 days from receipt by buyer of the repaired or replaced products or for the remainder of the warranty period for the initial delivery of such order as set forth in paragraph a above whichever is greater g Critical Applications Certain applications using Dataforth s products may involve potential risks of death personal injury or severe property or environmental damage Critical Ap
59. the Open icon or by selecting Open existing project from the File pull down menu Once the project has been loaded and the MAQ 20 system is connected using the Connect button on the Acquire panel PID Controller monitoring and control through ReDAQ Shape will resume PagetBota3 S XS DATAFORTH 5 0 The Controller Faceplate MA1056 PID Controller User Manual The PID controller s faceplate shown in Figure 19 is the primary interface to the controller used by engineers or operators in charge of the process process and controller and allows engineers and operators to interact with both access to all of the controller s operational It displays important information about the It also provides configuration settings and to the auto tuner Table 3 describes the various features of the faceplate Controller Name amp Description Engineering Unit Setpoint a GPM 350 PV GPM Process Variable ___ ___ i CO Controller Output 49 Controller Mode ay Settings Button Settings Figure 19 PID Controller Faceplate gt DATAFORTH Steam Flow Controller FIC 100 Upper Calibration Limits E 100 ug a Alarm Point Indicators Setpoint Indicator Process Variable Scale Controller Output Scale I Lower Calibration Limits Process Alarm Indicator Page 19 of 43 MA1056 MA 20 PID Controller User Manual Tabl
60. uid levels It affects the calculation of tuning parameters Desired speed of response This setting allows the user to specify how fast the tuned control loop should respond relative to the process dynamics Three options are available Slow and stable Regular and Fast response Note Fast response for a naturally slow process such as reactor temperature will be significantly slower than fast response for a naturally fast process such as steam flow Control modes to use This setting determines the control modes to be used in the controller proportional only P proportional pus integral P and proportional plus integral plus derivative PID Proportional plus integral P control is recommended unless there is a specific reason to use one of the others Note A proportional only controller P will not always be able to keep a process at its setpoint Controllers using derivative mode PID do not work well on some processes 8 3 The Auto Tune Sequence Once the auto tuner has been configured the tuning sequence can be started by clicking the Start button The sequence can be stopped at any time by clicking the Abort button While the auto tune sequence is in progress its progress is shown on the real time charts and all the changes and calculation results are logged in the Details window as shown in Figure 34 The Details window opens automatically when the Start button is clicked lly FIC 100 Auto Tune
61. ulti channel industrially rugged signal conditioning I O and communications modules Instrument Class Performance e 0 035 Accuracy e Industry leading t0 3C CJC Accuracy over full operating temperature range e Ultra low Zero and Span Tempco e Over range on one channel does not affect other channels e 1500Vrms Channel to Bus Isolation e 240Vrms Continuous Field I O Protection e ANSI IEEE C37 90 1 Transient Protection e Ventilated Communications and I O Modules e Industrial Operating Temperature of 40 C to 85 C e Wide Range 7 34VDC Power e CE Compliant UL CUL Listing and ATEX Compliance pending Industry Leading Functionality e The system is a Modbus Server and can be operated remotely with no local PC e Up to 4GB of logged data can be transferred via FTP during real time acquisition e Up to 24 I O modules or 384 channels per system per 19 rack width e Per channel configurable for range alarms and other functions e Backbone mounts within DIN rail and distributes power and communications e System firmware automatically registers the installation and removal of I O modules e 1 O modules can be mounted remotely from the Communications Module e Equal load sharing power supply modules allow for system expansion e Hot Swappable I O modules with Field side pluggable terminal blocks on most models e Sophisticated package enables high density mounting in 3U increments e DIN Rail can be mounted on a continuous flat panel or plate Distributed P
62. und loops and other hazards present in industrial environments Dataforth spans the globe with more than 50 International Distributors and US Representative Companies Our customers benefit from a team of over 130 sales people highly trained in the application of precision products for industrial markets In addition we have a team of application engineers in our Tucson factory ready to solve any in depth application questions Upon receipt of an RFQ or order our Customer Service Department provides fast one day delivery information turnaround We maintain an ample inventory that allows small quantity orders to be shipped from stock Dataforth operates under an ISO9001 2008 quality management system Contacting Dataforth Corporation Contact Method Contact Information Piniel suen lemnoosasomam Technical Support techinfo dataforth com Website SC wwwdataforth com O S Website www dataforth com Phone CC 520 741 1404 and toll free 800 444 7644 Fax 520 7141 0762 Dataforth Corporation 3331 E Hemisphere Loop Tucson AZ 85706 USA Errata Sheets Refertothe Technical Support area of Dataforth s website www dataforth com for any errata information on this product P DATAFORTH MA1056 PID Controller User Manual 1 0 System Features The MAQ 20 Data Acquisition System encompasses more than 25 years of design excellence in the process control industry It is a family of high performance DIN rail mounted programmable m
63. usted for every PID controller There are no generic values for the Basic Settings that will work on all controllers Controller Name The Controller name is a short name loop ID or tag name used to identify the controller All controllers should have a unique Controller name Description The Description is a meaningful description for the controller generally describing the process being controlled Tuning Settings A controller s tuning settings adjust the amount of proportional Controller gain integral Integral time and derivative action Derivative time produced by the controller for a given error If the Controller Algorithm is set to Noninteractive on the Advanced Settings tab the following tuning settings are available e Controller gain a higher controller gain makes the controller more responsive to setpoint changes and disturbances e Integral time specified in minutes a shorter integral time makes the controller respond faster to long term deviations from setpoint e Derivative time also specified in minutes a longer derivative time makes the controller more responsive to changes in the process variable Page2dot48 S ODAAT MA1056 PID Controller User Manual If the Controller Algorithm is set to Parallel on the Advanced Settings tab the following tuning settings are available e Proportional gain a higher controller gain makes the controller more responsive to setpoint changes and disturban
64. uto tuner do the following e Goto the Controllers faceplate e Click the Settings box to open the controller settings window e Click the Basic Settings tab e Click the Auto Tune button 8 2 Configuring the Auto Tuner The auto tuner has several settings that the user should adjust to ensure the process remains within safe boundaries during testing and to improve the accuracy of the auto tuning process It also has settings that affect the calculation of the tuning parameters These settings are described below PV deviation limits The PV deviation limits setting specifies the maximum deviation of the process variable from its starting value that is allowed If at any time during the auto tune sequence the process variable deviates farther away from its starting point than specified by the PV deviation limits value the auto tune sequence will terminate the controller output will be set back to its original value and the controller will be returned to its original mode auto or manual Deviation limits can be input as a percentage of the full soan of the process variable or specified in engineering units The Y axis of the Process Variable and Setpoint chart on the auto tuner auto scales according to this value This PV deviation limits value should be set a minimum of 2 times larger than the normal peak to peak fluctuations on the process variable CO step limits The CO step limits setting specifies the extents of the controll
65. ve D element of PID control Proportional Integral PI elements are more than enough Unless the reader is experienced at tuning control loops please refer to the Dataforth web site for AN122 through AN126 www dataforth com app notes aspx AN123 Tuning Control Loops for Fast Response AN124 Tuning Control Loops with the IMC Tuning Method AN125 Tuning Level Control Loops AN126 Tuning Surge Tank Control Loops CDATA ge 3 of 43 MA1056 MA 20 PID Controller User Manual 3 1 Typical Applications Although there is no limit to the types of processes that can be controlled with the Dataforth PID Controller typical applications may include e Steam water and chemical flow control e Tank level control Figure 1 e Heat exchanger and reactor temperature control e Pressure control Dataforth ReDAQ Shape with PID Controller Feed flows Level measurement Dataforth MAQ 20 Level control valve Figure 1 Level Control with MAQ 20 Pageta S OFS DATAFORTH MA1056 PID Controller User Manual 3 2 Key Features The Dataforth PID Controller comes with a range of features paralleled only by state of the art distributed control systems PID controllers are built into the MAQ 20 Communications Modules Up to 32 PID Loops can be implemented in a single MAQ 20 Communications Module Controllers run autonomously after configuration using ReDAQ Shape software or Modbus commands Automatic restart and control resum
66. y putting other loops in manual Try to correct the problem or adjust the applicable settings as described above and retry the auto tune sequence QDDATAFORTH ee 390143 MA1056 MA 20 PID Controller User Manual The Auto Tune Seguence Completed but the Tuning Settings Do Not Work If the control is too slow it is possible that the process is just a slow process Check how the response time after a setpoint change in automatic control compares to the response time after a controller output change in manual If the process responds fast after a controller output change in manual but slow after a setpoint change in auto the controller gain can be increased to make the controller respond faster If the control loop is unstable one or more of the following can be done to stabilize it e Turn off derivative mode if used e Divide the controller gain Kc or Kp by two or more if necessary e Use two times or more if necessary the calculated integral time Ti If the controller uses the parallel controller algorithm divide the integral gain Kp by two The incorrect tuning settings could have been caused by a relatively unstable process affecting the auto tuner s operation and subsequent tuning calculations e Process was not steady enough to do tuning e Stabilize the process if possible i e by putting other loops in manual e Increase PV deviation limits and CO step limits e Process has too much noise disturbances for tuning e

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