SNAP PID MODULE USER'S GUIDE
Contents
1. SNAP PID Module User s Guide 15 REMOVING A SNAP PID MODULE Removing a SNAP PID Module To remove a SNAP PID module use the SNAP module tool that came vvith the module 1 Holding the SNAP module tool as shovvn in the illustration at right insert it into the notch at the base of the module NOTE If you are facing the rack with the brain on the left side the notch is on the back of the module RETENTION BAR 2 Squeeze the module tool SE against the module to open the SCREW HOLE release latch and pull straight up on the module to remove it MODULE RELEASE LATCH RETAINING SCREW HOLE UNDER MODULE RELEASE LATCH Troubleshooting IF you encounter problems using the SNAP PID V please review the information below for solutions to common problems If this information does not solve your problem contact Opto 22 Product Support Contact information is found on page 2 of this guide Ethernet Brain Communications If you are having trouble establishing an Ethernet network connection with the SNAP Ethernet brain refer to the Troubleshooting section in Opto 22 form 1112 the SNAP Ethernet Brain Users Guide It Ethernet communications problems continue after you have tried the solutions in that guide contact Opto 22 Product Support for assistance SNAP PID Module Access Check the following items if there are problems accessing the PID module on the SNAP rack e Check that the correct kernel version is installed o2. Channel 1 Analog inputs share a common reference and are not isolated from each other 2 Connect PID output wiring to the module as shown in the diagram on the following page PID output can be 4 20 mA current and 0 10 VDC voltage outputs both of which share a common negative terminal PID output is calculated by the module and then sent simultaneously to both current and voltage outputs as a percent of output scale This PID output can be analog or TPO signals if TPO is selected both current and voltage outputs are switched from 0 to 100 SNAP PID Module User s Guide 5 QUICK START See the following wiring diagram for connection details ap US iy PID OUTPUT TT __ EXTERNAL nevice AF Loop supply REQUIRED 0 10V 4 20mA ks i I _ INTERNAL INTERNAL Cj pf CONNECTIONS l S CONNECTIONS SNAP MODULE FIELD CONNECTOR m OPTO 22 PART SNAP FIELDCO s OPTO 22 SNAP A Part ANALOG With Voltage Inputs 0 10VDC ume SNAP MODULE RELEASE LATCH PIN OPTO 22 PART SNAP MODLATCH z FIRST hor PIN a a RTN 8 IX PIN 1 14 Hr lu Lu z E GND SNAP PID V MODULE BASE CONTROL CONNECTOR BOTTOM VIEW Apply Power to the Rack When you apply power to the rack the top two LEDs on the SNAP PID V blink once See LED Indicators on page 28 for more information on LED functions Configure the SNAP PID Module Choose one of two ways to enter PID
3. Read Only Variables The following PID variables contain values that cannot be modified Variable Description Status Flag Hexadecimal word that indicates the state of PID module status flags See Status Flag Word on page 24 for bit descriptions Current PID Process Variable used for the most recent PID calculation Last PID Process Variable used for the second most recent PID calculation Oldest PID Process Variable used for the third most recent PID calculation Current PID Error Calculated PID error Setpoint PV used for the most recent PID calculation Last PID Error Calculated PID error Setpoint PV used for the second most recent PID calculation Output Change Calculated change in PID output between most recent PID calculation and the second most recent PID calculation in raw counts SNAP PID Module User s Guide 23 SNAP PID MODULE REFERENCE Variable Description Output Value Most recently calculated PID output value in raw counts Scantime Countdown Time remaining until the next PID calculation is performed Status Flag Word A status flag word indicates the state of certain PID module parameters A status flag word is a single hexadecimal word similar to a PID control word that displays the state of status flag bits These bits are read only and cannot be modified Status flag bits are primarily used with loManager s PID Module window since OptoENET PID Modul
4. SNAP PID Module Reference on page 17 for more information on PID loop scan times Step 2 Configure PID Parameters The PID parameters you enter will depend on your particular control application OptoENET PID Module Tuner default settings however usually provide a good starting point For complete descriptions of SNAP PID V module variables and other parameters shown in OptoENET PID Module Tuner see SNAP PID Module Reference on page 17 1 Click the Options button in the Ethernet Connection section lower left part of the window 10 SNAP PID Module User s Guide USING OPTOENET PID MODULE TUNER SOFTVVARE The OptoENET PID Module Tuner Options vvindovv appears Configuration View Module Je 7 Limits 1 Configuration Setpt Low poo Basetime sec po Setpt High prsco Scantime sec fo PY Low po TPO Period sec ps PY High prsco Filter E xponential po Output Low po Output Slew Rate fangs Output High 4095 Output Deadband po m Control IM TPO Output T Setpoint Source J Process Source T PID Inverse Control Word Ox Joo000005 OK Cancel Apply 2 In the Limits section enter setpoint process variable and output limit values 3 In the Configuration section enter PID loop base time and scan time values If needed for your PID control application also enter values for TPO period filter exponential output slew and output deadband 4 In the Control section do the
5. are absolute values and are not inverted 5 not used n a n a 6 not used n a n a 7 PID Mode 0 n a Sets SNAP PID V module s calculation mode Auto On or Manuali Manual Off Off 0 Manual mode Off The PID scan timer is stopped and reset Any current PID calculations are cancelled and all PID variables are reinitialized PID output value is sent to either current or voltage outputs Changes to all PID variables and control bits are allowed as well as direct writes to PID output Note If the Process Quality status flag bit is set Auto mode cannot be used until the flag is cleared 1 Auto mode On The PID scan timer is active and PID values are calculated and executed PID output value is sent simultaneously to both current and voltage outputs as a percent of the output scale Changes to scantime variables are ignored and will result in an error Changes to control bits are allowed except where noted Direct writes to PID output is not allowed Note If the Process Quality status flag bit is set PID output stops and PID mode is forced to Manual 0 Setpoint Source 0 Manual or Auto Sets an internal or external source for the setpoint value external 0 Setpoint obtained from external analog source connected to source SNAP PID V channel 0 1 Setpoint obtained from internal value 1 not used n a n a 2 not used n a n a 3 not used n a n a 4 not used n a n a 5 not used n a n a 6 not used
6. following a To use an internal setpoint value select the Setpoint Source checkbox Deselect the checkbox to use an external analog input for the setpoint b To use an internal process variable select the Process Source checkbox Deselect the checkbox to use an external analog input for the process variable c To have PID output use a time proportional TPO signal select the TPO Output checkbox Deselect the checkbox to use a regular analog signal If TPO output is used you should confirm that the TPO Period value in the Configuration section is correct for your application d To use the inverse of the PID output value select the PID Inverse checkbox Deselect the checkbox to use a regular noninverted signal If Setpoint Source or Process Source is selected that is an internal setpoint or process variable is used values are displayed in raw counts If Setpoint Source or Process Source is not selected that is an internal setpoint or process variable is not used values are from 0 to 10 corresponding to the 0 10 VDC analog input signal SNAP PID Module User s Guide 11 USING OPTOENET PID MODULE TUNER SOFTWARE Note that the hexadecimal control word in the Options window changes to reflect the changes you make to control settings 5 Optional To hide or display graphed values on the trend chart click the View tab and in the Pens section select or deselect the PV Input Setpoint and Output checkboxes All values a
7. second to last time the scan timer reached zero or tg 2 x t PV Process Variable the input signal Integral ratio Integral Scan time Derivative ratio Derivative Scan time Setpoint and process variable readings are taken when the scan timer reaches zero and the PID calculation is made PID Control Word The SNAP PID V module s control settings are configured by modifying a single hexadecimal control word When using ioManager software you need to use the control word to configure the PID module When using OptoENET PID Module Tuner it isn t necessary to enter a control word since control settings are made using the software s user interface SNAP PID Module User s Guide 17 SNAP PID MODULE REFERENCE Defining a PID Control VVord To determine a hexadecimal control vvord for a particular combination of control settings do the follovving 1 In the table Control Word Bits on page 18 identify the bits that correspond to the parameters you vvant to set 2 For each bit you select choose the binary value that corresponds to the control setting you vvant 3 Gonvert the binary values to hexadecimal to determine the PID control vvord For example read the table belovv from top to bottom and right to left to see hovv you might figure out a control vvord that sets the PID mode to Auto that is by setting bit 7 to 1 Binary data for each bit bits 1 7 are not used j 1000 Control vvord
8. to perform PID loop calculations at a constant speed without system degradation providing a highly scalable solution Up to twelve SNAP PID V modules can be used on an Opto 22 16 module B series mounting rack SNAP PID Module User s Guide 1 INTRODUCTION Inputs and Outputs The SNAP PID V can use 0 10 VDC analog inputs for PID setpoint and process variables Analog inputs share a common reference and are not isolated from each other PID output sharing a common negative terminal provides 4 20 mA current and 0 10 VDC voltage outputs The PID output value is calculated by the module and then sent simultaneously to both 4 20 mA and 0 10 VDC outputs as a percent of output scale Additionally PID output can be configured for analog or time proportional output TPO signals The standard SNAP removable top mounted connector allows easy wiring of inputs and outputs LED indicators shown on page 28 are provided to show PID calculation mode status manual or auto and PID output signal status analog or TPO Software Support PID loop tuning and module configuration can be performed using OptoENET PID Module Tuner software which is available free of charge on the Opto 22 Web site www opto22 com This software plots PID values against time to provide visual feedback when tuning PID loops Additionally the SNAP PID V can be accessed using OptoControl Opto 22 s development tool for industrial automation programming that is part of the Factor
9. trademarks of their respective companies or organizations SNAP PID Module User s Guide Table of Contents E E E TE ETI 1 SNAP PID V Apl Nana AN ANA A aad ecdaieatiaacaeeuteactacneess 1 Inputs and Outputs AA AA PA 2 Software SUpport castes stpsetestartacvechostachactersdsscvscidedcascateisdleclcaitatacsietesskslssesbachicachindtinckadion 2 What s in this Guide sc tancacceesnnczatse Dawid atta esa oad ab tlle lacsdbvhadtaateen sumac 2 T e ocak PAA PP PA PTR 2 Quick udha Tne Y 3 Check Brain GON AUI OEY AA 3 Determining Firmware Version Z Xa mamamana 4 Man AN RA 4 Attach Input and Output Wiring AA AA PRN PAN 5 Apply Power to the Pakana nt te r i 6 Configure the SNAP PID AQE Eva sve v n s r nd dt 6 Using ioManager Utility Software ax maca aa aaaa nan ac aaa ere et eter ere ere t inerte 7 E SK detearieendantanectceeed 7 Using OptoENET PID Module Tuner SONA ce hodh n or e 8 SS kaa AA GA LA AKA AA 8 Installing the DHUNA N anas ana a GB a 8 e RERE AA PA 9 Step 1 Connect to the SNAP Ethernet Brain maana 9 Step 2 Configure PID Parameters u LL nananana nen ceee ece se rere ecenereeececeer eres 10 Step 3 Run PID Calculations 01 v aaa cuac cuan are cesenecare ente rtorezeete tee neece r n t e r r n eee 12 Step 4 0Optimize PID Loop acar rise r 13 E kaaa 14 Using the SNAP PID Module with OptoControl nan n os un ecen eres erenrrezerercer enca 14 NS AA 14 Ac
10. 96 default 4 000 0 0000 to 0 9999 default 0 000 PID output Resolution Deadband range High Low limits 12 bits 0 to 100 default 0 Low 0 VDC or 4 mA default 0 High 10 VDC or 20 mA default 100 Max PID output step change 0 to 100 default 100 Analog PID outputs 0 to 10 VDC 4 to 20 mA TPO PID output Resolution Period range On Off levels 8 bits 2 56 sec to 10 92 min 0 10 VDC 4 20 mA Voltage Output Range 0 to 10 VDC Span 10 VDC Resolution 2 44 mV Response time of span AV Atime 99 9 19 98 V 3 ms Load current 5 mA min Short circuit output current 40 mA 26 SNAP PID Module User s Guide SPECIFICATIONS UH Accuracy 0 196 of span Gain temperature coefficient 50 ppm C Offset temperature coefficient 20 ppm C Current Output Range 4 to 20 mA Span 16 mA Resolution 3 9 HA Output at powerup 4 mA before initialization Response time of span AmA Atime 99 9 15 98 MA 3 ms Accuracy 0 1 of span Gain temperature coefficient 50 ppm C Offset temperature coefficient 20 ppm C Loop voltage with 250 Q loop resistance 8 VDC min to 32 VDC max Formula for max loop resistance Loop resistance loop voltage 3 02 Max loop resistance vs loop supply 250 Q 8 VDC min 450 Q 12 VDC 600 Q 15 V
11. AP PID MODULE VVITH OPTOCONTROL 6 When the PID loop is correctly optimized click Disconnect to close the link to the Ethernet brain and then select File Exit to close OptoENET PID Module Tuner IMPORTANT Do not click Manual Mode before disconnecting the Ethernet link and closing OptoENET PID Module Tuner This will stop the PID calculations that are running on the SNAP PID V module and your PID loop will no longer be controlled by the PID module Saving PID Values to a Log File You can use OptoENET PID Module Tuner to create a log file that contains process variable setpoint output and other PID values To create the log file do the following 1 Select the Log File checkbox in the OptoENET PID Module Tuner main window 2 In the file dialog box that appears enter a name for the file choose the location where you want to save it and then click Save Whenever PID values are graphed in the main window OptoENET PID Module Tuner will record the data listed below in an ASCII text file that you can open using a spreadsheet word processor or other software application PID calculation date and time Setpoint Gain Integral Derivative Current process variable Last process variable Oldest process variable Current error Last error Output change Output value Time remaining to next scan PID calculation Using the SNAP PID Module with OptoControl The SNAP PID V modul
12. DC 1050 Q 24 VDC 1450 Q 32 VDC max Setpoint Process Variable Inputs Range 0 to 10 000 VDC Overrange 0 to 11 VDC Resolution 400 uV Data freshness max 126 2 ms 63 1 ms per channel DSP notch filter 10 Hz 3 dB 32 Hz Input filtering analog front end T C 2 5 ms 3 dB 64 Hz DC common mode rejection 5 120 dB AC common mode rejection gt 120 dB 60 Hz Max survivable input 220 VAC VDC Max operating common mode voltage field terminal to logic connector 250 VAC VDC SNAP PID Module User s Guide 27 SPECIFICATIONS Accuracy full scale 0 05 Drift Gain temperature coefficient 30 ppm C Offset temperature coefficient 15 ppm C Input resistance single ended 1 M Q each channel Both inputs share the same reference point Module and Power Requirements Isolation inputs to analog outputs 250 Vims Logic supply voltage 5 0 VDC Logic supply current 250 mA DC Max number of modules per rack 12 Brain compatibility SNAP B3000 ENET Operating temperature 0 to 70 C Storage temperature 30 to 85 C LED Indicators LED 1 on the SNAP PID V indicates PID calculation SNAP PID V Top View mode When lit the PID module is in Auto Mode and is calculating PID values When not lit the PID PID CALCULATION fv 1 TPO SIGNAL se MODE STATUS LED STA
13. SNAP PID MODULE USER S GUIDE Form 1263 030703 July 2003 OPTO 22 43044 Business Park Drive e Temecula e CA 92590 3614 Phone 800 321 OPTO 6786 or 951 695 3000 Fax 800 832 OPTO 6786 or 951 695 2712 www opto22 com Product Support Services 800 TEK OPTO 835 6786 or 951 695 3080 Fax 951 695 3017 Email support opto22 com Web support opto22 com SNAP PID Module User s Guide Form 1263 030703 July 2003 Copyright 2001 2003 Opto 22 All rights reserved Printed in the United States of America The information in this manual has been checked carefully and is believed to be accurate however Opto 22 assumes no responsibility for possible inaccuracies or omissions Specifications are subject to change without notice Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the manufacturing date code This warranty is limited to the original cost of the unit only and does not cover installation labor or any other contingent costs Opto 22 170 modules and solid state relays with date codes of 1 96 or later are guaranteed for life This lifetime warranty excludes reed relay SNAP serial communication modules SNAP PID modules and modules that contain mechanical contacts or switches Opto 22 does not warrant any product components or parts not manufactured by Opto 22 for these items the warranty from the original manufacturer applies These products include but are not limite
14. TUS LED module is in Manual Mode and is not running PID 24 calculations LED 3 on the PID module indicates TPO signal status The SNAP PID V supports both analog and time proportional output TPO PID output signals When LED 3 is lit TPO PID output is being used When not lit analog PID output is being used PID Voltage Input 0 to 10V O U U O LI o U O 28 SNAP PID Module User s Guide
15. al to the Process Lo alarm Range 0 to 25000 in raw counts 27500 Manual or Auto Output Lo also called Output Low Sets the Output Lo limit If a PID output is calculated that is below the Output Lo limit the output is clamped to the limit and the Output Lo flag is set The Output Lo limit must be less than or equal to the Output Hi limit Range 0 to 4095 Manual or Auto Output Hi also called Output High Sets the Output Hi limit If a PID output is calculated that is above the Output Hi limit the output is clamped to the limit and the Output Hi flag is set The Output Hi limit must be greater than or equal to the Output Lo limit Range 0 to 4095 4095 Manual or Auto Output Slew Rate Limits the maximum change in peak output that occurs each time the PID is calculated This variable can be used to minimize PID overshoot when there is a large change in a setpoint step Changes to this limit take effect the next time the PID is calculated Range 0 to 4095 4095 Manual or Auto Output Limit also called Output Limit Deadband This variable sets the minimum number of PID output ravv counts needed to cause the output to change PID changes that are less than or equal to the Output Limit are ignored This variable can be used to minimize vvear on control linkages Changes to this limit take effect the next time the PID is calculated Range 0 to 4095 Manual or Auto
16. bits 7654 321 0 7654 3210 0000 Hexadecimal value 8 0 Enter this control word 80 Note that the leading zeros do not need to be entered in this example entering 80 in the Control Word field is sufficient See Binary Hexadecimal Conversion Chart on page 25 for a table of 4 bit binary data and equivalent hexadecimal values Control Word Bits Bit Name and Description Default To Modify Use Mode 0 not used n a n a 1 not used n a n a 2 TPO Output 0 Manual Sets PID output to use analog or TPO signals analog 0 Analog PID output The analog output value is set to the Low output Output Limit 1 TPO PID output The TPO output is set to the High Output Limit 3 Process Variable Source 0 Manual Sets an internal or external source for the process variable value external 0 Process variable obtained from external analog source source connected to SNAP PID V channel 1 1 Process variable obtained from internal value 18 SNAP PID Module User s Guide SNAP PID MODULE REFERENCE Bit Name and Description Default To Modify Use Mode 4 PID Inverse 0 Manual Sets PID output to use an inverted or non inverted signal not 0 PID output is not inverted inverted 1 PID output is inverted Inversion occurs only after the PID calculation has occurred For the PID module output limits and outputs made in Manual mode
17. ble Description Default To Modify Use Mode Output PID output value for analog or TPO outputs For analog output this variable is the PID output value written to the analog outputs subject to the applicable output limits Range 0 4095 0 10 VDC or 4 20 mA For TPO output this variable is the TPO duty cycle Range 0 to 100 0 Manual Manual Tune Proportional also called Proportional Term P term or Gain This is one of the four key values for PID loop tuning Gain Integral Derivative and Setpoint Range 0 000 to 255 996 1 000 Manual or Auto Setpoint also called SP The Setpoint value used in the PID calculation You can specify a setpoint value or select an external source for the value using OptoENET PID Module Tuner software or ioManager s PID Module window See Control Word Bits on page 18 for more information on PID module control settings Range 0 to 25000 in raw counts Manual or Auto Process Variable also called P The Process Variable value used in the PID calculation You can specify a process variable value or select an external source for the value using OptoENET PID Module Tuner software or ioManager s PID Module window See Control Word Bits on page 18 for more information on PID module control settings Range 0 to 25000 in raw counts Manual or Auto Setpoint Lo also called Setpt Low Sets the Setpoint Lo limit If
18. ble sets the derivative value used for the PID module s PID loop calculations using the following formula DerivRatio Derivative Scantime Enter the derivative and scantime values you want to use for your PID loop and then solve for DerivRatio Enter the result in the Tune DerivRatio field in ioManager s PID Module window Range 0 000 to 0 9992 0 000 Manual or Auto Filter Exponential This variable sets the filter exponential used for the Process filtering or Setpoint filtering equation using the following formula y bxy 1 b xy t 0 where ylt0 raw input data y 0 current filtered answer y1 last filtered answer b filter exponential For Process filtering the input to the filter is the raw Process Variable The output of this filter is used for the Process Variable in the PID calculation Range 0 255 For Setpoint filtering the input to the filter is the raw Setpoint value The output of this filter is used for the Setpoint value in the PID calculation Range 0 255 0 no filter 0 no filter Manual or Auto Manual or Auto SNAP PID Module User s Guide 21 SNAP PID MODULE REFERENCE pg alala ia m mm tejegE9E ee yjLhpqy4y 773gIXNQNL ug Variables Not Requiring Calculation Values for the PID variables listed in the following table can be entered directly into ioManager software It is not necessary to calculate these values in advance Varia
19. cessing PID VARA ES asa zun rks hit r rat rre nd r 15 Finding a PID Module Memory Map A QO T S S una vc nana nma 15 Removing a SNAP PID Module a kaanaaaaaa AA NAKAPA KAA kakak GANA ANNA 16 a AKA PRA PORAC AN APA PARROT 16 Ethernet Brain GommuniGa UONS aa c ra maa IGuh KAL edi b 16 SNAP PID Module User s Guide iii So SNAP PID Module AGES naaa Nman Unahan 16 SNAP PID Module Reference X manmanan 17 E E 17 oe REN 17 Gj E on 18 Control Word Bits ria ui e 18 KU Re RO E 20 Variables Requiring Calculation uang panama Naaman kat 20 Variables Not Requiring Calculation amn 22 Read Only Variables i ner nan s fstab kA ANAAA aden NAN 23 e paa ni aaa 24 Reading a Status Flag vu i beabacteceene ee pabnne Nias 24 Status Flag BITS AP APR NYA 24 Binary Hexadecimal Conversion Chart 0 uc 2 nana nana n anus n neser enet er eter ent ere r r n 25 AA dada et E EE 26 NAA AA PA NAA HAHAA 26 Voltage OT UK r n as araer aetna 26 ER e 21 Setpoint Process Variable NM PU S an mv vuan no coan anon enen ereseere zere eee rez ent ere et ere eeer eee 21 Module and Power REQUI EM GIT S 1 0 na aaa nana senet ere nt event ere et er eee 28 ae RAP 28 iv SNAP PID Module User s Guide OPTO 22 SNAP PID Module User s Guide Introduction The SNAP PID V module is designed for users of Opto 22 SNAP Ethernet I O systems with the SNAP B3000 ENET SNAP ENET RTC or SNAP VVLAN FH ADS b
20. com support You should be aware that OptoENET PID Module Tuner has the following restrictions e No automatic tuning The application does not automatically tune PID loops or otherwise automatically set PID parameters You must enter PID values and other settings manually e Works with one PID module at a time A SNAP PID V module can control a single PID loop and OptoENET PID Module Tuner software works with only one SNAP PID module at a time Up to twelve SNAP PID V modules can be used on a 16 module SNAP rack however and you can use OptoENET PID Module Tuner with different individual SNAP PID modules by simply selecting a new module on the SNAP rack System Requirements Here s what you need to install and run OptoENET PID Module Tuner e 90 MHz or higher personal computer 200 MHz Pentium Il or better recommended e Microsoft Windows 95 Windows 98 Windows NT 4 0 with latest Microsoft service pack installed or newer operating system e Microsoft Internet Explorer 5 or newer e Atleast 16 MB RAM for Windows 95 or Windows 98 or 32 MB RAM for Windows NT 64 MB or more recommended e Atleast 8 MB of available hard disk space e VGA or higher resolution monitor Super VGA recommended e Mouse or other pointing device Installing the Software After downloading the OptoENET PID Module Tuner installer from the Opto 22 Web site double click the installer s icon and follow the instructions that appear By default OptoENET PID M
21. d to OptoTerminal G70 OptoTerminal G75 and Sony Ericsson GT 48 see the product data sheet for specific warranty information Refer to Opto 22 form number 1042 for complete warranty information Opto 22 FactoryFloor Cyrano Optomux and Pamux are registered trademarks of Opto 22 Generation 4 ioControl ioDisplay ioManager ioProject ioUtilities mistic Nvio Nvio net Web Portal OptoConnect OptoControl OptoDisplay OptoENETSniff OptoOPCServer OptoScript OptoServer OptoTerminal OptoUtilities SNAP Ethernet 170 SNAP 1 0 SNAP OEM 170 SNAP Simple 1 0 SNAP Ultimate 1 0 and SNAP Wireless LAN 170 are trademarks of Opto 22 Activex JScript Microsoft MS DOS VBScript Visual Basic Visual C and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and other countries Linux is a registered trademark of Linus Torvalds Unicenter is a registered trademark of Computer Associates International Inc ARCNET is a registered trademark of Datapoint Corporation Modbus is a registered trademark of Schneider Electric Wiegand is a registered trademark of Sensor Engineering Corporation Nokia Nokia M2M Platform Nokia M2M Gateway Software and Nokia 31 GSM Connectivity Terminal are trademarks or registered trademarks of Nokia Corporation Sony is a trademark of Sony Corporation Ericsson is a trademark of Telefonaktiebolaget LM Ericsson All other brand or product names are trademarks or registered
22. e Tuner software displays this status information in the user interface Reading a Status Flag To read a hexadecimal status flag word do the following 1 Break the 8 bit word into its two separate hexadecimal values 2 Convert each hexadecimal value into its corresponding binary data 3 Match the positions of each 1 in the binary data to a status flag bit The table below illustrates an example of these steps Read the table from right to left to see how you might interpret a status flag word Status flag word 00000050 Hexadecimal value 5 0 Binary data 0101 0000 Status flag bits 7654 3210 tT This status flag word shows that bit 4 the Output Lo flag and bit 6 the TPO Status flag are set See Binary Hexadecimal Conversion Chart on page 25 for a table of binary data and equivalent hexadecimal values Status Flag Bits Flag Name and Description 0 Setpoint Lo 1 Setpoint input is below the Setpoint Lo limit and is clamped to that value for calculating PID output In Auto Mode this flag is checked when PID output is calculated If setpoint input re enters the normal range the flag will clear at the next scan time 24 SNAP PID Module User s Guide SNAP PID MODULE REFERENCE UH Bit Flag Name and Description 1 Setpoint Hi 1 Setpoint input is above the Setpoint Hi limit and is clamped to that value for calculating PID output In Auto Mode this flag is checked when PID output
23. e can be used as an analog input module with Opto 22 s OptoControl industrial automation software OptoControl R3 1d or newer is required to use the SNAP PID V with OptoControl Contact Opto 22 Product Support for additional information Contact information appears on page 2 Using Analog Inputs In OptoControl you can configure two types of analog input points with the SNAP PID V Both types of input points can range from 0 to 100 percent one type is scalable and the other is not 14 SNAP PID Module User s Guide USING THE SNAP PID MODULE VVITH OPTOCONTROL Accessing PID Variables PID variables from the SNAP PID V are stored in the SNAP B3000 ENET s memory map and can be accessed from OptoControl using the commands listed belovv See Opto 22 form 725 the OptoControl Command Reference for more information about these commands e Read Numeric Variable from O Memory Map e Write Numeric Variable to 1 0 Memory Map e Read Numeric Table from I O Memory Map e Write Numeric Table to 1 0 Memory Map Finding a PID Module Memory Map Address To determine the hexadecimal memory map address for a particular PID module variable 1 Open ioManager and select the SNAP Ethernet brain on the same rack as the PID module 2 Click the PID button and select Module from the submenu 3 At the top of the PID Module window select the PID module that will be used with OptoControl The memory map address appears to the right of the variable s description
24. guration e Acomplete description of your hardware including jumper configuration P addresses and net masks for devices on the system accessories installed such as expansion cards type of power supply brand and model types of 170 units installed third party devices installed for example barcode readers e Specific error messages seen Quick Start Check Brain Compatibility The SNAP PID V module can be used with the SNAP B3000 ENET SNAP ENET RTC or SNAP WLAN FH ADS Ethernet brain Firmware version 3 0 2 0 or higher must be installed on the Ethernet brain which must be located on the same rack as the PID module s NOTE If you have an older SNAP Ethernet brain that uses firmware prior to version 3 0 2 0 contact Opto 22 Product Support for assistance with firmware requirements for PID module support Follow these steps to check the firmware version installed on a SNAP Ethernet brain You will need to know the brain s IP address SNAP PID Module User s Guide 3 QUICK START Determining Firmware Version 1 On the PC choose Start Programs Opto 22 3SNAP Ultimate O ioManager ioManager The ioManager window opens 2 Select Inspect from the Mode menu The Inspect window opens 3 Type the IP address of the brain in the field at the upper left corner of the window and then click the Status Read button 4 Click Status Read in the Ethernet VO Menu 5 Scroll down until you see Kernel Versio
25. ick Debug 12 SNAP PID Module User s Guide USING OPTOENET PID MODULE TUNER SOFTVVARE The Debug vvindovv appears Current PY B Current Error Je Last PY fa Last Error fo ogy f Output Change JA ScanTime p7 Output Value fo Step 4 Optimize PID Loop 1 Observe the graphed process variable input setpoint and output values on the chart 2 To see the coordinate values for a point on the graph just click on that point Coordinate values appear near the cursor To measure distances between two points click on the graph and then drag the mouse Measurements will appear near the cursor Examples of viewing coordinate values and measuring distances appear below pap OptoENET PID Module Tu sap OptoENET PID Module Tune File Edit Help File Edit Help m Trend m Trend fao 4 000 Jasr o A 1500 Coordinate values Distance measurement 3 Enter new P D and SP values in the Tuning Parameters section if necessary and then click Apply 4 Continue to observe the graphed values and change PID values until the PID loop is optimized 5 f you need to adjust PID loop scan time base time or the limit values you set earlier do the following a Click Manual Mode to stop PID calculations Click Options Change values in the Limits and Configuration sections as needed Click OK Click Auto Mode to start PID calculations again papp SNAP PID Module User s Guide 13 USING THE SN
26. is calculated If setpoint input re enters the normal range the flag will clear at the next scan time 2 Process Lo 1 Process input is below the Process Lo limit and is not suitable for calculating PID output In Auto Mode this flag is checked when PID output is calculated When this flag is set the Process Quality flag is also set and the module is forced to Manual mode The output will not change After the condition is fixed you must change back to Auto Mode The flag will clear when the PID output is calculated 3 Process Hi 1 Process input is above the Process Hi limit and is not suitable for calculating PID output In Auto Mode this flag is checked when PID output is calculated When this flag is set the Process Quality flag is also set and the module is forced to Manual mode The output will not change After the condition is fixed you must change back to Auto Mode The flag will clear when the PID output is calculated 4 Output Lo 1 Output is clamped to the Output Lo clamp value In Auto Mode this flag is checked when PID output is calculated This flag is for indication only and will clear when the output is above the clamp value 5 Output Hi 1 Output is clamped to the Output Hi clamp value In Auto Mode this flag is checked when PID output is calculated This flag is for indication only and will clear when the output is below the clamp value 6 TPO Status 1 TPO is in the On portion of the TPO
27. lays aa Scan Rate ms Bf D Term Error l PID Calculation WGUGT iN mi Kerr E Control vford 0800000000 Status indicator Ia Logie pej 109 Status Flag Ox00000000 Connection Status Connection Status Not Connected indicator 2 In the Ethernet Connection group enter the SNAP Ethernet brain s IP address in the IP field SNAP PID Module User s Guide 9 USING OPTOENET PID MODULE TUNER SOFTWARE 3 Leave the default Port number of 2001 unless you have changed the default Command Processor port number for the SNAP Ethernet Brain If this is the case enter this port number in the Port field 4 Click Connect to establish a link to the SNAP Ethernet brain 5 From the Module drop down menu in the Current PID Module Values section select the position of the SNAP PID V module on the SNAP rack Values associated with the module you selected should appear and the connection status indicator in the lower right hand corner of the window turns green If a SNAP PID V module is not installed in the rack position you select the value fields will display zero values 6 Enter a scan rate for communicating with the SNAP Ethernet brain This rate determines how often OptoENET PID Module Tuner communicates with the SNAP Ethernet brain The default scan rate of 250 ms should be suitable for most 10 100 Mbps Ethernet connections IMPORTANT The Ethernet scan rate is not the same as the PID loop scan time See
28. n The kernel should be version 3 0 2 0 or higher Install the Module SNAP PID V modules can be installed in any position on an Opto 22 B series mounting rack Do not install more than twelve SNAP PID V modules on the same rack NOTE SNAP PID modules draw considerably more power than a standard SNAP analog or digital module A SNAP B16M SNAP B16MC or SNAP B16MC P rack can handle a maximum of twelve SNAP PID modules plus the Ethernet brain and up to four other digital or analog modules For detailed power requirements see the SNAP PID V module specifications on page 26 Make sure you have sufficient power for the brain and all modules on the rack 1 Remove the module from its packaging 2 Position the module over the connector on the rack aligning the small slot at the base of the module with the retention bar on the rack If it is next to another module make sure the male and female module keys are aligned as shown at right CONNECTOR MODULE RETAINING SCREW HOLE 3 Push straight down on the module to snap it into position RETENTION BAR If you need to remove the module see page 16 4 SNAP PID Module User s Guide QUICK START UH Attach Input and Output Wiring 1 Optional If you want to use PID setpoint and process variable analog inputs from external sources with the SNAP PID module follow the wiring diagram shown on page 6 to connect PID setpoint inputs to Channel 0 and process variable inputs to
29. n a n a 7 not used n a n a Second 8 bit byte in control word SNAP PID Module User s Guide 19 SNAP PID MODULE REFERENCE R c y jy3 UWR RA io 5 PID Variables PID variables are used to hold the parameters that you enter using ioManager software and also to hold values calculated by the PID module Unless otherwise indicated all variables are entered in raw counts Variables Requiring Calculation If you use ioManager software to enter PID values and other settings for the SNAP PID V you must calculate in advance the variables listed in the following table When using OptoENET PID Module Tuner software these calculations are done automatically VELA Description Default To Modify Use Mode Scantime Base This variable is used to calculate the PID loop basetime 100 ms Manual also called Scantime using the following formula Resolution Basetime sec 01 x 1 Scantime Base Enter the basetime value you want to use for your PID loop in the formula and then solve for Scantime Base using the following equation Scantime Base Basetime 1 01 1 Enter the result in the Scantime Base field in ioManager s PID Module window Range 0 255 10 ms to 2 6 sec Scantime Mult This variable is used to calculate the PID loop scantime 10 sec Manual also called Scantime using the following formula Multiplier Scantime sec Basetime x Scantime Mult 1 Enter the scantime value you wan
30. n the SNAP Ethernet brain See Check Brain Compatibility on page 3 for instructions on how to check the Ethernet brain s kernel version 16 SNAP PID Module User s Guide SNAP PID MODULE REFERENCE e Confirm that the module is plugged firmly into the mounting rack For applications where vibration or thermal expansion and contraction may be a consideration it may be beneficial to use screws to attach the PID and other SNAP modules to the SNAP mounting rack e fPID information doesn t appear in the ioManager PID Module screen or when using OptoENET PID Module Tuner do the following Check that the correct module location on the mounting rack is selected in ioManager s PID Module screen Confirm that signal input and output wiring is correctly connected to the module s screw terminal connector See Attach Input and Output Wiring on page 5 for wiring information SNAP PID Module Reference PID Velocity Algorithm The SNAP PID V module uses the following PID velocity algorithm Change in output Gain x A B C where A Error at ty Error at t4 B Error at to Integral ratio C Derivative ratio x PV input at t 2 x PV input at t4 PV input at to and Error Setpoint PV t Scan time the time between setpoint and process variable readings to Time when the scan timer reaches zero This is when PID is calculated t The last time the scan timer reached zero or ty t t The
31. odule Tuner is installed with other Opto 22 Ethernet 170 software in the Opto22 OptoENET I0 directory on your computer s C drive 8 SNAP PID Module User s Guide USING OPTOENET PID MODULE TUNER SOFTVVARE Tuning a PID Loop The following steps outline how to use OptoENET PID Module Tuner software to tune a PID loop controlled by a SNAP PID module Each step is described in more detail in the following sections For complete descriptions of SNAP PID V module variables and other parameters shown in OptoENET PID Module Tuner see SNAP PID Module Reference on page 17 These instructions assume you have already gone through the Quick Start procedure earlier in this guide Step 1 Connect to the SNAP Ethernet Brain Step 2 Configure PID Parameters Step 3 Run PID Calculations Step 4 Optimize PID Loop Step 1 Connect to the SNAP Ethernet Brain 1 To start OptoENET PID Module Tuner from the Microsoft Windows Start Menu select Programs Opto22 OptoENET I O OptoENET PID Module Tuner The OptoENET PID Module Tuner main window appears sag OptoENET PID Module Tuner File Edit Help Trend Enter P D and setpoint arameters i Current values from the PID module are Ethernet Connection r Current PID Module Values shown here Enter IP PJ address and j Te i Port foo Aa other Ethernet P Tem Setpoint a Control Word and connection Term Dutput a Status Flag arameters disp
32. period 0 TPO is in the Off portion of the TPO period 7 Process Quality 1 Process input was not suitable for the PID calculation as it was calculated using the Hi Lo process limits In Auto Mode this flag is checked when PID output is calculated If the flag is set the mode is forced to Manual After the condition is fixed you must change back to Auto Mode The flag will clear when the PID output is calculated If this flag is set after an initial powerup or reset command the PID module failed to load variables from its flash memory and all configuration parameters and variables are at factory default settings Binary Hexadecimal Conversion Chart For using PID module control words and reading status flags use the following chart to convert binary data to and from hexadecimal or hex values Binary Data Corresponding Binary Data Corresponding Hex Value Hex Value 0000 0 1000 8 0001 1 1001 9 0010 2 1010 A 0011 3 1011 B SNAP PID Module User s Guide 25 SPECIFICATIONS Binary Data Corresponding Binary Data Corresponding Hex Value Hex Value 0100 4 1100 C 0101 5 1101 D 0110 6 1110 E 0111 7 1111 F Specifications PID Scan time range programmable 100 ms to 1 8 hrs default 10 sec Proportional range gain 0 000 to 255 996 default 1 000 Integral range Derivative range 0 000 to 255 9
33. rain The SNAP PID V monitors input signals and adjusts output signals to control one proportional integral derivative PID loop performing all necessary PID calculations in the module itself Before the introduction of the SNAP PID V module using a PID loop with SNAP Ethernet 170 systems required an Opto 22 industrial controller running an OptoControl She strategy or a remote computer running SCADA software For non Ethernet 170 units the multifunction B3000 brain pa SNAP PID V could be used The SNAP PID V module makes this equipment unnecessary since all PID calculations are made in the module independent of a controller or other processor SNAP PID V Applications Typical applications for the SNAP PID V module include temperature pressure level flow and process control The SNAP PID V is ideal for remote installations or other environments where communication links are subject to interruption Since PID calculations run locally on the 170 module independent of a controller brain or other processor PID loop control can continue even if the communication link to the 1 0 system is broken The SNAP PID module is also useful in applications where multiple PID loops must be controlled at one location When multiple PID loop calculations run on a single industrial controller or computer a performance degradation can occur When additional SNAP PID V modules are added to a SNAP rack however all modules continue
34. re graphed by default 6 Optional To change the colors used for graphed values click the View tab and click the color box next to each value select a color and click OK 7 Click OK to close the Options window 8 In the OptoENET PID Module Tuner main Tuning Parameters window enter values for the following terms in p hoo the corresponding fields TE e P Gain proportional D foo e l lntegral SP foo e D Derivative Apply e SP Setpoint If you need to calculate starting P 1 D and SP values use the PID velocity algorithm shown on page 17 You can also start PID calculations using the default P D and SP values that appear in these fields and then adjust the terms as you tune the PID loop 9 Click Apply Step 3 Run PID Calculations 1 In the Ethernet Connection section of the main window click Scan to start receiving PID module values from the SNAP Ethernet brain The Comnection Status indicator in the lower right hand corner of the window turns green and the Trend chart starts graphing process variable setpoint and output values 2 Click Auto Mode to start running PID calculations on the SNAP PID V module The PID calculation status indicator in the lower right hand corner of the window turns green Control vford 0400000181 Status Flag 0x00000000 PID Calculation Status indicator Connection Status indicator 3 To view calculated PID values that are not shown in the main window cl
35. t to use for your PID loop in the formula and then solve for Scantime Mult using the following equation Scantime Mult Scantime Basetime 1 Enter the result in the Scantime Mult field in ioManager s PID Module window Range 0 65535 10 ms to 1 8 hr TPO Period Mult This variable sets the period of the PID module s TPO 2 56 sec Manual also called TPO output using the following formula Period Multiplier TPO Period 1 TPO Period Mult x 256 Enter the TPO period value you want to use for your PID loop in the formula and then solve for TPO Period Mult using the following equation TPO Period Mult TPO Period 256 1 Enter the result in the TPO Period Mult field in ioManager s PID Module window Range 0 255 2 56 sec to 10 92 min 20 SNAP PID Module User s Guide Variable SNAP PID MODULE REFERENCE Description Default re To Modify Use Mode Tune IntegRatio also called the Integral Ratio IntegRatio This variable sets the integral value used for the PID module s PID calculations using the following formula IntegRatio Integral Scantime Enter the integral and scantime values you want to use for your PID loop and then solve for IntegRatio Enter the result in the Tune IntegRatio field in ioManager s PID Module window Range 0 000 to 255 996 4 000 Manual or Auto Tune DerivRatio also called the Derivative Ratio DerivRatio This varia
36. the Setpoint input is less than the Setpoint Lo limit it is clamped to this limit If this condition occurs the Setpoint Lo status flag will also be set The Setpoint Lo limit must be less than or equal to the Setpoint Hi limit or an error will occur Range 0 to 25000 in raw counts Manual or Auto Setpoint Hi also called Setpt High Sets the Setpoint Hi limit If the Setpoint input is greater than the Setpoint Hi limit it is clamped to this limit If this condition occurs the Setpoint Hi status flag will also be set The Setpoint Hi limit must be greater than or equal to the Setpoint Lo limit or an error will occur Range 0 to 25000 in raw counts 27500 Manual or Auto Process Lo also called PV Low Sets the Process Lo alarm If the Process Variable input is less than the Process Lo alarm the Process Lo and Process Quality flags are set This occurs when the PID is calculated The Process Lo alarm must be less than or equal to the Process Hi alarm Range 0 to 25000 in raw counts Manual or Auto 22 SNAP PID Module User s Guide SNAP PID MODULE REFERENCE UH NEE Default Description To Modify Use Mode Process Hi also called PV High Sets the Process Hi alarm If the Process Variable input is greater than the Process Hi alarm the Process Hi and Process Quality flags are set This occurs when the PID is calculated The Process Hi alarm must be greater than or equ
37. values and set parameters for a SNAP PID V module 6 SNAP PID Module User s Guide USING IOMANAGER UTILITY SOFTVVARE e Ifyou have previously calculated PID values and parameters use ioManager See Using ioManager Utility Software on page 7 for instructions e IFyou want to iteratively tune a PID loop use OptoENET PID Module Tuner This software includes graphing features and is available free of charge from the Opto 22 Web site See Using OptoENET PID Module Tuner Software on page 8 for instructions IMPORTANT PID module settings are not saved when you cycle power to the SNAP Ethernet brain and the PID module PID module settings cannot be saved to the brain s flash memory If you turn off power to these components you will need to re enter PID module settings using either ioManager or the OptoENET PID Module Tuner software Using ioManager Utility Software ioManager does not provide visual feedback of changes to PID values You must first calculate optimal PID values for your application using the PID velocity algorithm described on page 17 and the PID variable formulas on page 20 After calculating these values enter them in the appropriate fields on the PID Module screen loManager utility software was installed on your computer when the SNAP Ethernet brain was installed and configured See the SNAP Ethernet Brain Users Guide for more information Entering PID Values These instructions describe how to enter and modif
38. y PID values using ioManager s Inspect mode You can also enter values as part of configuring and saving an 170 unit configuration file 1 On the PC choose Start Programs Opto 22 3SNAP Ultimate O ioManager ioManager The ioManager window opens 2 Select Inspect from the Mode menu The Inspect window opens 3 Type the IP address of the brain in the field at the upper left corner of the window 4 Click the PID button and from the submenu select Module 5 From the PID Module Number drop down menu select the number matching the position of the SNAP PID V module on the SNAP rack 6 For each parameter in the Description column to be modified enter a value in the corresponding field in the Value column Unless indicated all parameters are entered in raw counts For parameter descriptions see SNAP PID Module Reference on page 17 7 Click Apply SNAP PID Module User s Guide 7 USING OPTOENET PID MODULE TUNER SOFTWARE Using OptoENET PID Module Tuner Software OptoENET PID Module Tuner is an Opto 22 software application for Microsoft Windows that works with the SNAP Ethernet brain to set PID values and other parameters for a SNAP PID V module The primary use of this software is to graph PID values against time providing visual feedback for tuning the PID loop that the module controls OptoENET PID Module Tuner is available free of charge from the Software downloads section of the Opto 22 Web site at www opto22
39. yFloor suite of industrial automation software What s in this Guide This guide assumes that you have some familiarity with tuning PID loops Many commercial resources are available for learning about this subject To learn more about the SNAP Ethernet brain used with the SNAP PID module see Opto 22 form 1112 the SNAP Ethernet Brain User s Guide This document can be downloaded from the Opto 22 Web site at www opto22 com This guide includes the following sections e Quick Start to get your PID module installed and connected quickly e Instructions for setting PID parameters using ioManager utility software or OptoENET PID Module Tuner software e Wiring diagrams e Specifications For Help If you have problems installing or using SNAP PID modules and cannot find the help you need in this guide or on our Web site you can call fax or e mail Opto 22 Product Support 2 SNAP PID Module User s Guide QUICK START TE Phone 800 TEK OPTO 835 6786 951 695 3080 NOTE Email messages Hours are Monday through Friday and phone calls to 7 a m to 5 p m Pacific Time Opto 22 Product Support are grouped together Fax 951 695 3017 and answered in the Email support opto22 com Aa Opto 22 Web site support opto22 com When calling for technical support be prepared to provide the following information about your system to the Product Support engineer e Software and version being used e Ethernet brain firmware version e PC confi
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