Schneider Electric Process Control, PL7PMS 5.0 User Guide

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Preface

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Enhancements to PL7-PMS, Version V5 compared with previous versions

The main enhancements to TXT L PL7 PMS V5E software compared with the previous

TXT L PL7 PMS V4E version affect:

Data exchange between PL7-PMS and XTEL-CONF

In the V5 level version, the configuration used by PL7-PMS is generated by XTEL-CONF instead of PL7-3: type of PLC processor, configuration of the modules in the rack and the size of the memory cartridge. Therefore it is necessary to define the application structure using XTEL-CONF, prior to using PL7-PMS (refer to Divider A, Sub-section 2.1).

Single file name

There is only one configuration file generated by PL7-PMS, containing the entire configuration of the I/O modules installed in the PLC rack.

The configuration file name is PMS.BIN.

Simplified generation phase

Using the V5 level version of the software, the user no longer needs to generate the

STATION.APP file after modifying a .BIN file.

Terminology used

Some dynamic soft key names have been changed between the V4 and V5 level versions. These modifications comprise:

• In connected mode:

[STORE] (V4) becomes [STA

→

DSK] and lets the user transfer the process control application from the PLC memory to the PMS.BIN file. This transfer is made using

XTEL-TRANSFER.

[RETRIEVE] (V4) becomes [DSK

→

STA] and lets the user transfer the PMS.BIN file to the PLC memory. This transfer is made using XTEL-TRANSFER.

• In Local mode

[•BIN] (V4) becomes [RETRIEVE] and lets the user transfer any application file from disk to the PMS.BIN file in the X-TEL data base.

[STORE] (V4) remains [STORE] and lets the user transfer the PMS.BIN file to any application file on disk or diskette.

The [XTELCONF] dynamic soft key lets the user access XTEL-CONF, in order to change the I/O configuration of the application. This dynamic soft key can only be accessed if there is a difference between the data stored in the directory and the configuration stored in XTEL-CONF.

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1

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Connecting to a FIPIO field bus

PL7-PMS can be run on FTX 417/507 terminals connected to a FIPIO remote I/O field bus using connection point address 63.

Optional Function Blocks (OFBs)

PL7-PMS proposes three additional OFBs that operate in floating point mode: PIDF,

SCLF and ISCLF. These OFBs can only be executed on PMX V5 systems.

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2

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Compatibility between PL7-PMS V4 and PL7-PMS V5 applications

Any V4 level application can be converted to a V5 level application, by following the steps listed below:

1 Retrieve the V4 level application in X-TEL V5, via the Save/Restore or Copy/Paste commands,

2 Create a V5 host station,

3 Invoke the Import command from the PMS icon of the host V5 level station and import the following files:

StationV4\PMS\APPLI\xxx.BIN (required): application binary file, to directory StationV5\PMS\APPLI, then

StationV4\PMS\MOD\xxx.411 to xxx.16P (optional), to directory StationV5\PMS\MOD.

4 Run PL7-PMS from the V5 level station and perform the following operations:

• Select from Local/Working memory (depending on the function), the PMX file so that the RETRIEVE command is accessible,

• Select [RETRIEVE] to gain access to a list of xxx.BIN files available to the station,

• Select the [DIRBIN] command and select the previously imported xxx.BIN file,

• Select <Enter><Enter>, to retrieve the xxx.BIN file on the V5 station.

5 Quit PL7-PMS.

6 Run XTEL-CONF

• From the Generate menu, select the enter application parameters command,

• Quit XTEL-CONF.

7 Run PL7-3 and select the [V5CONF] command to assign the application program to the new configuration defined under XTEL-CONF.

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3

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Reusing V2.0 level Man-Machine Interface applications with PL7-MMI V5 software

This requires converting the V2.0 level Man-Machine Interface application to V2.5 level and then changing the configuration of the MMI OFB in PL7-3. It is assumed that the

PL7-3 application has also been updated (refer to the PL7-3 Operating Modes and

PL7-MMI V5 documentation). The following procedure must be used:

The V2.0 level Man-Machine Interface application must first be saved to diskettes from the PMX V4 station (Utilities menu, Backup command).

1

Run PL7-MMI 37 from the mmi icon of the host station:

• Select the module (PCM1, PCM2, etc.),

• Restore the Man-Machine application previously saved to diskette (Utilities menu,

Restore command),

• Declare the REGULATION option in PL7-MMI 37 (Utilities menu, Add options menu),

• From the Configuration Manager, configure the REGULATION option (Create menu, Configuration Manager CM option). To do this:

- Display the REGULATION screen (by double-clicking on REGULATION),

- Import the symbols (Utilities menu, Import command),

- Quit the REGULATION screen and then quit CM (Exit menu),

• Create the tables (Generate menu, Create Tables command). Once the tables are created, answer "No" to the message displayed: "Attention MMI.BIN file changed.

Do you want to run TRANSFER?",

• Quit PL7-MMI 37.

2

Run XTEL-CONF:

• Check the logical spaces (Generate menu, Enter application parameters option),

• Quit XTEL-CONF.

3 Run PL7-3 which will automatically read the PL7-3 binary file (PL7_3.BIN file):

• Assign the application program to the new configuration defined in XTEL-CONF

([V5CONF] command),

• Select Configuration mode and configure the new version 2.5 level MMI OFB,

• Validate the new configuration ([VALID] command then [YES]),

• Reconfigure the PL7-3 application (RECONFIGURATION command),

• Save the PL7-3 application to disk ([STORE] command),

• Quit PL7-3.

4 Run XTEL-TRANSFER and perform a complete transfer to the PLC (Transfer menu,

Disk

→

PLC Station/Complete Transfer command):

• Quit XTEL-TRANSFER.

5

Run PL7-MMI 37 once again, to transfer the new Man-Machine Interface application to the TSX PCM module:

• Select the tasks to transfer (Generate menu, Select Tasks command),

• Transfer the application to the module (Transfer menu),

• Quit PL7-MMI 37.

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4

Set-up and Methodology

TSX AEM Analog Input Module

Configuration Program

Analog Function Blocks

Process Control Function Blocks

Man-Machine Interface Design

Man-Machine Interface Operation

Application Example

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E

F

G

C

D

A

B

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Set-up and Methodology A

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A

Page

Presentation and Set-up

1.1

1.2

1.3

1.4

1.5

General

1.1-1 Features Supported by PL7-PMS

Configuration Required for PL7-PMS

Checking the Hardware

Connections

Installing the Software

1.5-1 Initial Preparations

1.5-2 Installation Procedure

1.6

Using the Keyboard and Mouse 1/6

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Methodology

2.1

Methodology Proposal for Setting-up a Process 2/1

1/1

1/1

1/2

1/3

1/4

1/4

1/4

1/5

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A / 1

Presentation and Set-up 1

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1.1

General

1.1-1 Features Supported by PL7-PMS

The PL7-PMS program, catalog reference TXT L PL7 PMS V5E, is an industrial process control program and set-up program for use with TSX AEM modules.

The PL7-PMS program comprises three main components:

• One that supports process control,

• PID algorithm in an Optional Function Block (OFB),

• One that lets the user implement TSX AEM 411/412/413/811/821/1601, 1602 or 1613 modules,

• Set-up (configuration, threshold selection, etc.),

• Configuration load OFBs,

• Diagnostics OFBs.

• One that lets the user design and operate a man-machine interface application,

• Process control screens,

• Application adjustment screens.

• Process control features,

• Process control processing (proportional, integral or derived action, filters, alarms, limits, etc.),

• Analog input module features,

• User assistance with configuration parameter input through easy to use menus and on-line documentation,

• User assistance with diagnostics and debug actions,

• Configuration transfer between the PLC memory, TSX AEM module memory and disk storage,

• Configuration and threshold documentation,

• Configuration and threshold data storage on disk,

• Configuration print-out.

• Man-machine interface application creation features,

• Graphic editor,

• Animation editor,

• Task configuration,

• Application transfer to the PLC and to a TSX PCM 37 module,

• Application documentation.

• Man-machine interface application operation features,

• Process control monitoring,

• Process control loop adjustment.

A

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A

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1.2

Configuration Required for PL7-PMS

The PL7-PMS program is designed to run on FTX 417 20 or FTX 507 terminals or IBM

PS/2 or compatible PCs with the following systems installed:

• OS/2 V1.3 or 2.1 operating system,

• X-TEL or MINI X-TEL Software Workshop (TXT L BASE V5• or TXT L BJR V5•),

• PL7-3 programming software (TXT L PL7 3 V5•, TXT L PL7 3 D V5• or TXT PL7 3 T V5•),

• Integrated PL7-MMI 37 Mini-Monitor software (TXT L PL7 M37 V5•).

This means that the system requires at least 4 MB of RAM memory installed and a 40 MB hard disk.

Important

Telemecanique cannot guarantee that these programs will operate correctly on all types and all configurations of PC compatible micro-computers, even if they meet the requirements listed above.

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Presentation and Set-up 1

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1.3

Checking the Hardware

The TXT L PL7 PMS V5 program package comprises:

• A 3 1/2" program diskette, ref. TXT LF PL7 PMS V5,

• A 3 1/2" OFB diskette, ref. TXT LF FB PMS V5,

• A 3 1/2" program diskette, ref. TXT LF PMS MMX V5,

• A software key module,

• A program licence contract,

• This documentation set, ref. TXT DM PL7 PMS V5•.

A

To use the PL7-PMS program, the user requires the following hardware:

• An FTX 417 20 or FTX 507 terminal or an IBM PS/2 or compatible PC (refer to the required configuration described in Sub-section 1.2),

• A terminal/PLC connection cable when a FTX 507 terminal is used,

• If an IBM PS/2 or compatible PC is used, the terminal/PLC connection requires a connection kit (TSX TAC 03) comprising:

• An RS-232C/Current loop converter,

• A Converter/PC connection cable with a 9-pin connector,

• A Converter/PC connection cable with a 25-pin connector,

• A Converter/PLC connection cable,

• A TSX SCC 02 key module holder.

Note

During the operating phase, the user requires:

• A TSX PCM 37 module,

• A TSX BMP 010 module,

• A color monitor (TSX VGA 14 or TSX VGA 19),

• A standard computer keyboard or a specific process control keyboard (T PMX KB1),

Remark

It is possible to replace the TSX BMP10/TSX VGA 19/T PMX KB1 hardware configuration with a TSX CPX 3714 operator console.

Connection and operation of the various elements required to support the operating phase is described in detail in the corresponding user documentation.

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A

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1.4

Connections

The connections that are specific to the terminal (monitor, keyboard, mouse, printer, key module holder, etc.) are assumed to have already been made according to the documentation supplied by the terminal manufacturer. This sub-section only describes the fitting of the software key module. To do this, insert the software key into the vacant slot in the software key module holder.

This operation must always be performed with the terminal powereddown.

Note:

The software key module contains the right of use required to run the PL7-PMS program. The Key

Manager supplied with the MINI X-TEL or X-TEL Software Workshop lets the user transfer this right of use to the Work Key Module so that only a single key is required (work key) once again releasing a slot in the key module holder.

For more information on the use of the Key Manager, refer to the MINI X-TEL or X-TEL Software

Workshop documentation.

The PL7-PMS V5 key module is identical to the one used with PL7-PMS V4.

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1.5

Installing the Software

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1.5-1 Initial Preparations

Before installing the PL7-PMS program on the hard disk, always:

• Read the licence and guarantee certificates that give the conditions of use and detail the restrictions that apply to copying and installing this program,

• Make a copy of the diskettes required for installation and only use this copy to avoid accidental damage to the original diskette.

Important

The PL7-PMS program diskettes are supplied write protected. Do not change the position of the write protect tab on these diskettes.

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Presentation and Set-up 1

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1.5-2 Installation Procedure

The following operations should be performed before installing the PL7-PMS software:

• Check that the MINI X-TEL or X-TEL V5 Software Workshop, the PL7-MMI 37 V5 and

PL7-3 V5 software is already installed:

• If so, install PL7-PMS V5 following the installation procedure described below,

• Otherwise, first install the MINI X-TEL or X-TEL Software Workshop (refer to the appropriate documentation). Then install PL7-3 V5 programming software (refer to the PL7-3 Operating Modes V5 documentation). Finally, install the PL7-MMI 37 V5 software, refer to the PL7-MMI 37 documentation).

• Close all work sessions in progress, to do so:

• Open the Desktop Manager window,

• Pull down the Desktop menu and select Close all.

A

PL7-PMS Program Installation

• Open an OS/2 full screen session, to do so:

• Open the Desktop Manager window,

• Double-click on the Main Group icon to open the Group - Main window,

• Double-click on the OS/2 Full Screen icon. The prompt [C:\] is displayed.

• Insert the PL7-PMS diskette, TXT LF PL7 PMS V5 into the diskette drive,

• Type the drive identification letter (a: or b:) where the diskette is located and press

<Enter> to confirm,

• Once the correct prompt (e.g. [A:\] or [B:\]) is displayed, type Install then press

<Enter> to confirm,

• Follow the prompts displayed on-screen,

• Once the installation procedure is completed, remove the program diskette and

insert the second (OFB) diskette, TXT LF FB PMS V5 into the diskette drive,

• Type Install then press <Enter> to confirm,

• Follow the prompts displayed on-screen,

• Once the installation procedure is completed, remove the second diskette and

insert the third diskette, TXT LF PMS MMX V5 into the diskette drive,

• Type Install then press <Enter> to confirm,

• Follow the prompts displayed on-screen,

• Once the installation procedure is completed and this is the last installation to

perform, run the configuration check. Press <Enter> to confirm,

• Remove the diskette from the drive and return to the X-TEL Software Workshop by pressing <Ctrl><Esc>.

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A

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1.6

Using the Keyboard and Mouse

Using the keyboard

To run PL7-PMS, Telemecanique recommends the use of a 102-key extended keyboard with the appropriate national layout.

Some PL7-3 function keys (e.g. CLEAR, ZOOM, QUIT) that are also used by PL7-PMS are not marked as standard on the keyboard but can be accessed by another key or combination of keys.

These keys, common to a number of Telemecanique programs are described in the

PL7-3 Operating Modes V5E User's Manual.

Using the mouse

As with the keyboard, the detailed procedures for using the mouse are described in the

PL7-3 Operating Modes V5E User's Manual.

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Methodology 2

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2.1

Methodology Proposal for Setting-up a Process

A

The methodology example described here is designed to assist the user during the generation, debug, storage and documentation phases of process control application development. As this is a methodology example only, the various operations are described without detailing the operating modes required.

Divider A, Section 1 Install the program

XTEL-CONF

XTEL-CONF

Create the application shell

I/O

Configuration

Refer to next page PL7-PMS application design

PL7-3 application design

Man-machine interface application design

XTEL-TRANSFER

PL7-MMI 37

Divider B, Section 4

PL7-3

PL7-MMI 37

Refer to next page

PL7-MMI 37

Debug

TSX AEM xxx modules

Transfer to PLC

Transfer to

PCM 37 module

(PL7-MMI 37)

Debug the process control application

(PL7-3)

⇔

Man-machine interface application operation & debug

(PL7-MMI 37)

Update application and documentation files

Update application and documentation files

Documentation

(PL7-MMI 37)

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A

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PL7-PMS and PL7-3 application design phase

PL7-PMS application design

Create directory

Divider B, Section 3

PMS.BIN file

Write module configurations

Divider B, Sub-section 4.1

PMS.BIN file

TSX AEM xxx module documentation

Divider B, Section 4.5

STATION.DOC file

PL7-3 application design

Configure the OFBs in

PL7-3

PL7-3 Configuration mode

Terminal memory

Program

Load OFB

Diagnostics OFB

Divider C, Sections 2 and 3

Terminal memory

Program process control

OFBs

Divider D

Terminal memory

Save and integrate the application file

PL7_3.BIN file

Document the application

STATION.DOC file

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Methodology 2

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Man-machine interface design and operation phases

A

Man-machine interface

application design

Module selection

Divider E, Sub-section 1.2

Process control task configuration

Divider E, Sub-section 1.3

Static screen creation

Screen animation

Divider E, Sub-section 2.2

Divider E, Sub-section 2.3

Screen test Divider E, Sub-section 2.3

Process control password definition

Divider E, Sub-section 2.4

Selection of tasks to transfer and generation of executable files

Divider E, Sub-section 2.6

Man-machine interface application operation

System operation

Trending curves

Graphic screens

Divider F, Section 1

TREND screen

Divider F, Sub-section 2.1

Adjust and debug the process control loop

TUNE screen

Divider F, Sub-section 2.2

Save the adjustment values

SAVE key

Divider F, Sub-section 2.1

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A

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TSX AEM Analog Input Module

Configuration Program B

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Page

TSX AEM Module Configuration Program

1.1

Selecting the Configuration Program

1.2

Display Screen Presentation

1.3

Mode Selection

1.4

Link with the PLC Memory

1.4-1 Dedicated PMS Field in the PLC Memory

1.4-2 Reservation in Connected Mode Operation

1.5

Methodology 1/9

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Selecting the Working Memory

2.1

Presentation

2.1-1 Common Dynamic Soft Key Functions

2/1

2/2

1/1

1/2

1/4

1/6

1/6

1/8

B

2.2

Selecting the AEM Memory

2.3

Selecting the PMX Memory

2.4

Selecting the AEM File

2.5

Selecting the PMX File

2/4

2/5

2/7

2/9

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Managing the Dedicated PMS Field

3.1

Dedicated PMS Field

3.2

PMS Directory

3/1

3/2

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B / 1

A

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TSX AEM Analog Input Module

Configuration Program B

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B Page

Operating Modes

4.1

Configuration Mode

4.2

Threshold Mode

4.3

Debug Mode

4.3-1 Mode Presentation

4.3-2 Status/Commands Screens

4.3-3 TSX AEM Module Faults Screen

4.4

Transfer Mode

4.4-1 PL7-PMS Files

4.4-2 Transfer Options

4.4-3 Using the Transfer Mode

4.5

Documentation Mode

4.5-1 General

4.5-2 Print-out Page Examples

4/12

4/12

4/14

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Appendix

5.1

Using the TSX AEM 821 Module in Synchro Mode

5.1-1 General

5.1-2 Using Synchro Mode

5.1-3 Synchro Mode Impact on Configuration Mode

5.1-4 Synchro Mode Impact on Debug Mode

5/1

5/1

5/2

5/4

5/4

5.2

Calibrating TSX AEM 1601 and 1602 Modules

5.2-1 General

5.2-2 Calibration Procedure

5.2-3 Trim Procedure

5/5

5/5

5/6

5/9

4/1

4/3

4/4

4/4

4/5

4/7

4/8

4/8

4/9

4/10

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TSX AEM Module Configuration Program 1

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1.1

Selecting the Configuration Program

The TSX AEM module configuration program is run by opening the corresponding PMS window. To do this:

3

4

1

2

Open the Desktop Manager window by double clicking on its icon,

Double click on the Telemecanique icon to open the Telemecanique Group window,

Open the User window by double clicking on XTEL/MINI X-TEL,

Enter the appropriate user parameters (user name and password) then select OK to confirm and the Volumes window will be displayed,

7

8

5

6

Open a Volume by double clicking on the icon of the volume to open,

Open a Project by double clicking on the icon of the project to open,

Open a Station by double clicking on the icon of the station to open,

Open the PMS function by double clicking on its icon. If the icon is not displayed in the Functions secondary window even after the program has been installed, then the function has not yet been defined. To define the function:

• Pull down the Define menu and select New,

• Click on PMS then click on OK to validate.

9 For greater visual comfort, select a full screen PMS session by clicking on the

Maximize icon in the top right corner of the window.

B

Note

• To close a session, click on the corresponding icon. This will pull down a menu allowing the user to select the appropriate Close/Exit commands.

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B

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1.2

Display Screen Presentation

The display screen is the window that displays PL7-PMS screens. All of the elements that are common to all Mini X-TEL or X-TEL Software Workshop programs (icons, window title line, window commands, etc.) are described in the appropriate Software

Workshop documentation.

Information displayed

1 2 3 4 5 6 7

8

9

& '

é "

7

8

5

6

3

4

1

2

é

"

9

&

'

Working memory,

Network address of the terminal,

Working memory and its address if MEM AEM or MEM PMX is selected,

TSX AEM module number or the file name if DISK working memory is selected,

Application number,

Current page number,

Application name,

Configuration parameter display field,

Real-time events field: displays the PLC status,

Parameter entry line,

Current task display field (DISP, MODIFY, etc.),

Display line for dynamic soft keys [F1] to [F9],

User or syntax error message display field.

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TSX AEM Module Configuration Program 1

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Screen display sequence principles

Working Memory

Selection

(1)

B

↑ ↓

←

→

CLEAR

QUIT

Operating Mode

Selection

←

↑

→

↓

(2)

CLEAR

QUIT

Operating Sub-Mode

Selection

CLEAR

↑

ENTER

↓

QUIT

Selected Mode

Screen

(1) Access to connected mode: AEM MEMORY or PMX MEMORY requires:

• Previous transfer of a memory configuration file to the PLC memory,

• At least one TSX AEM module is declared in the XTEL-CONF I/O configuration.

(2) Only in Debug and Transfer modes.

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B

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1.3

Mode Selection

The mode selection screen, which is the basic screen in PL7-PMS, lets the user access all of the functions supported by the program.

This screen comprises two parts:

• A menu field that lets the user select the:

• Working memory (Module, PLC or Disk),

• Operating modes (Configuration, Thresholds, Debug, Transfer AEM and Documentation),

• Operating sub-mode for Debug and Transfer AEM modes.

• A data field (in connected mode operation) that displays the:

• Working memory,

• Processor type,

• Current directory.

Function keys

< ↑ > < ↓ >

<

→

> <

<Enter>

←

>

Move the cursor within the active column: working memory, operating modes or operating sub-modes. An item in a column can also be selected by entering its number.

Let the user move between columns.

Validates all of the selections made.

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TSX AEM Module Configuration Program 1

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Dynamic soft keys

[EXIT]

[READ ME]

[UTILS]

Lets the user exit PL7-PMS with the possibility to select save or compare actions.

Lets the user access the on-line documentation.

Lets the user access the utility functions.

B

The other dynamic soft keys that are specific to the selected mode are described in

Section 2, Selecting the Working Memory.

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B

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1.4

Link with the PLC Memory

1.4-1 Dedicated PMS Field in the PLC Memory

When the PMS function is declared at station level, a dedicated field is automatically created when the STATION.APP field is generated by XTEL-CONF. The size of this field, which is assigned a default setting by XTEL-CONF, can be changed by the user.

The position of the field is determined by the size of the fields assigned to PL7-3 and the other dedicated functions that it follows. This field is fully controlled by the PL7-PMS program.

PL7-3 Data

PL7-3 Program

Application

File xxx.APP

Other dedicated functions

PMS pl7_pms

PMS field contents

When the image of the PLC memory is created by XTEL-CONF, the field is blank. It will be filled-in later by the PL7-PMS (1) program. It comprises:

• A directory comprising a:

• Correspondence table between logical and physical slot numbers of the modules in the racks. The program generates a default assignment (2) that can be modified by the user,

• Table that gives the start address and the size of the configurations stored in the dedicated field.

• The configurations stored in rising order of logical number.

(1) On condition that the PLC memory comprises the PL7-3 I/O configuration and the slots taken by TSX AEM modules.

(2) Numbering from 0 to 63 is the order in which modules are entered in the I/O configuration by

XTEL-CONF.

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TSX AEM Module Configuration Program 1

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PMS dedicated field

Correspondence table between configuration number and module location

Address and size of stored configurations

Configuration 0 AEM 0

Configuration 1 AEM 0

Configuration 0 AEM 1

Directory

This field contains data that can only be accessed by PL7-PMS program functions and that handle its organization. A compacting function lets the user optimize the contents of the field. The image of this dedicated field is stored in the PMS.BIN

file in the PMS\APPLI directory on the hard disk or diskette.

Configuration j AEM n

A configuration stored in this field can be transferred to a TSX AEM module by the

AEMLD OFB.

B

PL7-3

Directory

Conf 0 AEM 0

PMS Field

Conf k AEM n

AEMLD

OFB

The AEMLD OFB is described in Divider C, Section 2.

The term configuration used here designates all of the parameters defined:

• In Configuration mode to adapt the module to the sensors used,

• In Threshold mode to define the threshold values.

It is equivalent to the term application used on-screen by the implementation program.

For each module, the user can define a number of configurations that differ only in the selected threshold values (each configuration is numbered from 0 to 8). In most cases, a single configuration (numbered 0) is all that is required (with set threshold values or without the need to use the Threshold function).

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B

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1.4-2 Reservation in Connected Mode Operation

On a single MAPWAY, ETHWAY, FIPWAY or ETHERNET network, any FTX 417/507 terminal or microcomputer can be physically connected to any PMX station. Therefore a number of terminals can request logical connection to the same PLC station.

To avoid access and procedure conflicts, each terminal will on request reserve the entire

PMS dedicated field. This reservation is only performed when access, in read or write, is required to a directory or configuration.

If the PMS dedicated field is not already reserved by another logical device, the device that requests the reservation can gain access to the field.

From this moment on, any attempt to access it by another logical device will be rejected and the message TSX ALREADY RESERVED will be displayed. Once the action in progress is completed, the reservation is terminated.

Attention

PL7-PMS cannot be used to set-up a remote station via a TELWAY network.

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TSX AEM Module Configuration Program 1

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1.5

Methodology

The TSX AEM module configuration program lets the user work in:

• Local mode, with the disk as the working storage,

• Connected mode (on-line) with the module memory (MEM AEM) or the PLC memory

(MEM PMX) as the working memory.

LOCAL MODE

FTX 507 FTX 507

CONNECTED MODE

PLC Processor

TSX AEM

MEM PMX

B

PMX File

AEM File

MEM AEM

Using the local mode to create TSX AEM configurations and the dedicated PMS field is recommended. There is nothing to stop the user generating a complete application in connected mode but this mode should preferably be reserved for modifications, corrections and debug functions.

Set-up comprises a design phase followed by a debug phase:

Design

Debug

Create directory

Create configurations

PMX FILE

PMX FILE

Documentation PMX FILE

Debug

Adjust

AEM MEMORY

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B

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Design phase

• Create the directory

• Open the PMS window,

• Select PMX FILE as the working memory,

• Select DIR PMS (the program automatically recognizes the STATION.APP and

STATION.IOC files if they exist),

• Select <Enter> to exit.

• It is possible to generate a library of configurations by performing the

MEM PMX

→

AEM FILE transfer action. Any files stored in this way take a 411, 412,

413, 811, 821, 16I (for 1601), 16U (for 1602) or 16P (for 1613) extension depending on the type of TSX AEM module selected.

• Documentation

• Select PMX FILE as the working memory,

• Document each configuration (the output will be sent to the printer or to a disk file).

Debug phase

• Debug and adjustment

• Select MEM AEM as the working memory,

• Modify the configuration (parameters, thresholds, etc.),

• Transfer the configuration to the PLC memory (MEM AEM

→

MEM PMX),

• Debug all of the configurations that may be downloaded to TSX AEM modules.

• Documentation

• Select MEM PMX as the working memory,

• Document each configuration (the output will be sent to the printer or to a disk file).

Remark

In File mode, PL7-PMS directly accesses the PMS.BIN file. No backup or save action is required.

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Selecting the Working Memory 2

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2.1

Presentation

The working memory selection determines the operating mode of the PL7-PMS program and whether it uses local (off-line) or connected (on-line) modes.

Local mode operation

In this example, the hard disk is selected as the location of the working memory field.

The local mode lets the user:

• Define configurations for all TSX AEM module channels (AEM file).

The configurations that are generated in this way are assigned to specific types of

TSX AEM module (TSX AEM 411 to 1613),

• Generate the PMS.BIN file that is the image of the dedicated PMS field (PMX file).

B

Connected mode operation

In this example the AEM memory field (module memory) or PMX memory field

(dedicated memory field in the PLC) was selected as the working memory field. The connected mode lets the user:

• Generate or modify a configuration,

• Generate the dedicated PMS field,

• Transfer the configurations from the disk to the module memory or the dedicated memory field in the PLC.

When the terminal is connected to a TSX AEM module, the PL7-PMS program also lets the user perform Debug actions.

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B

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2.1-1 Common Dynamic Soft Key Functions

The dynamic soft keys that are common to the various modes are described below:

[AEM]

[APPLI]

Selects the number of the working module. In Documentation mode, the "*" wildcard validates all configured TSX AEM modules,

Selects the number of the working configuration. In Documentation mode, the "*" wildcard validates all of the configurations of the selected module. AEM = * and APPLI = * let the user document all of the configurations stored in PMX memory or in a PMX file,

[AEM/APP]

[DIR PMS]

[READ ME]

[R/S AEM]

[R/S PMX]

[STA → DSK]

Selects the number of the module and of the working configuration,

Lets the user access the AEM directory on-screen (refer to Divider B,

Sub-section 3.2) or create it, if it does not already exist.

Lets the user access the PL7-PMS program help screens,

Toggles the TSX AEM module between Run and Stop,

Toggles the PLC between Run and Stop.

Displays a screen that lets the user store the contents of the dedicated

PMS field as a PMS.BIN file stored in the

XPROPRJ\PROJECT\STATION\PMS\APPLI directory:

[AUTO/MAN] Lets the user select the type of save to perform. In

Automatic mode, all of the modifications are systematically stored. In Manual mode, all of the modifications made will only be stored when the user presses the [STA → DSK] key.

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Selecting the Working Memory 2

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[COMPARE] Compares the source and target (destination) files.

[STA → DSK] Stores the file and after confirmation by the user, runs XTEL-CONF to update the STATION.APP file corresponding to the configuration.

[DSK → STA] Displays a screen that lets the user transfer, to the dedicated PMS field in the PLC memory, the contents of a PMS.BIN file previously stored on disk:

B

[COMPARE]

[DSK → STA]

Compares the source file and the dedicated PMS field,

Retrieves the selected file.

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B

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2.2

Selecting the AEM Memory

The AEM Memory field is the only one that supports module debug and operation actions.

The configuration is saved directly to the module memory each time it is validated.

The AEM memory can only be used if a STATION.APP configuration file, that must at least contain the I/O configuration generated using XTEL-CONF, has been transferred to the PLC memory. The PLC can be stopped (STOP) or running (RUN).

[UTILS] Lets the user access AEM memory utility functions:

0 - APPLICATION CHARACTERISTICS: Displays information relative to the module and its configuration,

1 - RUN AEM: Starts the module running (RUN),

2 - STOP AEM: Stops the module (STOP).

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Selecting the Working Memory 2

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2.3

Selecting the PMX Memory

The PLC memory is primarily a storage location. It lets the user store the various configurations in the dedicated PMS field of the PLC memory.

Storing the configurations in the PLC memory means that the PLC program, via the

AEMLD Optional Function Block (OFB) can, if necessary, reload the configurations in the module. The AEMLD OFB is described in Divider C, Section 2).

The PMX memory can only be used if a STATION.APP configuration file, that must at least contain the I/O configuration generated using XTEL-CONF, has first been transferred to the PLC memory. The PLC can be stopped (STOP) or running (RUN).

B

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B

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[UTILS] Lets the user access PMX MEMORY utility functions:

0 - LIST OF APPLICATIONS: Displays a screen with a list of configurations assigned to a module:

The upper boxes show the module number, location address and type,

The lower boxes show the number, name, date and time of creation or of the last modification and the size of each configuration stored in the PLC memory.

1 - RUN PMX: Starts the PLC running,

2 - STOP PMX: Stops the PLC,

3 - DELETE THE APPLICATION: After confirmation by the user, this action deletes the configuration of the selected channel.

4 - CHANGE THE FIELD NAME: Assigns a comment of up to 24 characters to the configuration.

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Selecting the Working Memory 2

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2.4

Selecting the AEM File

Selection of this memory field is recommended when creating TSX AEM module configurations in the design office. The files generated in this way can be exported to another station. This selection does not require the physical presence of a PLC or a

TSX AEM module, nor the downloading of a configuration.

The configurations are saved to a hard disk or diskette (the storage media is defined in the X-TEL Software Workshop at Volumes level) as they are validated.

All of the configurations created in this way are generic. They are not assigned to a specific TSX AEM module, nor to a specific PL7-3 application (library function).

B

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B

__________________________________________________________________________________________

[UTILS] Lets the user access DISK memory utility functions:

0 - DIRECTORY (MOD): Displays a list of files stored in the PMS\MOD directory.

1/8 - LIST OF APPLICATIONS: Displays the list of all the configuration files stored in the PMS\MOD directory.

Regardless of the utility function selected:

[SEARCH] Lets the user search for a file in the list,

[DELETE] After user confirmation (YES), deletes the file selected by the cursor.

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Selecting the Working Memory 2

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2.5

Selecting the PMX File

This mode lets the user generate, in Local mode, the image of the PLC memory.

The PMX memory can only be used if a station configuration has first been created using

XTEL-CONF.

B

[STORE]

[RETRIEVE]

Stored the configuration to an xxx.BIN file. The default name of this file is PMS.BIN. Two dynamic software keys can be accessed:

[FILE]

[STORE]

Lets the user change the default name of the file stored: for example xxx.BIN.

Performs the store action.

Lets the user retreive an xxx.BIN file previously stored using the

[STORE] dynamic software key. The file is restored to the X-TEL working field as PMS.BIN.

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B

__________________________________________________________________________________________

[UTILS] Lets the user access the PMX file utility functions:

0 - DIRECTORY\APPLI: Displays the list of files stored in the

PMS\APPLI directory (.BIN, .DOC files etc.),

1 - LIST OF PMX FILES: Displays the list of configuration files (.BIN

files),

2 - APPLICATION LIST: Displays a list of all of the configurations assigned to a given TSX AEM module in the current .BIN file,

3 - DELETE APPLICATION: Deletes the configuration specified by an TSX AEM module number and by a configuration number from the current .BIN file,

4 - MODIFY AREA NAME: Assigns a comment of up to 24 characters to the current .BIN file.

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Managing the Dedicated PMS Field 3

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3.1

Dedicated PMS Field

This field in the PLC memory is used to store the various configurations that may be downloaded to the TSX AEM modules.

This field is fully managed and controlled by the PL7-PMS program:

• The directory is created by PL7-PMS,

• The configurations originate with:

• Direct entry into the PMX memory using PL7-PMS,

• An AEM FILE to PMX MEMORY transfer,

• An AEM MEMORY to PMX MEMORY transfer.

B

Directory

Configuration 0 AEM 0

Configuration 1 AEM 0

Dedicated PMS Field

Configuration j AEM n

An attempt to transfer a configuration to the PLC memory or any attempt to modify an existing configuration can cause the display of one of the two messages listed below:

• Space full: The dedicated PMS field is not large enough to store the new configuration. The user should change the size of this field using XTEL-CONF and then repeat the transfer of the STATION.APP file and its assigned binary file.

• Space to pack: The size of the dedicated PMS is adequate if it is first packed

(compacted). Optimizing the dedicated memory field ensures that any "gaps" created by configuration transfer or deletion operations are eliminated. The packing operation is selected by the [PACK] key that is accessed from the directory screen (refer to Subsection 3.2).

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B

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3.2

PMS Directory

A TSX AEM configuration is defined by:

• A module number from 0 to 63,

• An application number from 0 to 8.

The directory defines the correspondence between the physical location of the module in the I/O configuration of the PLC and its logical number in the configuration.

The directory is created by PL7-PMS and stored at the start of the dedicated PMS field in the PLC memory. The TSX AEM modules that are found in the I/O configuration are assigned an AEM number in rising order, from 0 to 63.

The assignment of these numbers can be changed by the user.

If the PL7-PMS program is run in connected mode (AEM MEMORY or PMX MEMORY), selecting the [DIR PMS] dynamic soft key will display the PMS DIRECTORY screen or lets the user create this directory.

TSX-PMS Field (Area)

RESERVED

FREE

The number of words reserved is set by XTEL-CONF. This number cannot be modified using PL7-PMS.

The number of words free is the amount of unused memory space.

PMX FILE PMS.BIN is the name that the PMS field is stored on disk with, using the [STA → DSK] command.

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Managing the Dedicated PMS Field 3

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Dynamic soft keys

[ALL DIR] Lets the user gain detailed access to the PMS directory, specifying the following information for each module:

• Hardware location: rack, module,

• Type (TSX AEM 411 to 1613),

• Assigned AEM number,

• The size of the configuration assigned to each application.

[TOP] Displays the start of the directory field,

[BOT] Displays the end of the directory field,

[PREVPAGE] Displays the previous page,

[NEXTPAGE] Displays the next page.

This view of the directory is the one provided for documentation purposes.

[AEM]

[PACK]

[../..]

[UPDATE]

Modifies the AEM number assignments that are proposed by default by the system. A number can only be assigned to a single slot.

Compacts the dedicated PMS field. This action lets the user recover the memory spaces left open for example by previous configuration deletions,

Only displayed if the configuration comprises more than 16 TSX AEM modules. This dynamic soft key lets the user move between groups of modules.

Any modification to the module slot location, adding or deleting a

TSX AEM module from the I/O configuration generated by

XTEL-CONF, is indicated in the AEM directory by an asterisk at the start of the line describing the module.

The [UPDATE] key, that is only displayed in this case, lets the user update the directory to match the new I/O configuration.

B

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B

__________________________________________________________________________________________

[DIFF] This key displays the differences between the configuration of the

TSX AEM modules as stored in the PMS directory and the current configuration of the TSX AEM modules.

In Connected mode, the current configuration of the TSX AEM modules corresponds to the configuration stored in the PLC.

In Local mode, the current configuration of the TSX AEM modules corresponds to the I/O configuration defined with XTEL-CONF.

This key is only displayed if a difference is found (i.e. a module added or deleted from the configuration).

-

#

=

+

The characters displayed on-screen outside of the table indicate the following information:

Identical,

One or more modules added,

One or more modules removed,

Different module type.

If the configuration comprises more than 16 modules, the following additional dynamic software keys are displayed:

[TOP] Lets the user access the first module on the first page of the directory.

[BOT] Lets the user access the last module on the last page of the directory.

[PREVPAGE] Lets the user access the first module on the previous page of the directory.

[NEXTPAGE] Lets the user access the last module on the next page of the directory.

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Operating Modes 4

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4.1

Configuration Mode

The Configuration mode lets the user enter or modify the configuration parameters for all of the channels of a module. When a configuration is created, all of the parameters take a default value which can be changed by the user before validating the configuration.

A detailed description of each parameter is provided in the documentation supplied with each module. In addition, the on-line documentation assists the user when making selections.

The Configuration mode screen is accessed from the PL7-PMS program primary window:

• Select the working memory (refer to Section 3),

• Pressing <

→

> lets the user access the Mode Selection screen,

• Enter a TSX AEM module and application number using the [AEM] and [APPLI] or

[AEM/APP] dynamic soft keys. If the AEM file is used, select a file name using the

[FILE] dynamic soft key),

• Select 0 - CONFIGURATION then press <Enter> to validate.

A specific screen is displayed for each type of TSX AEM module selected. As an example, the screen shown below corresponds to the configuration parameters of a

TSX AEM 821 module.

B

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B

__________________________________________________________________________________________

Depending on the type of TSX AEM module and the number of channels declared, the configuration screen will comprise 1 to 5 pages. Each page is split into three columns:

Parameters For the parameters,

Values

Limits

Lists the value of each parameter. This field must be filled in by the user,

Displays the possible choices or the limits that apply to each parameter. This is the display field that is displayed when the [HELP] dynamic soft key is pressed.

Dynamic soft keys

[AP.NAME] Lets the user enter the configuration name (up to 16 alphanumeric characters),

[TOP]

[BOT]

Displays the first page and places the cursor at the start of this page,

Displays the last page and places the cursor at the start of this page,

[MODIFY]

[COPY]

Modifies the value of the parameter selected by the cursor, or lets the user access it for modification (displays dynamic soft keys or a data entry line),

Copies the configuration of the selected channel to another channel or to all channels (when the "*" wildcard is selected),

[HELP SYN] When SYNC operating mode is selected (TSX AEM 821 module used in Sync mode). This key displays a help screen that is specific to this mode. For more information on the Sync mode, refer to Divider B,

Section 5.

[PREVPAGE] Displays the previous page,

[NEXTPAGE] Displays the next page,

[HELP] Displays help information in the third column relative to the parameter selected by the cursor.

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Operating Modes 4

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4.2

Threshold Mode

This mode lets the user display and modify the thresholds of a configuration in the selected working memory.

Threshold modification can only be performed if the module was previously configured.

The Threshold mode screen is accessed from the PL7-PMS program primary window:

• Select the working memory (refer to Section 3),

• Pressing <

→

> lets the user access the Mode Selection screen,

• Enter a TSX AEM module and application number using the [AEM] and [APPLI] or

[AEM/APP] dynamic soft keys. If the AEM file is used, select a file name using the

[FILE] dynamic soft key),

• Select 1 - THRESHOLDS then press <Enter> to validate.

A specific screen is displayed for each type of TSX AEM module selected (TSX AEM 411,

412 and 413 modules only support a single threshold for each channel while

TSX AEM 811, 821 and 1613 modules support up to two thresholds for each channel.

TSX AEM 1601 and 1602 modules do not support thresholds). As an example, the screen shown below corresponds to the configuration parameters of a TSX AEM 821 module.

B

The "VALIDITY ZONE" column indicates the possible limit values for each of the thresholds depending on how the channels are configured.

[MODIFY] Lets the user modify the threshold selected by the cursor.

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B

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4.3

Debug Mode

4.3-1 Mode Presentation

The Debug mode lets the user modify the bits and words of the module discrete I/O or register interface. It can only be accessed if the AEM memory is selected.

A detailed description of each of the parameters is provided in the documentation supplied with the modules. The Sync mode for TSX AEM 821 modules is described in

Divider B, Section 5.

The Debug mode screen is accessed from the PL7-PMS program primary window:

• Select the AEM memory (refer to Section 3),

• Pressing <

→

> lets the user access the Mode Selection screen,

• Enter a TSX AEM module and application number using the [AEM] and [APPLI] or

[AEM/APP] dynamic soft keys,

• Select 2 - DEBUG,

• Pressing <

→

> lets the user access function selection,

• Select the required function, then press <Enter> to validate.

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Operating Modes 4

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4.3-2 Status/Commands Screen

This screen displays all of the information and commands available for the module's discrete I/O and register interfaces. These are displayed as mnemonics that indicate the status of bits: bits at 1 are displayed in reverse video (or with increased brightness).

A plain language message is displayed in the data entry line to comment the bit or word selected by the cursor.

The left part of the screen (STATUS) displays the information provided by the module on the discrete I/O (Ixy,i) and register (IWxy,i) interfaces (operating mode, module and channel faults).

The right part of the screen (COMMANDS) displays the commands sent to the module via the discrete I/O (Oxy,i) and register (OWxy,i) interfaces.

Any modification of a command bit or a numerical value results in the sending of a request directly addressed to the module via the message interface. The program will then update the discrete I/O and register command interfaces so that their data corresponds to the actual module status.

This mechanism means that it is possible to debug the module while the PLC is stopped.

B

Ixy,i Oxy,i

TSX AEM

Module

FTX 507

IWxy,i

OWxy,i

MSG

Interface

(requests)

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B

__________________________________________________________________________________________

[READBDEF] Lets the user acknowledge faults and perform a new fault read,

[SET/RES] Lets the user modify the status of the command bit selected by the cursor,

[MODIFY]

[R/S AEM]

[TRIM]

[CALIB]

[FAULTS]

Lets the user modify the value of the parameter selected by the cursor,

Lets the user select module RUN or STOP,

Lets the user access the trim screen for TSX AEM 1601 and 1602 modules (refer to Divider B, Sub-section 5.2),

Lets the user access the calibration screen for TSX AEM 1601 and

1602 modules (refer to Divider B, Sub-section 5.2),

Lets the user display the fault display screen.

The fault bits that are specific to the Sync mode (SYNC MODE, SYNC STATUS and

OVERRUN) are described in Divider B, Section 5.

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Operating Modes 4

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4.3-3 TSX AEM Module Faults Screen

This screen displays a list of all the fault bits of the module and their status:

• The module fault bits and the results of the self-tests are displayed in the upper part of the screen,

• The application fault bits are displayed in the lower part of the screen,

Regardless of the type of fault, all of the bits at 1 are displayed in reverse video (or highlighted).

B

[READBDEF] Lets the user acknowledge all fault bits and causes a new read.

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B

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4.4

Transfer Mode

4.4-1 PL7-PMS Files

The PL7-PMS program files are designated by a name of up to eight characters, followed by a three character extension that identifies the file type. These files are stored in the various software workshop sub-directories.

The application files are stored at station level, in the PMS sub-directory:

PL7-3 APPLI

MOD

PMS APPLI PMS.BIN

ANALOG.BIN

PL7-PMS binary file

MOD AEM.411

AEM1.821

AEM2.811

AEM3.16I

AEM4.16U

AEM5.16P

Module configuration

The directory that can be accessed at station level is the PMS directory comprising two sub-directories:

• The APPLI sub-directory which comprises the PMS.BIN file and any files stored in

PM FILE mode using the [STORE] command,

• The MOD sub-directory which comprises the files in which the TSX AEM module configurations are stored. Each file is the image of a configuration available for downloading to a module. Each application generates a .AEM file where AEM takes the value 411, 412, 413, 811, 821, 16I, 16U or 16P depending on the type of

TSX AEM module selected for use.

The complete set of files that form the PMS directory is generated by the PL7-PMS function.

In the remainder of this section:

• PMX FILE corresponds to the files in the PMS\APPLI directory,

• AEM FILE corresponds to the files in the PMS\MOD directory.

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Operating Modes 4

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4.4-2 Transfer Options

The various options supported by the Transfer mode are described below:

PMS\APPLI Directory

PMX FILE

(PMS.BIN Files)

Directory

Config 0

Config 1

AEM 0

AEM 0

PMX FILE

↔

AEM FILE

PMS\MOD Directory

AEM FILE

(AEMx.xxx Files)

Config a

Config b

B

Config n

Config j AEM k

MEM PMX

↔

AEM FILE MEM AEM

↔

AEM FILE

TSX Series 7 PLC

MEM PMX

↔

MEM AEM

MEM PMX

(PLC Processor)

MEM AEM

(TSX AEM Module)

The Transfer mode only applies to a TSX AEM configuration in the dedicated PMS field. Transfers between the PMX file and the PMX memory are performed using the

[STA → DSK] and [DSK → STA] dynamic soft keys.

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B

__________________________________________________________________________________________

4.4-3 Using the Transfer Mode

The Transfer mode can be accessed from the primary window of the PL7-PMS program:

• Select the source memory that contains the application to transfer (refer to Section 4

- Configuration Mode),

• Access the Mode Selection screen using command <

→

>,

• Define the configuration to transfer: Enter a TSX AEM module number and an application number using the [AEM] and [APPLI] (or [AEM/APP]) commands or enter a file name using the [FILE] command,

• Select the Transfer mode, which will display the Destination column,

• Access target (destination) memory selection using command <

→

>,

• Select the target (destination) memory and press <Enter> to validate.

Dynamic soft key functions

[FILE]

[AEM]

[APPLI]

[AEM/APP]

Lets the user enter the back-up file name if the selected target memory is an AEM file,

Lets the user select the number of the working module if the selected target memory is the AEM or PMX memory,

Lets the user select the number of the working configuration if the selected target memory is the AEM or PMX memory,

Lets the user select the number of the working module and configuration if the selected target memory is the AEM or PMX memory,

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4 / 1 0

Operating Modes 4

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Transfer screen example

B

The upper table displays the selected source and target (destination) memories.

The target (destination) memory selection can still be modified using the cursor up and cursor down keys or the equivalent keys on the number pad.

The lower frame displays the address or the name of the source (left column) and target

(destination) (right column) applications.

[COMPARE] Compares the contents of the source memory with the contents of the target (destination) memory,

[UTILS]

<Enter>

Lets the user access the utility functions available for the source memory,

The first time <Enter> is selected, the configuration is read from the source memory. The second time <Enter> is pressed starts the transfer between the source and target (destination) memories.

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4 / 1 1

B

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4.5

Documentation Mode

4.5-1 General

This mode lets the user print to a printer or to a file all or part of a TSX AEM application

(configuration and thresholds). When the user selects an output to a file, the file obtained can be used later by XTEL-DOC.

This mode is accessed from the PL7-PMS primary window:

• Select the working memory (refer to Section 3),

• Access Mode Selection using the <

→

> command,

• Enter a TSX AEM (1) module number and an application number (1) using the [AEM] and [APPLI] (or [AEM/APP]) commands or enter a file name using the [FILE] command,

• Select the DOCUMENTATION mode, then press <Enter> to validate.

(1) The "*" wildcard character validates all of the applications in the selected module.

Entering AEM = * and APPLI = * lets the user document all of the applications stored in the PLC memory.

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4 / 1 2

Operating Modes 4

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Dynamic soft key functions

[P.SKIP]

[GRAP Y/N]

Lets the user immediately skip one page,

Defines the type of printer: Graphic (Yes) or ASCII (No). This selection is displayed in the CURRENT PARAMETERS frame,

[P.NBR]

[REV]

[PRI/FILE]

[FILE]

[DIR Y/N]

Lets the user enter the number of the first page of the documentation file. This number is displayed under PAGE NUMBER in the CUR-

RENT PARAMETERS frame,

Lets the user enter an optional revision level for the documentation file. This number is displayed under REVISION in the CURRENT

PARAMETERS frame,

Lets the user define the output required: printer or xxx.DOC file.

The selection is displayed in the CURRENT PARAMETERS frame.

Lets the user enter the name of the xxx.DOC documentation file, when output to file is selected,

Lets the user select whether or not to print-out the directory. The selection made is displayed in the CURRENT PARAMETERS frame.

<Enter> Prints the documentation file with the parameters defined in the

CURRENT PARAMETERS frame.

Important

When output to disk is selected, the output file will be located in:

• The PMS\APPLI directory if the print directory option is requested ([DIR Y/N] dynamic soft key),

• In the PMS\MOD directory if the print directory option was not selected.

In both cases, the file name is followed by the .DOC extension.

To ensure that the file generated in this way is usable at a later stage by XTEL-DOC, two conditions must be met:

• The file must be located in the PMS\APPLI directory,

• The file must be generated with the graphic printout option selected ([GRAP Y/N] dynamic soft key).

B

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4 / 1 3

B

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4.5-2 Print-out Page Examples

Parameters

INPUT RANGE

SCAN MODE

FUNCTION MODE

SCAN PERIOD

CHANNEL 0

• Type of scaling

• Square root

•B.P. exceeded

• Upper limit

• Lower limit

Values Limits

4/20 mA

NORMAL

SYNC

50 ms

[ -10/10V , , 4/20 mA ]

[ NORM , SIMP ]

[ SYNC , AUTO ]

1 : 1000

Y

N

VALID

USER

+2000

0

[ INHIB. , VALID. ]

[ INPUT , NORM , USER ]

[ Y,N ]

[ Y,N ]

-32000 : +32000

-32000 : +32000

Parameters

CHANNEL 1

• Type of display

•Square root

•Exceed B.P.

Values

N

N

VALID.

NORM

Limits

[ INHIB. , VALID. ]

[ INPUT , NORM , USER ]

[ Y,N ]

[ Y,N ]

CHANNEL 2

• Type of scaling

•Square root

•B.P. exceeded

• Upper limit

•Lower limit

VALID.

USER

N

N

+10000

0

[ INHIB. , VALID. ]

[ INPUT , NORM , USER ]

[ Y,N ]

[ Y,N ]

-32000 : +32000

-32000 : +32000

Application Application name object rev date page

REGUL 3.821 APPLI 0.0 13/11/91 2-1

AEM 821 2

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4 / 1 4

Appendix 5

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5.1

Using the TSX AEM 821 Module in Synchro Mode

5.1-1 General

The synchro mode is specific to the TSX AEM 821 module and lets the user synchronize measurement acquisition over the period of the task where they are used. This mode should be reserved for cases where the control loop sampling period cannot exceed

150 ms.

B

Principle of operation

At the start of each cycle, the TSX AEM 821 module receives an order that triggers its processing. This requires calculation of the instant of input data acquisition as closely as possible to the start of the next cycle. This mechanism lets the user obtain input values that are as up to date as possible for any given cycle N.

Cyclic Task TSX AEM 821

Input acquisition

Processing

Output update

Cycle N-1

Measurement acquisition

Input acquisition

Cycle N

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B

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5.1-2 Using Synchro Mode

Precautions for use

When using synchro mode, always respect the following conditions:

• Declare its use when configuring the TSX AEM 821 module, (in Configuration Mode,

"Operating Mode" parameter, value "SYNC". For more information refer to Divider B,

Sub-Section 5.1-3),

• Declare the IT task in the PL7-3 configuration, even if it is not used elsewhere,

• The IT must have an execution time that is less than 3 ms,

• Program the EXEC AEMLD instruction corresponding to the TSX AEM 821 module in the task where the module is declared so that it is scanned once and once only,

• Assign an AEMLD OFB to each TSX AEM 821 module and only to it,

• The module measurement acquisition period (in Configuration mode, "Scan Period" parameter) must match the period of the task in which the module is declared. It must be greater than the duration of an acquisition cycle + 5 ms to avoid causing an

OVERRUN error.

Reminder: The duration of an acquisition cycle is 6 ms + 2.5 ms * N, where N is the number of valid channels.

Error handling (syncro error)

If any of the precautions above are ignored, a SYNCHRO ERROR occurs (indicated by the setting to 1 of bit 2 of status word STATUS0 of the AEMDG OFB assigned to the

TSX AEM 821 module) and the setting of a bit of the register interface that is visible in

Debug Mode.

As long as this error is present, no measurement acquisition takes place. The user must therefore ensure that no synchro error is present before attempting to use the measurements.

To eliminate this error, check that all of the precautions for use listed above are always respected.

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Appendix 5

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Error handling (channel overrun error)

When the processing of the measurements from the valid channels exceeds the scan time of the TSX AEM 821 (defined in Configuration Mode, Parameter "Scan Period"), the module goes into a channel overrun error condition.

This error is indicated by setting to 1, bit 3 of status word STATUS0 in the AEMDG OFB assigned to the TSX AEM 821 module and by setting a register interface bit that is visible in Debug mode.

As long as this error is present, no measurement acquisition takes place. The user must therefore ensure that no synchro error is present before attempting to use the measurements.

To eliminate this error, first inhibit unused channels, then increase the TSX AEM 821 module sampling time (defined in Configuration Mode, "Scan Period").

Important

If it is necessary to increase the module scan period to prevent this error condition, the user should also change the task time defined. For correct synchro mode operation, the scan time and the task time must be identical.

B

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B

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5.1-3 Synchro Mode Impact on Configuration Mode

Selecting Synchro mode requires setting two additional configuration parameters (1):

• OPERATING MODE, that lets the user select between:

• AUTO, an autonomous mode where the module performs cyclic data acquisition,

• SYNCHRO, where the module synchronizes a data acquisition cycle with the task in which it is declared,

• SCAN PERIOD that must be identical to the period of the task in which the module is declared. This parameter is only accessible if Synchro Mode is selected.

Filtering is not available when Synchro mode is selected.

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5.1-4 Synchro Mode Impact on Debug Mode

Selecting Synchro mode causes additional information to appear (1):

• In the Status screen:

• SYNC MODE is displayed in reverse video if the module is operating in SYNCHRO mode (image of bit IWxy,2,3),

• SYNC STATE normally displayed in reverse video is the indicator showing correct operation of the synchronization mechanism. It is no longer displayed if a synchronization error occurs (image of bit IWxy,2,1),

• OVERRUN is displayed in reverse video if the module is in an overrun error condition

(image of bit IWxy,2,2),

• In the Error screen

• SYNCHRONIZATION ERROR is displayed in reverse video as soon as an error occurs and returns to normal when [READBDEF] is selected to read the fault bits if the error condition has actually ended (image of bit 64 of the fault bit string).

(1) In relation to the configuration parameters defined in the TSX AEM 821 User's

5 / 4

Appendix 5

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5.2

Calibrating TSX AEM 1601 and 1602 Modules

5.2-1 General

The TSX AEM 1601 and TSX AEM 1602 are preset at the factory and tested prior to delivery.

The quality of the components used means that any error caused by component aging remains within the specified accuracy tolerances. However, to compensate for any drift that may occur over time or to meet the requirements of users that normally perform periodic recalibration, it is possible to recalibrate the module using PL7-PMS version V5 software.

There are two possible adjustment procedures that meet two different requirements:

• A standard recalibration procedure where the value of the offset and gain are adjusted,

• A trim procedure that forces the measurement value.

Typical applications: Equalizing the values obtained from various devices connected to the same sensor (e.g. display unit and regulator system).

B

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B

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5.2-2 Calibration Procedure

Principle

A correction is applied at two points on the scale: at zero (offset adjustment) and at the full scale value (gain adjustment).

Measured

Value at

100%

Actual

Conversion

Line

Ideal Conversion Line

Measured

Value at

0%

0

Voltage

(or Current)

Full Scale

Range

Simply send the module the values read for point 0 and full scale range. The module itself will the perform the corrections required to output values that correspond to the ideal conversion diagram.

Conditions

Recalibrating the module requires a voltage generator for TSX AEM 1601 modules or a current generator for TSX AEM 1602 modules. Its resolution/precision must be at least equal to that of the module, i.e. 4000 points/0.2% (a resolution 10 times higher is recommended).

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Appendix 5

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Accessing the recalibration screen

From the SETUP screen, select [CALIB] to access the screen shown below:

B

This screen lets the user set the zero point and the full scale range for each of the 16 module channels. The adjustment range for both the zero point and the full scale range is restricted to

±

2% of the full scale range.

Note

With TSX AEM 1602 modules, calibration can only be performed on the 0-20 mA range.

Dynamic function keys

[CANCEL]

[MODIFY]

[MEASURE]

[R/S AEM]

[RESET]

Cancels the selection made with the cursor,

Lets the user modify the value selected by the cursor,

Copies the current measurement value to the value field selected by the cursor,

Starts or stops the module (Run or Stop),

Resets the module to its factory settings.

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B

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Calibration procedure

First set the module to Run.

1. Select the channel to calibrate, using the

↑

and

↓

keys,

2. Move the cursor to the MEASUR. AT 0% column,

3. Apply the voltage or current level corresponding to zero (for the 0-10 V range, simply short the two connectors for the channel),

4. Select the MEASURE. key. This copies the CURRENT MEASUR. value to the

MEASUR. AT 0% column,

5. Place the cursor in the MEASUR. AT 100% column,

6. Apply the voltage or current corresponding to 100% of full scale range and let the measurement value stabilize,

7. Select the MEASURE. key. This copies the CURRENT MEASUR. value to the

MEASUR. AT 100% column,

8. Repeat steps 1 to 7 for each of the 16 channels,

9. Press <Enter> to validate all of the values entered (the module is now recalibrated),

10. Reset the module to Run.

Simplified calibration procedure

The previous calibration procedure lets the user calibrate each of the 16 channels separately. This lets the user allow for the entire data acquisition circuit from the sensor to the module.

It is also possible to follow a simplified and faster calibration procedure, where a single channel is calibrated as described above and the newly determined offset and full scale range values are simply copied to the other channels. To follow this procedure:

1. Adjust the zero level for channel 0 and note the current measurement value,

2. Move the cursor to channel 1 and using the [MODIFY] key, enter the previously noted value. Follow the same procedure to set the zero point for channels 2 to 15,

3. Adjust the full scale range (100%) value for channel 0 and not the current measurement value,

4. Move the cursor to channel 1 and using the [MODIFY] key, enter the previously noted value. Follow the same procedure to set the full scale range for channels 2 to 15,

5. Press <Enter> to validate all of the settings,

6. Reset the module to Run.

Note

For the module to accept the new values, it must be stopped. The user will be asked to confirm the new values by pressing <Enter>.

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Appendix 5

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5.2-3 Trim Procedure

Principle

Trim implies deliberately "modifying" the measurement value so that it is the same as that provided by another measurement device taken as a reference.

B

Conversion Line after Trim

Initial Conversion Line

0 100%

For a given point, the user gives the module the required value (that measured by another device). The measurement shift determined in this way is then applied to the entire conversion diagram.

Alignment conditions

Unlike calibration, setting the alignment does not require a generator as a reference.

Simply use a measurement device connected to the same sensor as a reference.

If the square root feature is used normally, it must be disabled.

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B

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Accessing the trim screen

From the SETUP screen, select [TRIM] to access the screen shown below:

This screen lets the user modify the current measurement value for the 16 module channels. The adjustment range is again restricted to

±

2% of full scale range.

Dynamic function keys

[CANCEL]

[MODIFY]

[R/S AEM]

[RESET]

Cancels the selection made with the cursor,

Lets the user modify the value selected by the cursor,

Starts or stops the module (Run or Stop),

Resets the module to its factory settings.

Trim procedure

First set the module to Run.

1. Select the channel to adjust, using the

↑

and

↓

keys,

2. Apply the voltage or current level corresponding to the selected operating point,

3. Select the [MODIFY] key and enter the required value for the selected point,

4. Repeat steps 1 to 3 for each channel to adjust,

5. Press <Enter> to validate all of the values entered.

The module will now Stop after confirmation from the user,

6. Reset the module to Run.

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5 / 1 0

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Analog Function Blocks C

___________________________________________________________________________

Page

PL7-PMS Program OFBs

1.1

Presentation

1.2

Configuring the OFBs

1.3

Programming the OFBs

1/1

1/2

1/3

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Configuration Load OFB: AEMLD

2.1

General

2.2

AEMLD OFB Presentation

2.3

Parameter Description

2.4

Error List

2.5

Using the AEMLD OFB

2.6

Operating Modes - Performance Levels

2.6-1 Operating Modes

2.6-2 Internal Operating Diagram

2.6-3 Performance Levels

2/1

2/1

2/2

2/4

2/4

2/5

2/5

2/6

2/7

C

2.7

Example 2/7

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Diagnostic OFB: AEMDG

3.1

General

3.2

AEMDG OFB Presentation

3.3

Parameter Description

3.4

Error List

3.5

Using the AEMDG OFB

3.6

Operating Modes - Performance Levels

3.6-1 Operating Modes

3.6-2 Performance Levels

3/1

3/1

3/2

3/3

3/4

3/6

3/6

3/6

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C / 1

PL7-PMS Program OFBs 1

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1.1

Presentation

The Optional Function Blocks (OFBs) supplied with PL7-PMS software are split into two families:

• The PMS family comprizing:

- AEMLD and AEMDG analog OFBs (described in this Divider, Sections 2 and 3).

They are used to load the TSX AEM module configuration (AEMLD) or provide module diagnostics (AEMDG),

- SCL and ISCL scaling OFBs (described in Divider D, Sections 3 and 4),

- The PID process control OFB (described in Divider D, Section 2),

- The SAVE OFB (described in Divider D, Section 8).

• The PMS2 family comprizing:

- SCLF and ISCLF scaling OFBs (described in Divider D, Sections 6 and 7),

- The PIDF process control OFB (described in Divider D, Section 5).

The OFBs are supplied on a diskette (ref. TXT LF FB PMS V5). Their installation procedure is described with PL7-PMS program installation (Divider A, Section 1).

To use these OFBs in an application, the user must first:

• Ensure that the PMS icon is present at station level. If this is not the case even after program installation, then it was not declared at the station level. Refer to the

PL7-PMS program installation procedure (Divider A, Section 1),

• Declare the type of OFB in the PL7-3 configuration,

• Define the number of OFBs to use,

• Program the OFBs in PL7-3 (except for the SAVE OFB which is implicitly programmed).

C

FTX 507

AEMLD

PL7-3

! IF B0.THEN SET...

( )

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C

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1.2

Configuring the OFBs

Before using an OFB in an application program, the user must first declare the type and number of OFBs in PL7-3 configuration mode.

Declaring the type and number of OFBs

From the CONFIGURATION MODE SELECTION SCREEN, select 4 - OPTIONAL

FUNCTION BLOCKS. The screen will then display a list of OFBs that have already been declared along with the number of OFBs for each type.

If the PMS and PMS2 families of OFBs are not present in the list, select the [NEW OFB] dynamic soft key. A new screen will be displayed that lets the user view the entire list of OFBs available on the hard disk. Use the [PREV FAM] and [NEXT FAM] dynamic soft keys to view the various families and the [INS] command to select the types of OFB required by the application.

After validating the new selections, the CONFIGURATION OF OPTIONAL FUNCTION

BLOCKS screen is displayed once again. The [MODIFY] command then allows the user to define, for each type declared, the number of OFBs to use.

For more information, refer to the PL7-3 Operating Modes User's Manual, Divider B,

Sub-section 6.7.

When more than one version of the same OFB is displayed (e.g. AEMLD V46 and

AEMLD V50), choose the most recent (i.e. the one with the highest version number).

Remark

The user must configure one (and only one) SAVE OFB, that will be used by the PID and PIDF function blocks (refer to Divider D, Section 8).

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PL7-PMS Program OFBs 1

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1.3

Programming the OFBs

The OFBs in the PMS and PMS2 families (except for the SAVE OFB), can be programmed in any program module in Ladder Diagram language (using an operation block) or in Literal language. In both cases the syntax used is the same:

EXEC OFBi(In1;...;Inn=>Out1;...;Outm)

OFBi

In

Out

;

=>

OFB type and number,

Input objects,

Output objects,

Separator between input and output parameters,

Separator between parameters.

The OFBs are programmed in PROGRAM mode.

The PL7-3 program supports the [EXEC], [CONTENT] and [PARAM] dynamic soft keys that let the user specify respectively the values of the OFB constants and the I/O parameters. An instruction is entered using the following procedure:

• Press [EXEC],

• Enter the type and number of the OFB, (e.g. AEMLD1),

• Select [CONTENT] to access the internal constants of the OFB:

C

• Initialize each constant, then press <Enter> to validate,

• Select [PARAM] to display the OFB:

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C

• Assign a variable to the OFB input and output parameters,

• Validate the screen, then validate the equation by pressing <Enter>.

It is not always necessary to use (wire) all of the I/O. Some of the parameters corresponding to unused I/O take a default value.

The [IF], [THEN] and [ELSE] dynamic soft keys determine conditional execution of the

OFBs (e.g. after a hot or cold restart):

IF (SY0+SY1) THEN RESET B0

IF NOT B0 THEN EXEC AEMLD1(W12;=>); SET B0

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Configuration Load OFB: AEMLD 2

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2.1

General

The AEMLD OFB lets the user, on request, transfer a configuration from the dedicated

PMS field in the PLC memory to a TSX AEM module:

TSX AEM

Module

Dedicated

PMS

Field

Directory

Configuration 0 AEM 0

Configuration 1 AEM 0

Configuration j AEM n

AEMLD

C

Once the configuration has been downloaded, the OFB sets the module to Run.

Note

There are three versions of the AEMLD OFB (V4.5, V4.6 and V5.0). Only V5.0 is compatible with

TSX AEM 1613 modules.

__________________________________________________________________________________________

2.2

AEMLD OFB Presentation

__________________________________________________________________________________________

The AEMLD OFB has two input parameters, an internal constant (defined during the programming phase) and internal data (used during program execution). It does not have any outputs.

AEMLD

Inputs AEM : word

APPLI : word

Internal data

READY

ERROR

STATUS

LOAD

: bit

: bit

: word

: word

Internal constants

INIT_AEM : word

Internal data can be accessed by the program via its symbol or variable. E.g. AEMLD1,

STATUS.

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C

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2.3

Parameter Description

Input parameters

AEM

Type

Word

Access

(2)

Description

Contains the logical number of the TSX AEM module to which the OFB is assigned. On cold restart or reconfiguration of the PLC, it is automatically reinitialized with the contents of the I_AEM internal

APPLI Word (2) Specifies the number of the application to transfer. It is initialized by default to 10. It must be assigned an immediate value or a word type PL7-3 variable that contains the number of the application to transfer. If this parameter is not initialized, the default value (10) means that the OFB cannot be used as it corresponds to an application number that is outside of the range allowed (0 to 8).

Internal data

READY

ERROR

STATUS

LOAD

Type

Bit

Bit

Word

Bit

Access

(1)

Description

Set to 0 during the transfer, this bit changes to 1 once

(1)

(1)

This bit changes to 1 if the transfer is unsuccessful.

This word identifies the cause of an unsuccessful transfer by setting the corresponding bit to 1 (refer to

(2) When this bit is set to 1, it starts the transfer of the configuration whose number is specified in APPLI to the corresponding TSX AEM module.

Its effect is equivalent to executing the OFB via the

EXEC command. It is used to force a configuration from an adjustment terminal.

It has no effect when a TSX AEM 821 module is used in SYNCHRO mode.

(1) Read by program and by adjust (Debug mode etc.),

(2) Read by program and by adjust (Debug mode etc.),

Written by adjust (Debug mode etc.),

(3) Read by adjust (Debug mode etc.),

Written in Program mode by selecting [CONTENT].

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Configuration Load OFB: AEMLD 2

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Internal constants

I_AEM

Type word

Access

(3)

Description

This word specifies the number of the AEM module to which the OFB is assigned. Its value is between 0 and 63 (its default value is 64 so that the OFB is not assigned to an AEM module).

Summary of OFB status depending on the status of ERROR and READY bits

1

1

0

0

READY OFB Status

1

0

0

1

Transfer in progress

Transfer correctly completed

Transfer unsuccessful (the cause is found in the STATUS word)

Status normally impossible

C

(1), (2) and (3) refer to Sub-Section 2.3.

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C

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2.4

Error List

STATUS internal data

Bit 0 = 1 : TSX AEM module failure

Bit 1 = 1 : Transfer not possible (STOP command refused)

Bit 2 = 1 : IT task not configured or synchronization period different

Bit 3 = 1 : Do not transfer a conf. with synchro (AEM 821) in adjust mode

Bit 4 : Not significant

Bit 5 = 1 : Module missing

Bit 6 = 1 : AEM parameter missing from directory

Bit 7 = 1 : AEM modules directory not defined or incoherent

Bit 8 = 1 : Module type and I/O configuration incompatible

Bit 9 = 1 : Application APPLI missing from directory or incoherent

Bit 10 = 1 : Application refused by module

Bit 11 : Not significant

Bit 12 = 1 : Transfer cancelled by power break or software error

Bit 13 = 1 : OFB version incompatible with directory

Bit 14 = 1 : Communication error (exchange impossible with module)

Bit 15 = 1 : System error (inadequate software PLC version, ...)

Note

Bits 2 and 3 only apply to TSX AEM 821 modules used in Synchro mode.

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2.5

Using the AEMLD OFB

The AEMLD OFB must be called-up after a cold or a hot restart or a module replacement.

It can also be called-up on request and operates like a standard PL7-3 function block:

! IF (SY0 + SY1) THEN RESET B1

! IF NOT B1 + IWxy,i,D THEN EXEC AEMLD0(...==>); SET B1 (with i

= 1 for TSX AEM 4xx modules and i = 2 for TSX AEM 8xx modules)

Simply test the internal data READY (bit AEMLD0,READY) to determine if the load procedure is complete. Configuration loading can also be run from Sysdiag by setting the LOAD internal data to 1.

Important:

The OFB must be called-up in the task in which the module is configured.

For TSX AEM 821 modules used in Synchro mode, it is necessary to have one OFB per module. In addition, the transfer is refused if the request is from an adjustment tool (LOAD bit).

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Configuration Load OFB: AEMLD 2

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2.6

Operating Modes - Performance Levels

2.6-1 Operating Modes

The management of module operating modes is fully user transparent. When a transfer request is made, the OFB checks that:

• The PMS function is defined for the station,

• The directory is valid (module logical number and application number),

• The module is present and ready to run (module operating correctly and self-test procedure complete).

Once these checks are performed, the OFB will:

• Stop the module,

• Send the configuration and the threshold table to the module,

• Define inhibited channels,

• Send a RUN command to the module without checking that the command is accepted.

C

Reaction to a power break/return

If a transfer was in progress when the power break occurred, the OFB will switch to the following state:

• Bit AEMLDi,ERROR = 1,

• Bit 12 of status variable = 1.

Reaction to a cold restart

The parameters are reinitialized with the default values. The contents of I_AEM (internal constant) is transferred to the TSX AEM module (input parameter).

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C

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2.6-2 Internal Operating Diagram

Start

Preliminary checks

Stop the module (STOP)

Transfer the configuration

Start the module (RUN)

Transfer the configuration table

Transfer the threshold table (1)

Acknowledge unused channels (2)

Transfer the application name

End

(1) The mechanism used depends on the type of module selected:

• Register interface (OWxy,3 to 6) for TSX AEM 4.. modules,

• Message interface (requests 2 and 4) for TSX AEM 8.. modules.

(2) Via register OWxy,1 that defines the:

• Channels used by the TSX AEM 4.. modules,

• Channels inhibited for TSX AEM 8.. modules.

For further details on register interfaces, refer to the specific User's Manual for the modules.

To load a configuration, first stop the TSX AEM module. Any data present on its inputs will not be accepted while loading is in progress.

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Configuration Load OFB: AEMLD 2

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2.6-3 Performance Levels

Loading a configuration from TSX (PLC) memory to the TSX AEM module memory requires at least 7 master task cycles.

AEMLD OFB memory occupation

2504 words regardless of the number of uses

AEMLD OFB execution time (per cycle)

Data field

264 words per use

3 ms

TSX 87-40

1.2 ms

Constants field

8 words per use

TSX 107-40

0.9 ms

C

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2.7

Example

In a configuration comprising two TSX AEM modules.

Module 0 (slot 5) always executes the same application while module 1 (slot 6) can execute two different applications (the applications in fact only differ in the values used in the threshold tables).

PMX memory

Model 40

Processor

TSX AEM 413

TSX AEM 811

Conf 0

Dedicated

PMS field

Conf 0

Conf 1

Directory

AEM 0

AEM 1

AEM 1

Module 0

Module 1

The TSX AEM modules are declared in task AUX0.

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The programming described below corresponds to the following processing:

• On a cold or a hot restart, transfer configuration 0 from TSX memory to the AEM memory of the two modules,

• On receipt of an operator command, transfer configuration 1 to module 1.

Each module is assigned an AEMLD OFB (AEMLD0 to module 0 and AEMLD1 to module 1).

C

Programming

Bit B0 is used to detect a cold restart (a cold restart resets all bits to 0).

MAST task

! IF SY1 THEN RESET B0

< SET TASK AUX0

! IF NOT CTRL4,R THEN START CTRL4

AUX0 task

! IF NOT B0 THEN EXEC AEMLD0(;0=>);

EXEC AEMLD1(;0=>);

SET B0

! IF RE(I1,0) THEN EXEC AEMLD1(;1=>)

Possible variation for module 1:

! IF NOT B0 THEN 0

→

W60; JUMP L10

! IF RE(I1,0)THEN 1

→

W60

ELSE JUMP L20

! L10 : EXEC AEMLD1(;W60=>)

! L20 : Program continues

Possible variation for automatic loading when a module is changed:

! IF NOT B0 + IW5,1,D THEN EXEC AEMLD0(;0=>)

! IF NOT B0 + IW6,2,D THEN EXEC AEMLD1(;0=>)

! SET B0

! IF RE(I1,0) THEN EXEC AEMLD1(;1=>)

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2 / 8

Configuration Load OFB: AEMLD 2

__________________________________________________________________________________________

In this program the AEM input parameter is initialized, on cold restart, with the value of the I_AEM internal constant. This supposes that the I_AEM internal constant was first initialized with the number of the module to which the OFB is assigned.

If this possibility is not required, specify the module number as an input parameter. The program will read:

EXEC AEMLD0(0;0=>);

EXEC AEMLD1(1;0=>);

Application number,

Module number.

! IF RE(I1,0) THEN EXEC AEMLD1(1;1=>)

It is possible to use a single OFB for the two modules EXCEPT IF ONE OF THEM IS A

TSX AEM 821 MODULE USED IN SYNCHRO MODE.

The configuration must then be designed to transfer the application first to module 0 then to module 1:

! IF NOT B0 THEN EXEC AEMLD0(0;0=>);

SET B0; SET B2

! IF B2.AEMLD0,READY THEN EXEC AEMLD0(1;0=>);

RESET B2

This gives the following results in Grafcet:

C

Activation

! EXEC AEMLD0(0;0=>)

AEMLD0, READY

Activation

! EXEC AEMLD0(1;0=>)

AEMLD0, READY

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C

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2 / 1 0

Diagnostic OFB: AEMDG 3

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3.1

General

The AEMDG OFB combines the error data from a TSX AEM module:

• Module related errors found when running the self-tests:

• Module absent or failed,

• Different module or I/O codes,

• Terminal block error.

• Application errors related to each channel:

• Upper or lower limits exceeded,

• Sensor failure or connection breakage,

• Synchronization failure when a TSX AEM 821 module is used.

The AEMDG OFB is primarily intended for use with diagnostic applications (e.g.

APPLIDIAG, DIAG, etc.).

For more information on these programs, refer to the corresponding documentation.

TSX AEM

AEMDG OFB MMX

DIAGNOSTICS or FTX 507

Error

C

Status

Note

There are three versions of the AEMDG OFB (V4.5, V4.6 and V5.0). Only V5.0 is compatible with

TSX AEM 1613 modules.

__________________________________________________________________________________________

3.2

AEMDG OFB Presentation

__________________________________________________________________________________________

The AEMDG OFB has two input parameters, an output parameter and an internal constant (defined during the programming phase) and internal data (used during execution).

AEMDG

Inputs INIT : bit ERROR : bit Output

AEM : word

Internal data

INHIB : bit

STATUS0 : word

STATUS1

STATUS2

: word

: word

Internal constant

I_AEM : word

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3 / 1

C

__________________________________________________________________________________________

3.3

Parameter Description

Inputs

INIT

Type

Bit

Access

(2)

Description

When set to 1, this bit reinitializes the OFB. The

ERROR output and the STATUS variables are set to

AEM Word (2) It comprises the logical number of the TSX AEM module to which the OFB is assigned.

On PLC cold restart or reconfiguration, it is automatically initialized with the contents of the I_AEM internal constant.

Internal data

INHIB

Type

Bit

Access

(4)

Description

When this bit is at 1 module status monitoring is inhibited, the ERROR output and the STATUS vari-

(1)

(1)

This word comprises errors assigned to the module.

These words comprise the application errors assigned to each channel.

STATUS1

STATUS2

Output

Word

Word

ERROR

Type

Bit

Internal constants

I_AEM

Type

Word

Access

(1)

Description

This bit changes to 1 when an error occurs.

Access

(3)

Description

This word specifies the TSX AEM module to which the OFB is assigned. It takes a value between 0 and

63 (its default value is 64 so that the OFB is not assigned to an AEM module).

(1) Read by program and adjustment (Debug mode),

(2) Read by program and adjustment (Debug mode),

Written by adjustment (Debug mode),

(3) Read by adjustment (Debug mode),

Written in program mode by the [CONTENT] key,

(4) Read by program and adjustment (Debug mode),

Written by program and adjustment (Debug mode).

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Diagnostic OFB: AEMDG 3

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3.4

Error List

STATUS0 Internal Data

Bit 0 = 1 : TSX AEM module faulty or failure

Bit 1 = 1 : Terminal block fault

Bit 2 = 1 : Synchronization fault (AEM 821 synchronous mode)

Bit 3 = 1 : Channel Overrun (AEM 821 synchronous mode)

Bit 4

to Not significant

Bit 10

Bit 11 = 1 : Module type and I/O configuration incompatible

Bit 12 = 1 : AEM module missing

Bit 13 = 1 : Directory access error (does not exist, incoherent, etc.)

Bit 14 = 1 : Communication error (exchange with the module not possible)

Bit 15 = 1 : System error (inadequate software PLC version, etc.)

C

STATUS1 Internal Data

Bit 0 = 1 : Lower limit exceeded on channel 0

Bit 1 = 1 : Higher limit exceeded on channel 0

Bit 2 = 1 : Sensor break on channel 0

Bit 3 Not significant

Bit 4 = 1 : Lower limit exceeded on channel 1

Bit 5 = 1 : Higher limit exceeded on channel 1

Bit 6 = 1 : Sensor break on channel 1

Bit 7 Not significant

Bit 8 = 1 : Lower limit exceeded on channel 2

Bit 9 = 1 : Higher limit exceeded on channel 2

Bit 10 = 1 : Sensor break on channel 2

Bit 11 Not significant

Bit 12 = 1 : Lower limit exceeded on channel 3

Bit 13 = 1 : Higher limit exceeded on channel 3

Bit 14 = 1 : Sensor break on channel 3

Bit 15 Not significant

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3 / 3

C

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STATUS2/STATUS3/STATUS4 Internal Data

Bit 0

Bit 1

Bit 2

=

=

=

1

1

1

: Lower limit exceeded on channel

: Higher limit exceeded on channel

: Sensor break on channel

Bit 3 Not significant

Bit 4 = 1 : Lower limit exceeded on channel

Bit 5 = 1 : Higher limit exceeded on channel

Bit 6 = 1 : Sensor break on channel

Bit 7 Not significant

Bit 8 = 1 : Lower limit exceeded on channel

Bit 9 = 1 : Higher limit exceeded on channel

Bit 10 = 1 : Sensor break on channel

Bit 11 Not significant

Bit 12 = 1 : Lower limit exceeded on channel

Bit 13 = 1 : Higher limit exceeded on channel

Bit 14 = 1 : Sensor break on channel

Bit 15 Not significant

2

4

4

4

STATUS

3

8

8

8

4

12

12

12

5

5

5

6

6

6

7

7

7

9

9

9

10

10

10

11

11

11

13

13

13

14

14

14

15

15

15

3.5

Using the AEMDG OFB

__________________________________________________________________________________________

Executing the OFB

The AEMDG OFB must be called for execution only once after PLC cold restart or reconfiguration.

The module monitoring function is automatically run cyclically. It is up to the user to ensure that the instruction that calls for execution of the OFB is only found once by the

PLC program. Therefore this instruction should be conditional on an event that will only be true for a single PLC cycle.

Executing the AEMDG OFB

Once the OFB is called-up, it runs continually in the PLC monitoring task. To stop (inhibit) this execution, set the AEMDGi INHIB input bit to 1 by program or by adjustment.

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3 / 4

Diagnostic OFB: AEMDG 3

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Programming

Given the internal operation of the OFB (1), is not necessary to assign a PL7-3 variable to the ERROR output as it can be read directly by the AEMDGi ERROR variable.

For the OFB to run after a cold or hot PLC restart.

! IF SY1 THEN RESET B0

! IF NOT B0 THEN EXEC AEMDGi(;W0=>); SET B0

With

B0 = Cold or hot restart detection bit (set to 0 on a cold restart),

W0 = TSX AEM module number,

Fault acknowledgment

All of the errors that occur on the module are stored. The AEMDGi,INIT input must be set to 1 to acknowledge the errors indicated by STATUS0, STATUS1 and

STATUS2 and then the OFB must be reinitialized. When an error is found, the OFB continues to monitor the module and indicate error information.

If the AEMDG OFB is used together with diagnostics programs (APPLIDIAG, SYSDIAG, etc.), the AEMDG,INIT input is directly controlled by these programs. However to acknowledge errors from the PLC application, and allowing for how the OFBs operate, as described in (1), the AEMDG OFB must be executed with the INIT input set to 1:

!

IF B1 THEN AEMDGi(B1;W0=>); RESET B1 with B1 = error acknowledgment command,

W0 = AEM number.

!

!

If this program line is combined with the one affecting OFB execution on power return

(or on a cold restart), the result is:

IF SY1 THEN RESET B0; RESET B1

IF NOT B0+B1

THEN EXEC AEMDGi(B1;W0=>); RESET B1

C

(1) The output parameters are only transferred to the assigned PL7-3 variables when the EXEC

AEMDG instruction is scanned.

When the AEMDG OFB is used, a PL7-3 variable assigned to the ERROR output is only refreshed once.

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C

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3.6

Operating Modes - Performance Levels

3.6-1 Operating Modes

When the OFB is called-up for execution, it checks that:

• The PMS function is defined for the station,

• The directory exists and is valid (module logical number),

• The module is present and operational (module OK and self-tests complete),

• The type of module is the same as that defined in the directory.

The AEMDG OFB then reads the register interface to detect application errors.

__________________________________________________________________________________________

3.6-2 Performance Levels

The modules are monitored approx. every 200 ms. This time may rise to a second if the

PLC processor load is considerable.

Execution and response times

The system response time depends on the PL7 application. It varies from 1 to 5 master task cycles.

AEMDG OFB memory occupation

1752 words

regardless how often it is used

Data field

136 words each usage

AEMDG OFB execution time (per cycle)

2.5 ms

TSX 87-40

1 ms

Constants field

8 words each usage

TSX 107-40

0.8 ms

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3 / 6

________________________________________________________

Process Control Function Blocks D

___________________________________________________________________________

Page

Process Control OFBs - General

1.1

Presentation

1.2

Process Control Loops

1.3

Floating Point Parameters

1/1

1/2

1/4

__________________________________________________________________________________________________

PID OFB

2.1

PID OFB Presentation

2.1-1 General

2.1-2 Features

2.1-3 PID OFB Description

2.1-4 Reaction to a PLC Power Return

2.1-5 Accessing Variables

2.1-6 Performance Levels

2.2

Setting-up the PID OFB

2.2-1 General

2.2-2 Measurement Acquisition

2.2-3 PID OFB Programming

2.2-4 Updating Outputs

2.2-5 Debug - Adjust

2.2-6 Suggestions for Use

2/26

2/26

2/27

2/29

2/31

2/33

2/34

2/1

2/1

2/2

2/12

2/22

2/24

2/25

__________________________________________________________________________________________________

SCL OFB

3.1

General

3.2

SCL OFB Presentation

3.3

Parameter Description

3.4

Status Word

3.5

Performance Levels

3.6

Using the SCL OFB

3/1

3/1

3/2

3/4

3/4

3/5

__________________________________________________________________________________________________

ISCL OFB

4.1

General

4.2

ISCL OFB Presentation

4.3

Parameter Description

4.4

Status Word

4.5

Performance Levels

4.6

Using the ISCL OFB

4/1

4/1

4/2

4/4

4/4

4/5

D

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D / 1

________________________________________________________

A

Process Control Function Blocks D

___________________________________________________________________________

D

Page

PIDF OFB

5.1

PIDF OFB Presentation

5.2

5.1-1 General

5.1-2 Features

5.1-3 PIDF OFB Functional Description

5.1-4 Process Variable

5.1-5 Set Point

5.1-6 PID Action

5.1-7 Feed-forward Compensation

5.1-8 Command Processing

5.1-9 Width Modulated Output

5.1-10 Selecting Corrector Operating Mode

and Control Signal Processing

5.1-11 Cascade Set-up with two Correctors

5.1-12 Man-Machine Interface Related Parameters

5.1-13 Parameters Linked to OFB Execution

5.1-14 Error Processing

5.1-15 OFB Reports

5.1-16 Reaction to a PLC Power Return

5.1-17 Accessing Variables

5.1-18 Performance Levels

Setting-up the PIDF OFB

5.2-1 General

5.2-2 Measurement Acquisition

5.2-3 PIDF OFB Programming

5.2-4 Updating Outputs

5.2-5 Debug - Adjust

5.2-6 Suggestions for Use

__________________________________________________________________________________________________

SCLF OFB

6.1

General

6.2

SCLF OFB Presentation

6.3

Parameter Description

6.4

Status Word

6.5

Performance Levels

6.6

Example of Use

6/1

6/2

6/2

6/4

6/4

6/5

5/26

5/26

5/27

5/31

5/34

5/36

5/37

5/17

5/18

5/19

5/20

5/21

5/23

5/24

5/25

5/1

5/1

5/2

5/3

5/4

5/6

5/8

5/10

5/13

5/14

5/15

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D / 2

________________________________________________________

Process Control Function Blocks D

___________________________________________________________________________

Page

ISCLF OFB

7.1

General

7.2

ISCLF OFB Presentation

7.3

Parameter Description

7.4

Status Word

7.5

Performance Levels

7.6

Example of Use

7/1

7/1

7/2

7/4

7/4

7/5

__________________________________________________________________________________________________

SAVE OFB

8.1

General 8/1

__________________________________________________________________________________________________

Appendix

9.1

PID Parameter Set-up Method

9.2

PID Parameter Influence and Effects

9.3

PID Process Control Limits

9/1

9/4

9/7

D

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D / 3

________________________________________________________

A

Process Control Function Blocks D

___________________________________________________________________________

D

___________________________________________________________________________

D / 4

Process Control OFBs - General 1

__________________________________________________________________________________________

1.1

Presentation

This divider described process control OFBs and also the OFBs used to support process control OFBs:

• Scaling OFBs, required to scale the input to, and output from, the PID corrector,

• The SAVE OFB which combines the saving of all parameters for all process control

OFBs used by the application.

These OFBs are part of two separate families: the PMS family that also comprises analog OFBs (described in Divider C) and the PMS2 family.

PMS

OFB

PID

SCL

PMS2

ISCL

SAVE

PIDF

SCLF

ISCLF

Function

PID corrector. The digital values handled by this OFB are

Converts an integer value into a floating point value (in the new scale). The floating point variable output from this OFB can only be used by a Man-Machine Interface

Performs the opposite function to the SCL OFB, i.e. it converts a floating point value from the Man-Machine

Saves all of the parameters of the process control OFBs

PID corrector. The digital values handled by this OFB are

Scales an integer value into a floating point value that can

Performs the opposite function to the SCLF OFB, i.e. it scales a floating point value from the PIDF OFB into an integer value (refer to Section 7).

D

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1 / 1

D

__________________________________________________________________________________________

1.2

Process Control Loops

Process control loop based on a PID OFB (using a PMX V4 or PMX V5 PLC)

Wi

SCL OFB

TSX AEM

I

F

MMX

Man-Machine

Interface

▲

F

▼

F

Values converted to floating point by OFB

(*)

PID OFB

I

ISCL OFB

TSX AST/ASR

Wj

(*) values that cannot be accessed by PL7-3, SYSDIAG, etc.

The SCL and ISCL OFBs do not affect the process control system and their presence is not required. They enable the display or entry in floating point mode of an integer value from a Man-Machine Interface terminal.

F Floating point format values

I Integer format values

1 / 2

Process Control OFBs - General 1

__________________________________________________________________________________________

Process control loop based on a PIDF OFB (only for use with PMX V5 PLCs)

TSX AEM

I

DWi

F

MMX

Man-Machine

Interface

▲

F

DWj

F

SCLF OFB

F

▼

PIDF OFB

F

ISCLF OFB

TSX AST/ASR

I

The SCLF and ISCLF OFBs are an integral part of the process control system. Their use is required.

D

F Floating point format values

I Integer format values

1 / 3

D

__________________________________________________________________________________________

1.3

Floating Point Parameters

General

The IEEE format used in PMX PLCs enables numbers to be displayed over the range

[10 -38 ; 10 38 ], positive or negative. The functions and tools available in the X-TEL Software

Workshop (PL7-3, SYSDIAG, etc.) can be used to display these numbers:

• In decimal notation, if their absolute value is within the range [0,0001; 1000 000]. For example: -0.025 or 97572.5,

• In mantissa/exponent format otherwise. For example: 1.57 E-8 or

-2.8 E12.

PIDF, SCLF and ISCLF OFBs

These OFBs handle data that is only valid within the range [0,0001; 1000 000], corresponding to the decimal display range.

If one of the parameters is not within this range, it is automatically limited to the nearest limit. Only the intermediate calculation variables (not displayed for the user) and certain parameters initialized with "unrealistic" values can take values that are outside of this range. For example, the PIDFi,RSP parameter is initialized with 10 30 . This is done by the

OFB to determine whether the parameter is used or not.

• Flloating point parameter display range

- 1 000 000 -0.0001

0 +0.0001

+1 000 000

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1 / 4

PID OFB 2

__________________________________________________________________________________________

2.1

PID OFB Presentation

2.1-1 General

The PID OFB supports PID process control loops on PMX Series 7 Model 40 PLCs. It cannot be used with TSX Series 7 PLCs. There is no limit to the number of process control loops that can be run by a single PLC, but for best performance the following numbers should not be exceeded:

Type of processor

V4 level

PMX 47-40

PMX 67-40

PMX 87-40

PMX 107-40

Type of processor

V5 level

PMX 47-40

PMX 67-40

PMX 87-40/107 40

Number of loops

16

16

32

48

Like the other OFBs, the PID OFB is an extension of the PL7-3 programming language.

It works from a measurement supplied by a TSX AEM analog input module that is used as the process variable and generates an output that can be:

• Analog, applied to the process by a TSX AST or TSX ASR output module,

• Duration modulated, sent to the process by a discrete output module such as a

TSX DST.

TSX AST/ASR

D

TSX AEM

OFB - PID

PV

SP

-

+

P. I. D.

ANA

PWM

TSX DST

The PID OFB works from variables (process variable, set point, deviation, output), expressed in 0 - 10000 format.

Some variables used for Man-Machine Interface purposes are converted into floating point notation in a user transparent manner.

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2 / 1

D

__________________________________________________________________________________________

2.1-2 Features

The PID OFB includes most of the features normally supported by conventional PID process control loops. It corresponds to a mixed layout corrector comprising the following functions:

• Digital filter on process variable (measurement input),

• Derivative action applied to the process variable or deviation,

• Direct or reverse action,

• Output range 0-4000 or 0-10000,

• High and low alarms on the process variable with hysteresis,

• High and low alarms on the deviation with hysteresis,

• High and low limitation of the set point,

• High and low limitation of the output signal,

• Anti-reset windup,

• Selection of manual and automatic modes with smooth changeover,

• Selection of local and remote set points,

• Selection of internal and external process variables (for debugging),

• Limitation of output rate of change,

• Output bias (used mainly for feed-forward applications),

• Deadband,

• Continuous or pulse width modulated output,

• Conversion of PID analog variables into physical units that can be used for Man-

Machine Interface purposes.

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2 / 2

OUTPUT

BIAS

(or feed-forward input)

EXTERNAL

SETPOINT

INTERNAL

SP

Limiter

Filter

INS

–

+

DEV.

Alarm

PROCESS

VARIABLE

SIMULATED

PV

MANUAL

OUTPUT

P. I. D.

+

+

H/L

Limit

Rate of Ch.

Limit

Deadband

Direct

Reverse

Derivative

Action

MAN

AUTO

0-4000

Change of

Range

0-10000

Discrete I/O

Analog

Output

__________________________________________________________________________________________

Detailed description of the PID corrector

D

Anti-reset

Windup

Set Point

-

+

Dev.

e

∫

+

+

+

X

Output

Bias

Limits

H/L

+

+ u

PV d dt

PV

A mixed structure corrector is used. Its transfer function, in the case of a derivation of the error is:

1 e (p)

= KP 1 +

TI x p

TD x p

+

1 + TD/KD x p with KP : Proportional gain

TI : Integral time

TD : Derivative time

The expression 1 + (TD/KD) x p gives a "spread" of the derived action. The value of KD

(maximum gain on the derived action) is set to 10.

Digital Process Variable Filter

A low pass type filter is used. Its equation is:

EFn =

α

*EFn-1 + (1-

α

)*EBn

• EFn is the filtered input value at time n,

•

α

is the filtering constant (

α

= T_FILT/T_FILT + T),

- T_FILT is the filtering constant,

- T is the sampling period,

• EBn is the raw input value at time n.

This function is inhibited for T_FILT = 0 (default value).

Process Variable or Deviation Derivative Action

The derivative action can apply to the process variable or to the deviation.

The type of derivative action is selected by bit PV_DEV:

PV_DEV = 0: Derivative action on the process variable (default value),

PV_DEV = 1: Derivative action on the deviation.

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PID OFB 2

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Direct or Reverse Action

Reminders:

Direct action:

An increase in the process variable causes a corresponding increase in the output signal

(Figure 1).

Reverse action:

An increase in the process variable causes a corresponding decrease in the output signal (Figure 2).

10000

Output gain = 2 gain = 1

10000

Output gain = 0.5

gain = 0.5

gain = 1 D gain = 2

Dev.

Fig 1

Direct Action

Fig 2

Reverse Action

The choice of the type of action to use is made via the DIR_REV bit:

DIR_REV = 0: Direct action,

DIR_REV = 1: Reverse action (default value).

Dev.

Analog Output Range

To make it easier to use devices with 4000 point resolution (e.g. TSX ASR 200 analog output module), the OFB has a parameter that lets it provide an output value in 0 - 4000 range format.

The OUTRANGE bit is used to select the output range:

OUTRANGE = 0: Analog output in 0 - 4000 range (default value),

OUTRANGE = 1: Analog output in 0 - 10000 range.

The analog output value is expressed by default in the 0 - 4000 range. The output range selected must be coherent with that selected at output module level.

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Process Variable High and Low Alarms

The process variable used is continually compared with two thresholds:

• High threshold: PV_HL,

• Low threshold: PV_LL.

The thresholds are programmable digital values expressed in the same format as the process variable (0 - 10000). By default these values are 0 for the low threshold and

10000 for the high threshold.

If the process variable used is external to the valid interval defined by the thresholds, an alarm bit is set to 1 in status word STATUS0 and the output bit ERROR is set to 1 (refer to Divider D, Sub-section 2.1-3).

• Hysteresis

The comparison for each threshold is performed with a hysteresis factor (h) of 0.5% of the full scale range (i.e. 50).

D

Deviation High and Low Alarms

In the same way as for the process variable value, two thresholds are defined to monitor the deviation between the actual process variable and the preset set point (DEV_HL and

DEV_LL).

These thresholds are programmable digital values that are expressed in the same format as the deviation (-10000 +10000). By default these values are set to -10000 for the low threshold and +10000 for the high threshold.

If the deviation exceeds the limits defined by the high and low thresholds, an alarm bit is set to 1 in status word STATUS0 and the output bit ERROR is set to 1 (refer to Divider

D, Sub-section 2.1-3).

The comparison is performed with a hysteresis factor (h) of 0.5% of the full scale range, i.e. 100 for a range of 20000.

Hysteresis

Threshold High

Hysteresis

Threshold Low

Alarm High

Alarm Low

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PID OFB 2

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Set Point High and Low Limitation

Variations in the set point are restricted to two limit values (SP_MAX and SP_MIN).

These limits are user programmable digital values expressed in 0 - 10000 format.

Their default values are:

• 0 for the lower limit,

• 10000 for the higher limit.

Processing of these limitation values is performed with the set point used in the algorithm, i.e. based on the internal or external set point.

The set point used is compared with the high and low limitation values. If a limitation is exceeded, the set point takes the limitation value. If this occurs, an alarm bit is reset to

1 in status word STATUS0 (refer to Divider D, Sub-Section 2.1-3).

Output Signal High and Low Limitation

The output signal from the algorithm is restricted to the limitation values (OUT_MAX and

OUT_MIN).

These limitations are user programmable digital values that are expressed in 0 - 10000 format.

Their default settings are:

• 0 for the low limit,

• 10000 for the high limit.

Processing of these limitation values is performed with the output value calculated by the algorithm, before output rate of change limitation, deadband, direct/reverse and format actions.

The calculated output signal value used is compared with the high and low limitation values. If a limitation is exceeded, the set point takes the limitation value. If this occurs, an alarm bit is reset to 1 in status word STATUS0 (refer to Divider D, Sub-Section 2.1-3).

D

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Anti-Reset Windup

The PID OFB is equipped with an anti-reset windup mechanism that effects the integral action and restricts variations after a major change to the set point (or start-up using a low process variable).

D

Smooth Manual/Automatic Mode Transition

• Automatic mode to Manual mode

On transition from automatic to manual mode, the manual output value is automatically aligned with the calculated output value to avoid a sudden change.

• Manual mode to Automatic mode

On transition from manual to automatic mode, there are various options that may cause a smooth or a rough transition:

Tracking

NO

No integral

Smooth

Rough

Integral action Ti

≠

0

Smooth

Smooth (1)

(1) The integral term is recalculated to ensure a smooth transition.

Selecting a Local or Remote Set Point

Selection of the local/remote set point is performed by a bit that lets the algorithm operate with:

• A local set point that can be modified by the user via a programming terminal,

• A remote set point supplied by the PL7-3 application.

This approach means that the set point can follow a rate of change and support cascaded loops.

The SP_RSP bit is used to select local or remote set points:

SP_RSP = 0: Local set point (default value),

SP_RSP = 1: Remote set point.

Note

If the Remote Set Point input (RSP) is not used, the program forces selection of the internal Set

Point SP_RSP = 0.

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PID OFB 2

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Selecting an Internal or External Process Variable

To simplify debugging of a control loop application, a simulated process variable can be used by the control algorithm in place of the correct process variable.

This internal process variable (PV_SIMUL) lets the system run with an open loop and therefore test the algorithm directly by analyzing the output obtained as a function of the required input. This function is especially useful during the debug and adjust phases of a PL7 application.

An internal or external process variable value is selected by bit 0 of the Command word:

Bit 0 = 0: Simulated process variable,

Bit 0 = 1: Process variable (default value).

Output Rate of Change Limitation

The variation of the output between two sample cycles can be restricted to the value:

Sn - Sn-1

≤

OUTRATE

The OUTRATE variable comprises a user programmable digital value that is expressed in 0 - 10000 format.

Its default value is 10000, disabling the limiting action.

This operation can be inhibited by forcing bit 5 of the Command word to 0.

Deadband

To avoid premature wear on the actuators, the algorithm includes a deadband (DBAND) on the output.

If the difference between the calculated output and the last applied output is less than the deadband value, the output remains unchanged.

The deadband is expressed in 0 - 10000 format.

Its default value is 0 so that it is disabled.

D

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Output Bias

In pure proportional control applications (without integral action), there remains a degree of error between process variable and set points.

To compensate for this error, the OFB has the OUTBIAS output variable to shift the output in order to compensate for the error.

This variable can also be used as the feed-forward input to the PID OFB. This only applies to the function described above.

The OUTBIAS variable is a value expressed in 0 - 10000 format.

Its default value is 5000.

D

Width Modulated Output

The algorithm can be used either to control an analog output or a width modulated output.

The modulated output is a direct function of the calculated output and the modulation period as the ratio between modulated output activation time and modulation period corresponds to the percentage of the analog output sent.

Example: Modulation corresponding to an output of 33%.

T-CYCLE

As the modulated output is updated in the OFB, the output activation time must be a multiple of the period of the task that contains the OFB. This restriction sets the modulation resolution: It is the ratio task period/modulation period.

For example, if the maximum acceptable resolution is 5% and if the control loop is running in a 500 ms auxiliary task, the minimum modulation period is 10 seconds (1).

The modulation period (T_CYCLE), is expressed in tenths of a second. The default value is 20 seconds (T_CYCLE = 200).

The modulation is selected by setting the OUT_TYPE bit to 1 (default value = 0).

(1) The OFB includes an adjustment system to process as best possible, values that are not multiples of the task period.

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2 / 1 0

PID OFB 2

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Scaling for Man-Machine Interface Purposes

The PID OFB converts variables expressed in the 0-10000 range into new variables designed for operator display after scaling:

• Process variable (measurement), set point, output,

• High and low thresholds for set point and deviation,

• High and low limits for set point and deviation,

• Deadband, bias and output rate of change slope.

The scaled variables in floating point format cannot be used by PL7-3.

To scale variables with an output format that depends on the measurement format, define the high and low limits of the full scale range in measurement physical units

(internal constants S_PVMAX$ and S_PVMIN$).

Remark

Variables Kp, Ti, Td, Tfilter and Tcycle expressed in units reduced within the algorithm are also scaled so that they can be expressed in the usual way (Kp without units, time parameters in seconds).

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2 / 1 1

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2.1-3 PID OFB Description

Presentation

The PID OFB operates in the same way as all other Optional Function Blocks.

It comprises:

• Two input parameters,

• Four output parameters.

• 25 internal constants (defined during the programming phase),

• 37 internal data including internal data dedicated to the man-machine interface (used during execution).

Inputs

Internal

Data

Internal

Constants

PV

RSP

: Word

: Word

PID

ERROR : Bit

STATUS0 : Word

OUTPUT : Word

PW_OUT : Bit

INHIB : Bit

.........

: …

TRACKING : Bit

PV_DEV : Word

.........

: …

OUTRATE$ : Word

Outputs

Input Parameters

PV

Type

Word

RSP Word

Access

(1)

Description

Process variable. Minimum value: 0, Maximum value:

(1) Remote process control loop set point.

Minimum value: 0, Maximum value: 10000.

(RSP = Remote Set Point).

(1) Read by program and adjustment (data mode, etc.).

(2) Read by program and adjustment (data mode, etc.),

Written by adjustment (data mode, etc.).

(3) Read by program and adjustment (data mode, etc.),

Written by program and adjustment (data mode, etc.).

(4) Fall back value defined by internal constants.

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PID OFB 2

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Output Parameters

ERROR

Type

Bit

Access

(1)

Description

At 1 indicates that a limit or a threshold was exceeded. Reading STATUS0 lets the user determine

STATUS0 Word (1)

OUTPUT Word (1)

OFB operation report. Each bit corresponds to an error and is reset to 0 only when the cause of the error ends. For a detailed description of its contents

Analog output. It can be the result of the algorithm calculation (in Auto mode) or the value of the manual output (in Man mode). Depending on the user selection (OUTRANGE bit), it is expressed in 0 - 4000 or

PW_OUT Bit (1) PID logic output where the "form ratio" is the image of the analog value.

Note

The OUTPUT analog output is always calculated. The OUT_TYPE bit (defined as an internal constant) lets the user set-up the duration modulation output.

D

(1), (2), (3) and (4) refer to the Input Parameters description.

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2 / 1 3

D

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Internal Data - Commands

The tables below list all of the internal variables of PID OFB commands that can be accessed by the user in read or write modes.

On a PLC cold restart, all of these variables are initialized either with their default values or with the fall back values defined by the internal constants.

INHIB

Type

Bit

Access

(3)

Description

Set to 1, this bit inhibits the OFB alarms by forcing the

SP

OUT_MAN

SP_RSP

MAN_AUTO

LIBELLE

UNIT

S_PVMAX

S_PVMIN

KP

TI

TD

Word

Word

Bit

Bit

Bit

Msg

Msg

Word

Word

Word

Word

Word

(2)

(3)

(3)

(3)

(2)

(2)

(2)

(2)

(2)

(3)

(3)

(3)

PID local set point. Minimum value 0, maximum

PID manual output value. Minimum value 0, maxi-

Type of set point used, Local (SP) or Remote (RSP).

PID operating mode, manual (MAN) or automatic

PID corrector action (4).

A string of up to 9 characters for the name of the process control loop controlled by the PID OFB

A string of up to 9 characters for the type of physical unit selected for the variable set by the PID OFB

Higher limit of the measurement full scale range in physical units (dedicated man-machine interface information). Minimum value: -15000, maximum value: +15000.

Important: This parameter is used for the calcula-

Lower limit of the measurement full scale range in physical units (dedicated man-machine interface information). Minimum value: -15000, maximum value: +15000.

Important: This parameter is used for the calcula-

PID corrector gain multiplied by 100. Minimum value:

PID corrector integral time expressed in tenths of a second. Minimum value: 0, maximum value: 20000

PID corrector derived time expressed in tenths of a second.

Minimum value: 0, maximum value: 10000 (4).

2 / 1 4

PID OFB 2

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Internal Data - Commands (continued)

T_FILT

Type

Word

Access

(3)

Description

Digital filter constant time expressed in hundreds of

PV_HL

PV_LL

DEV_HL

DEV_LL

SP_MAX

SP_MIN

OUT_MAX

OUT_MIN

T_OFB

T_CYCLE

DBAND

OUTBIAS

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

(3)

(3)

(3)

(3)

(2)

(3)

(3)

(3)

(3)

(2)

(3)

(3)

Process variable higher threshold. Minimum value:

Process variable lower threshold. Minimum value: 0,

Higher threshold on calculated deviation.

Lower threshold on calculated deviation. Minimum

Higher limit on set point used. Minimum value: 0,

Lower limit on set point used. Minimum value: 0,

Higher limit on output. Minimum value: 0, maximum

Lower limit on output. Minimum value: 0, maximum

PID OFB processing period expressed in tenths of milliseconds. Its true value is always automatically adjusted to remain an integer multiple of the period of the task in which the OFB is executed.

If for example T_OFB declared in 800 ms and the period of task AUX0 is 300 ms, the real T_OFB is

Pulse width modulation period expressed in tenths of a second. Minimum value: 2, maximum value:

Output variation after which the algorithm sends a new action (deadband). If the output variation is less than this value, the action remains unchanged.

Static error compensation in the absence of any integral action or feed-forward input (mutually exclusive). Minimum value: -10000, maximum value:

10000 (4). For pure proportional mode, (Ti = 0) and

OUTRATE Word (3) Output variation limit between two module sampling cycles. Minimum value: 0, maximum value: 10000

(4).

(1), (2), (3) and (4) refer to the Input Parameters description.

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2 / 1 5

D

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Internal Data - Commands (continued)

PV_SIMUL

Type

Word

Access

(2)

Description

PID corrector internal value used when setting up the control loop application. Minimum value: 0, maxi-

FORCE

COMMAND

Bit

Word

(3)

(3)

At 1, this bit forces algorithm execution in the next

Determines the PID operating mode.

Each bit selects a PID function, the image of which is found in the output variables STATUS0 and STATUS1.

The functions that are accessible from this word are process variable selection and activate or inhibit

D

TRACKING Bit (3) At 1, this bit makes the set point track the process variable when manual mode with local set point is selected. Default value: 0.

(1), (2) (3) and (4) refer to the Input Parameters description.

Internal Data - Information

The tables below present all of the PID OFB data internal variables accessible to the user in read. On PLC cold restart, all of these variables are initialized with their default values.

STATUS1

Type

Word

Access

(1)

Description

OFB operation report.

Each bit of this parameter corresponds to a PID state. For a detailed description of its contents, refer

PV_USED

SP_USED

DEV

READY

NUMBER

Word

Word

Word

Bit

Word

(1)

(1)

(1)

(1)

(1)

Process variable value used in the algorithm.

Set point used in the algorithm.

Deviation (process variable - set point).

This bit is linked to the internal counter that handles

PID OFB execution sequencing. It is set to 1 when the counter indicates that the OFB will be executed in the next cycle. This function lets the user link a number of actions to run (affecting the process variable or set point) when the OFB is actually

Contains the number of the PID OFB (dedicated

Man-Machine Interface information).

2 / 1 6

PIDi, OUTBIAS

OUTPUT

BIAS

(or feed-forward input)

PIDi, SP

INTERNAL

SP

PIDi, SP_RSP

Limiter

EXTERNAL

SETPOINT

PIDi, SP_MAX

PIDi, SP_MIN

PIDi, RSP

PIDi, PV

Filter

-

INS

Alarm

PIDi, DEV Alarms

PIDi, DEV_HL

PIDi, DEV_LL

PIDi, SP_USED

DEV.

+

PIDi, PV_USED

PROCESS

VARIABLE

PIDi, T_FILT

PIDi, PV_HL

PIDi, PV_LL

PIDi, PV_DEV

PIDi, COMMAND

Bit 0

PIDi, Kp

PIDi, Ti

PIDi, Td

P. I. D.

Derivative

Action

SIM.

PV

PIDi, PV_SIMUL

+

+

PIDi, OUT_MAX PIDi, DBAND

PIDi, OUTRATE PIDi, DIR_REV

H/L

Limit

Rate of Ch.

Dead-

Limit band

Direct

Reverse

PIDi, OUT_MIN

Change of

Range

PIDi, OUTRANGE

0-4000

0-10000

PIDi, OUTPUT

Analog

Output

PIDi, MAN_AUTO

MAN

AUTO

Discrete Output

PIDi, PW_OUT

MANUAL

OUTPUT

PIDi, OUT_MAN

PIDi, OUT_TYPE

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Internal Constants - Structure Variables

The internal constants comprise all of the PID corrector structure selection variables.

PV_DEV

OUT_TYPE

OUTRANGE

Type

Bit

Bit

Bit

Access

(1)

Description

Type of deviation action, on the process variable or the deviation. Default value = 0 (derived from the

(1)

(1)

Set-up the analog output. Default value = 0 (analog

PID corrector analog output range, 0 - 4000 or

D

DIR_REV$ Bit (1) PID corrector type of action, direct (0 - 10000 format) or reverse (10000 - 0 format). Default value = 1

(reverse action).

Note

Any modification to the PV_DEV, OUT_TYPE and OUTRANGE parameters is immediately accepted while any modification to the DIR_REV$ parameter or to any one of the initialization values described later will only be accepted after a cold restart (bit SY0).

(1), (2), (3) and (4) refer to the Input Parameters description.

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2 / 1 8

PID OFB 2

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Internal Constants - Initialization Values

The internal constants also comprise all of the internal data initialization values (fall back values used after a cold restart).

By convention, the names of the initialization variables are identical to those of the corresponding internal data with a distinctive $ suffix.

LIBELLE$

Type

Msg

Access

(2)

Description

A string of up to 9 characters for the name of the process control loop controlled by the PID OFB

UNIT$ Msg (2)

S_PVMAX$

S_PVMIN$

KP$

TI$

TD$

T_FILT$

PV_HL$

PV_LL$

Word

Word

Word

Word

Word

Word

Word

Word

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

A string of up to 9 characters for the type of physical unit selected for the variable set by the PID OFB

Higher limit of the measurement full scale range in physical units (dedicated man-machine interface information). Minimum value: -15000, Maximum value: +15000.

Important: This parameter is used for the calcula-

Lower limit of the measurement full scale range in physical units (dedicated man-machine interface information). Minimum value: -15000, Maximum value: +15000.

Important: This parameter is used for the calcula-

PID corrector gain multiplied by 100.

Default value: 100 (gain = 1), Minimum value: 1,

PID corrector integral time expressed in tenths of a second.

Default value: 0 (no integral action), Minimum value:

PID corrector derivative time expressed in tenths of a second.

Default value: 0 (no derivative action), Minimum

Digital filter time constant expressed in hundreds of a second.

Default value: 0 (no digital filter),

Process variable high level threshold.

Default value: 10000 (no high level threshold), Mini-

Process variable low level threshold.

Default value: 10000 (no low level threshold),

Minimum value: 0, maximum value: 10000.

2 / 1 9

D

D

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Internal Constants - Initialization Values (continued)

DEV_HL$

Type

Word

Access

(2)

Description

Calculated error high level threshold.

Default value: +10000 (no high level threshold),

DEV_LL$ Word (2)

SP_MAX$

SP_MIN$

OUT_MAX$

OUT_MIN$

T_OFB$

T_CYCLE$

DBAND$

OUTBIAS$

OUTRATE$

Word

Word

Word

Word

Word

Word

Word

Word

Word

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

Calculated error low level threshold.

Default value: -10000 (no low level threshold),

High limit on set point used. Default value: 10000 (no

Low limit on set point used. Default value: 0 (no low limit).

High limit on output. Default value: 10000 (no high limit).

Low limit on output.

Default value: 0 (no low limit). Minimum value: 0,

PID OFB processing period expressed in tenths of milliseconds. Its true value is always automatically adjusted to remain an integer multiple of the period of the task in which the OFB is executed.

If for example T_OFB declared as 800 ms and the period of task AUX0 is 300 ms, the real T_OFB is

900 ms.

Default value: 30 (period = 300 ms). Minimum

Width modulation period expressed in tenths of a second. Default value: 0 (period = 20 ms).

Output variation after which the algorithm sends a new action (dead band). If the output variation is less than this value, the action remains unchanged.

Default value: 0. Minimum value: 0, maximum

Static error compensation in the absence of any integral action. Default value: 5000. Minimum value:

Output variation limit between two module sampling cycles.

Default value: 10000. Minimum value: 0, maximum value: 10000.

2 / 2 0

PID OFB 2

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Status and Command Words

• STATUS0

This word provides a report on OFB operation. Each bit of this parameter corresponds to an error and is reset to 0 only when the cause of the error is resolved.

Bit 0 : Can only run on a PMX PLC

Bit 1 = 1 : Low level process variable alarm

Bit 2 = 1 : High level process variable alarm

Bit 3 = 1 : Low level deviation alarm

Bit 4 = 1 : High level deviation alarm

Bit 5 = 1 : Low setpoint limit reached

Bit 6 = 1 : High setpoint limit reached

Bit 7 = 1 : Low output limit reached

Bit 8 = 1 : High output limit reached

Bit 9 = 1 : Low output limit exceeded in manual mode

Bit 10 = 1 : High output limit exceeded in manual mode

Bit 11 = 1 : Output rate of change limit reached.

Bit 12 = 1 : Output deviation in the deadband.

Bit 13 : Not significant.

Bit 14

Bit 15

: Not significant.

: Not significant.

D

• STATUS1

This word provides a report on OFB operation. Each bit of this parameter corresponds to a PID state.

Bit 0 : 0, PID in manual mode

1, PID in automatic mode

Bit 1 : 0, Direct action

1, Reverse action

Bit 2 : 0, Derivative action on process variable

1, Derivative action on deviation

Bit 3 : 0, Local setpoint

1, Remote setpoint

Bit 4 : 0, Internal process variable

1, External process variable

Bit 5 : 1, Filtered process variable

Bit 6 : 1, Pulse width modulated output used

Bit 7 : 1, Tracking mode

Bit 8 : 1, PL7-3 application overrun

Bit 9 :

to : Not significant.

Bit 15:

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2 / 2 1

D

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• Command word

This word is used to determine the PID operating mode. Each bit selects a PID function the image of which is in the Status output variable.

Bit 0 : 0, Local process variable used,

1, Remote process variable used,

Bit 1 : 0, Measurement low threshold disabled,

1, Measurement low threshold enabled,

Bit 2 : 0, Measurement high threshold disabled,

1, Measurement high threshold enabled,

Bit 3 : 0, Error low threshold disabled,

1, Error low threshold enabled,

Bit 4 : 0, Error high threshold disabled,

1, Error high threshold enabled,

Bit 5 : 0, Output rate of change limitation disabled,

1, Output rate of change limitation enabled.

By default this word is initialized at 63 (H'3F') corresponding to:

• External process variable usage,

• Process variable and deviation checks enabled,

• Limitation of output rate of change enabled.

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2.1-4 Reaction to a PLC Power Return

Hot Restart (1)

The PID OFB restarts with the following states:

• MAN, LOCAL mode (internal setpoint),

• Output at 0,

• Setpoints and adjustment values are identical to those used prior to the power break.

Changeover to AUTO mode, and when necessary to using an EXTERNAL setpoint is controlled by the program.

(1) To define the meaning of the terms “hot restart” and “cold restart”, refer to the PL7-3, Reference

Manual, Divider A, Section 7.

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PID OFB 2

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Cold Restart

The PID OFB is initialized in the following state:

• MAN, LOCAL mode (internal setpoint),

• Output set to 0,

• Setpoint aligned with the measurement value (refer to the note),

• Adjustment values equal to the default value defined in the INTERNAL CONSTANTS

(where applicable),

Note

This usually results in a set point value of 0 given that TSX AEM modules output a null measurement value during the self-test process.

INTERNAL

CONSTANTS

STRUCTURE

CONSTANTS

PV_DEV

OUT_TYPE

OUT_RANGE

INTERNAL

DATA

INHIB

SP

OUT_MAN

SP_RSP

MAN_AUTO

DIR_REV$

1

2

DIR_REV

D

INTERNAL

DATA

INITIALIZATION

VALUES

.

.

.

.

.

.

KP$

.

.

.

OUTRATE$

1

2

.

.

.

.

.

.

KP

.

.

.

OUTRATE

STATUS1

PV_USED

SP_USED

DEV

READY

COMMANDS

DATA

Shaded areas identify the values used by the PID OFB.

1

Effect of a cold restart,

2

Effect of the SAVE function (refer to Sub-section 8).

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2 / 2 3

D

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2.1-5 Accessing Variables

• The Input/Output parameters cannot be directly modified from a terminal. To modify an input parameter value, it is essential to assign a PL7-3 variable (Program mode,

[PARAM] function key),

• The internal constants can be modified using the [SAVE] key accessible from the

Man-Machine Interface or from PL7-3, either in Program mode ([CONTENT] function key) or in Constants mode,

• Internal data (commands) can be modified from a terminal from PL7-3 in Data mode or by using SYSDIAG software. Internal data can also be modified from the PLC program (e.g. SET PID0,SP_RSP; W102

→

PID0,PV_HL).

• All of the I/O parameters, all internal data and all internal constants can be read either from the terminal or from the PLC program (e.g.: PID0,STATUS

→

W110; IF PID0,

READY THEN ...).

FTX 507

X-TEL PL7-3

Program

Mode

CONTENT PARAM

SYSDIAG

PL7-3

Data Mode

IW4,3 PV

RSP

PID0

ERROR

STATUS

OUTPUT

PW-OUT

INTERNAL

CONSTANTS

.

.

.

KP$

.

.

.

OUTRATE$

INTERNAL

DATA

COMMANDS

INFORMATION

PROGRAM

! PID0,STATUS

→

W113

! SET PID0,SP_RSP

! W102

→

PID0,PV_HL

! IF PID0,READY THEN

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2 / 2 4

PID OFB 2

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2.1-6 Performance Levels

PID OFB memory requirements

5456 words regardless of the number of times it is used

Data Field

120 words each time it is used

PID OFB execution time (per cycle)

Constants Field

40 words each time it is used

7 ms

PMX 87-40

3 ms

PMX 107-40

2.5 ms

7.9 ms

PMX 67-40

3.8 ms

PMX 87-40

3 ms

PMX 107-40

2.7 ms

D

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2.2

Setting-up the PID OFB

2.2-1 General

Reminders:

Once all of the preliminary (hardware and software) configuration operations have been performed, creating a control loop application requires writing a program corresponding to:

• Measurement acquisition by the sensors,

• PID algorithm execution,

• Sending commands to the actuators.

D

Measurement

Acquisition

TSX 7 Model 40

Process

Actuator

Control

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PID OFB 2

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2.2-2 Measurement Acquisition

The 4 or 8 channel TSX AEM analog input modules perform the conversion from electrical input level signal to a 0 - 10000 standard format ready for direct processing by the PID OFB.

Eight types of module cover the range of standard applications most often encountered in the acquisition of continuous input level signal:

• TSX AEM 411 4 isolated high level channels (voltage or current input),

• TSX AEM 412 4 isolated low level channels (thermocouple or voltage input),

• TSX AEM 413 4 isolated low level channels (Pt 100 probe or voltage),

• TSX AEM 811 8 isolated high level channels (voltage or current input),

• TSX AEM 821 8 high level high speed channels (voltage or current input),

• TSX AEM 1601 16 non isolated high level channels (voltage input),

• TSX AEM 1602 16 non isolated high level channels (current input),

• TSX AEM 1613 16 non isolated low level channels (Pt 100 probe input).

The choice of an input module depends on the type of input sensors used with it.

D

Using the measurements

How the measurements are used depends on the type of module used. A quick reminder on measurement data acquisition methods is given below. For more information on accessing these measurements, refer to the appropriate user's documentation:

• For TSX AEM 411/412/413 modules:

TSX AEM User's Manual (TSX D43 727), Section 7,

• For TSX AEM 811 modules:

TSX AEM 811 User's Manual (D23 001E), Section 7,

• For TSX AEM 821 modules:

TSX AEM 821 User's Manual (TSX D23 006E), Section 4,

• For TSX AEM 1601/1602 modules:

TSX AEM 1601/1602 User's Manual (TSX DM AEM 16E), Section 4,

• For TSX AEM 1613 modules:

TSX AEM 1613 User's Manual (TSX DM AEM 1613E), Section 4.

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2 / 2 7

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Brief reminders on measurement acquisition

TSX AEM 4xx or TSX AEM 811/821 modules with up to 4 channels:

No specific programming required.

PID0

IW5,3 PV

RSP

D

TSX AEM 811 module with more than 4 channels:

Programming:

Master task, run text block: EXCHG TXT2

TSX AEM 811

W22 PV

PID1

RSP

W20

Measure 0

TXT2

Measure 7

TSX AEM 821 module with more than 4 channels:

Auxiliary task programming:

! READEXT(I5;W30;W50)

TSX AEM 821

W34 PV

PID2

RSP

W30

Measure 0

Measure 7

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PID OFB 2

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2.2-3 PID OFB Programming

The PID OFB structure lets the user easily place control loop functions in the sequential program and take advantage of all of the features of the PL7-3 programming language to create traditional control loop applications.

The PID OFB is programmed like any other standard PL7-3 function block in one of the periodical tasks in the PLC, in the selected program module.

Parameter assignment (reminders)

• I/O parameters:

The PID OFB I/O parameters must be assigned to PL7-3 variables. The PV and

OUTPUT parameters are always required, all others are optional.

They can be read but not written in Data mode. Any change in assignment must be performed in Program mode.

• Internal data:

Internal data can be read and written:

• From the programming terminal in Data mode,

• By program.

• Internal constants:

The internal constants can be accessed in Program mode via the [CONTENT] dynamic soft key or in Constants mode.

D

Syntax:

EXEC PIDi(Process Variable;Remote Set Point=>error bit;word status0;analog output; discrete output).

PID OFB execution must not be conditional.

Example 1: Single loop

! L10 : EXEC PID1(IW4,3;W15=>B12;W8;OW7,3;)

With:

• IW4,3 = TSX AEM module measurement value,

• W15 = Remote Set Point value,

• B12 = Error bit,

• W8 = Status word status0,

• OW7,3 = Analog output.

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PARAM CONTENT

Allows access to

I/O parameters

Allows access to internal constants

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Example 2: Cascade loop control

The cascade is obtained by stringing PID OFBs together. Execution of the OFB representing the external loop precedes that of the OFB representing the internal loop.

There are two ways to program a cascade loop:

• Directly, leaving open the action of the preceding block but setting the instructions for the following block:

! L10 : EXEC PID1(IW4,3;W15=>B12;W8;;)

! L20 : EXEC PID2(W20;PID1,OUTPUT=>B22;W90;OW6,3;)

Important, in Debug mode, the open output PID1 cannot be displayed in real-time.

• Indirectly, using a variable linked to the action of the preceding block and the instruction value of the following block:

! L10 : EXEC PID1(IW4,3;W15=>B12;W8;W13;)

! L20 : EXEC PID2(W20;W13=>B22;W90;OW6,3;)

Example 3: Mixed process control (combining PID control and feed-forward action)

The OUTBIAS parameter in the OFB PID can be used to superimpose on the output value calculated by the PID algorithm, a value calculated from an external value to anticipate its variations.

< CALCULATE THE ANTICIPATION VALUE

! IW4,5•W52/100

→

PID3,OUTBIAS

< EXECUTE THE ALGORITHM

! EXEC PID3(IW4,4;=>;;OW6,4;)

Note

This application of the OUTBIAS variable is incompatible with its usual offset shift usage.

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PID OFB 2

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2.2-4 Updating Outputs

The control signal to the process is sent either using TSX ASR analog output module

(continuous output from the PID) or using TSX DST discrete output modules (PID width modulation).

If the analog output solution is selected, the user can select one of the modules listed below:

• TSX ASR 200: 2 isolated channels, 12 bit resolution (bipolar voltage or current),

• TSX ASR 401: 4 isolated channels, 11 bit resolution + sign (voltage

±

10 V),

• TSX ASR 402: 4 isolated channels, 12 bit resolution (4 - 20 mA current range with power supply),

• TSX ASR 403: 4 isolated channels, 12 bit resolution (4 - 20 mA, current range and external power supply),

• TSX AST 200: 2 channels, unipolar or current operation, isolated from the PLC bus,

8 bit resolution.

The choice of an input module depends on the type of input sensors used with it.

For more information on using these modules, refer to the appropriate TSX AST/ASR

Analog Output Modules User's Manual (TSX D23 007 E), Sections 3 and 4.

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Brief reminders on analog output updating

TSX ASR 200 module

Programming:

! EXEC PID3(W100;=>;;OW5,0;)

PID3 TSX ASR 200

OUTPUT OW5,0

OUTRANGE = 0 (0 - 4000 output)

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TSX ASR 4.. module

Channel 0 programming:

! H'00F0'

→

OW5,1

! EXEC PID3(;=>;;OW5,3;)

PID3 TSX ASR 4..

OUTPUT OW5,3

OUTRANGE = 1 (0 - 10000 output)

D

TSX AST 200 module

Programming:

! EXEC PIDi(;=>;;W50;)

PIDi

OUTPUT W50

! W50/16

→

O5,0[8]

OUTRANGE = 0 (0 - 4000 output)

TSX AST 200

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PID OFB 2

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2.2-5 Debug - Adjust

Adjusting the set-up of a process control loop is normally performed using a manmachine interface terminal (via the TREND and TUNE) screens. For more information, refer to Divider F.

All of the parameters of the PID OFB can also be displayed (in standard 0 - 10000 format) in Debug and Data modes.

Display screen example:

The ALT O key combination displays a list of the internal parameters of the OFBs declared in the configuration. In the case of the PID OFB, this key can be used as an online help function:

D

"Fdwr" type parameters represent OFB PID variables scaled for Man-Machine Interface purposes.

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2.2-6 Suggestions for Use

To obtain best control loop results, always select the:

• Measurement acquisition rate for TSX AEM modules,

• Sampling period (OFB parameter T_OFB) compatible with the process constant.

Measurement acquisition rate

The acquisition time is 100 ms per channel except for TSX AEM 821 modules that take

6 ms + 2.5 ms per channel.

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Determining the T_OFB parameter

The T_OFB parameter contains the PID OFB sampling period value.

The default value (300 ms) covers most of the possible applications where the process has a response time of a few seconds. If a fast process must be controlled (time constant of around a second), the value of T_OFB may be reduced. If the process is very slow, the T_OFB parameter can be increased.

Reminder: T_OFB is automatically adjusted to the closest possible multiple of the period of the task in which the OFB is executed.

The value of T_OFB must be selected according to the process allowing for the following rule:

T_OFB

≤

time constant / 10

Example:

For a process with a time constant of 5 seconds, T_OFB must not exceed 1 second.

If the OFB is in a 300 ms auxiliary task and the user imposes parameter T_OFB at 1 second, the OFB automatically calculates the new T_OFB value at 900 ms (the multiple of 300 ms closest to 1 second).

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PID OFB 2

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Selecting the task for the control loop

It is up to the user to select the task. It is recommended that the AUX0 task be reserved for such applications.

Important

The PID OFB works from measurements provided by the TSX AEM modules.

However, when the PLC is powered-up the modules perform a self-tests sequence that lasts a few seconds, during which time the measurement values are not significant.

It is up to the user to eliminate the risk of using these erroneous measurement values

(e.g. by maintaining the PLC OFB in manual mode until the module has completed its self-test phase).

The example provided in Divider G describes a typical application.

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SCL OFB 3

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3.1

General

The SCL OFB converts a PLC variable from an integer value to a floating point value and performs scaling.

This OFB is intended primarily to simplify man-machine interface operator dialog programming.

It ensures coherence of the information displayed by a man-machine interface console, comprising:

• Variables that are automatically scaled by the PID OFB, and

• Variables expressed as integer values obtained from PL7-3 application calculations.

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3.2

SCL OFB Presentation

The SCL OFB comprises an input parameter, two output parameters, four internal constants (defined during the programming phase) and six internal data (used during execution).

Input VALUE : Word

SCL

ERROR : Bit

STATUS : Word

Outputs

Internal

Data

INHIB : Bit

VAL_MAX : Word

VAL_MIN : Word

OUT_MAX : Word

OUT_MIN : Word

OUTPUT : Dword

Internal

Constants

VAL_MAX$ : Word

VAL_MIN$ : Word

OUT-MAX$ : Word

OUT-MIN$ : Word

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The internal data can be accessed by the program via their symbols or variables (e.g.

SCL1, OUT_MAX). The OUTPUT variable (in floating point notation) cannot be accessed from PL7-3. It can only be used by the Man-Machine Interface system.

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3.3

Parameter Description

Input Parameter

VALUE

Type

Word

Access

(1)

Description

Contains the integer value of the variable to scale.

The value must be within the limits set for the input full scale range.

Output Parameters

ERROR

Type

Bit

STATUS Word

Access

(1)

Description

This bit changes to 1 when an error is detected. The output from the OFB contains an incorrect value.

Reading the STATUS parameter will let the user

(1) A status report on the operation of the OFB. Each bit in this word indicates a type of error and it is only reset to 0 when the cause of the error has disappeared. This word is detailed in Sub-section 3.4.

(1) Read by program and in adjust (Data Mode, etc.),

(2) Read/Write by program and in adjust (Data Mode, etc.),

(3) Can only be used for man-machine interface purposes,

(4) Read by program and in adjust (Data Mode, etc.),

Write in adjust (Data Mode, etc.).

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SCL OFB 3

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Internal Data

Type Access Description

INHIB Bit (2) At 1, this bit inhibits the OFB alarms by forcing the

OUTPUT

VAL_MAX

Double

Word

Word

(3)

(4)

This floating point double word contains the value of the variable converted to floating point notation in the new scale. This value can only be used by a Man-

Value of the higher limit of the selected input scale

VAL_MIN

OUT_MAX

OUT_MIN

Word

Word

Word

(4)

(4)

(4)

Value of the lower limit of the selected input scale

Value of the higher limit of the selected output scale

Value of the lower limit of the selected input scale range.

Internal Constants

Type

VAL_MAX$ Word

VAL_MIN$

OUT_MAX$

OUT_MIN$

Word

Word

Word

Access

(4)

Description

Initial value of the higher limit of the full scale range

(4)

(4)

(4)

Initial value of the lower limit of the full scale range

Initial value of the higher limit of the full scale range

Initial value of the lower limit of the full scale range used to express the output value.

D

(1), (2), (3) and (4) refer to Sub-section 3.3.

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3.4

Status Word

This word provides a report on OFB operation. Each bit corresponds to an error and is only reset to 0 when the cause of the error has been removed.

Bit 0 = 1 : Can only be run on a PMX.

Bit 1 = 1 : Input higher threshold exceeded.

Bit 2 = 1 : Input lower threshold exceeded.

Bit 3 = 1 : Inverse input.

Bit 4 = 1 : Inverse output.

Bit 5 = 1 : Null input range.

Bit 6 = 1 : Null output range.

D

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3.5

Performance Levels

Memory Requirements

Approx. 1000 words regardless how often it is used

Data Field

24 words each usage

Constants Field

8 words each usage

SCL OFB Execution Time (per cycle)

1.3 ms

PMX 87-40

0.5 ms

PMX 107-40

0.4 ms

1.5 ms

PMX 67-40

0.6 ms

PMX 87-40

0.5 ms

PMX 107-40

0.4 ms

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SCL OFB 3

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Example:

To display the level of water in a tank.

The following preset limit values apply:

• VAL_MAX = 10000,

• VAL_MIN = 0,

• OUT_MAX = 75 cm,

• OUT_MIN = 2 cm.

The process variable from word W50, equals 1000.

! EXEC SCL1(W50=>B10;W40)

Starts scaling word W50 (B10 = Error bit and W40 = Status word).

The scaled output (SCL1, OUTPUT) takes a value of 9.3 cm and can only be used by a Man-Machine Interface system.

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ISCL OFB 4

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4.1

General

The ISCL OFB performs the opposite function to the SCL OFB. It can convert a variable expressed in floating point notation into a variable expressed as an integer value.

This OFB is intended primarily to simplify PL7-3 application programming by converting variables generated directly in floating point notation by the man-machine interface system into values that can be used in PL7-3.

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4.2

ISCL OFB Presentation

The ISCL OFB comprises three output parameters, four internal constants (defined during the programming phase) and six internal data (used during execution).

ISCL

ERROR : Bit

STATUS : Word

OUTPUT : Word

Outputs

Internal

Data

INHIB

VALUE

: Bit

: Floating point double word

VAL_MAX : Word

VAL_MIN : Word

OUT_MAX : Word

OUT_MIN : Word

Internal

Constants

VAL_MAX$ : Word

VAL_MIN$ : Word

OUT-MAX$ : Word

OUT-MIN$ : Word

D

The internal data (except VALUE) can be accessed by the program via the symbols used

(e.g. ISCL1, OUT_MAX).

Important

If an ISCL OFB is used in a PL7-MMI 37 Man-Machine Interface application, the

ISCL VALUE parameter must be declared in Write only.

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4 / 1

D

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4.3

Parameter Description

Output Parameters

ERROR

Type

Bit

Access

(1)

Description

This bit changes to 1 when an error is detected. The output from the OFB contains an incorrect value.

Reading the STATUS parameter will let the user

STATUS Word (1)

OUTPUT Word (1)

A status report on the operation of the OFB. Each bit in this word indicates a type of error and it is only reset to 0 when the cause of the error has disap-

Contains the integer value of the scaled variable.

(1) Read by program and in adjust (Data Mode, etc.),

(2) Read/Write by program and in adjust (Data Mode, etc.),

(3) Can only be used for man-machine interface purposes,

(4) Read by program and in adjust (Data Mode, etc.),

Write in adjust (Data Mode, etc.).

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ISCL OFB 4

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Internal Data

Type Access Description

INHIB Bit (2) At 1, this bit inhibits the OFB alarms by forcing the

VALUE

VAL_MAX

Double

Word

Word

(3)

(4)

Floating point value of the variable taken from the man-machine interface, for conversion to an integer value. This double word cannot be read by

Value of the higher limit of the selected input scale

VAL_MIN

OUT_MAX

OUT_MIN

Word

Word

Word

(4)

(4)

(4)

Value of the lower limit of the selected input scale

Value of the higher limit of the selected output scale

Value of the lower limit of the selected input scale range.

Internal Constants

Type

VAL_MAX$ Word

VAL_MIN$

OUT_MAX$

OUT_MIN$

Word

Word

Word

Access

(4)

Description

Initial value of the higher limit of the full scale range

(4)

(4)

(4)

Initial value of the lower limit of the full scale range

Initial value of the higher limit of the full scale range

Initial value of the lower limit of the full scale range used to express the output value.

D

(1), (2), (3) and (4) refer to Sub-section 4.3.

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4.4

Status Word

This word provides a report on OFB operation. Each bit corresponds to an error and is only reset to 0 when the cause of the error has been removed.

Bit 0 = 1 : Can only be run on a PMX.

Bit 1 = 1 : Input higher threshold exceeded.

Bit 2 = 1 : Input lower threshold exceeded.

Bit 3 = 1 : Inverse input.

Bit 4 = 1 : Inverse output.

Bit 5 = 1 : Null input range.

Bit 6 = 1 : Null output range.

D

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4.5

Performance Levels

Memory Requirements

1080 words regardless how often it is used

Data Field

24 words each usage

Constants Field

8 words each usage

ISCL OFB Execution Time (per cycle)

0.8 ms

PMX 87-40

0.3 ms

PMX 107-40

0.3 ms

0.9 ms

PMX 67-40

0.4 ms

PMX 87-40

0.3 ms

PMX 107-40

0.3 ms

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ISCL OFB 4

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Example:

To read a preset input value from PL7-3 using a man-machine interface terminal.

The following preset limit values apply:

• VAL_MAX = + 60 deg.C,

• VAL_MIN = - 30 deg.C,

• OUT_MAX = + 6000,

• OUT_MIN = - 3000.

The process variable from the VALUE word equals + 27.35 deg.C.

! EXEC ISCL1(=>B20;W50;W60)

Starts converting the VALUE word (B20 = Error bit, W50 = Status word and W60 =

Scaled integer value).

The scaled output (ISCL1, OUTPUT) takes a value of 2735 and is transferred to W60.

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PIDF OFB 5

5.1

PIDF OFB Presentation

5.1.1

General

The PIDF OFB is used to set-up a PID process control loop on PMX V5 level PLCs.

The PIDF OFB uses a measurement value provided by a TSX AEM xxx analog input module and generates an output value that can be:

• Analog, applied to the process by a TSX AST xxx or TSX ASR xxx output module,

• Duration modulated, sent to the process by a TSX DST xxx type discrete output module.

TSX AST/ASR

TSX AEM

+

–

P.I.D.

ANA

PWM

ISCLF

CONSIGNE

Externe

SCLF

Remote

Set Point (RSP)

Filtre d'entrée

TSX DST

The numerical values handled by the PIDF OFB are in floating point notation.

The inputs to the OFB (process variable, set point and their assigned parameters) are expressed in physical units.

The analog output from the OFB is expressed as a % of the Full Scale Range (F.S.R.), in 0.-100 format.

The SCLF and ISCLF OFBs before or after the corrector allow the use of the physical range by converting the data from analog I/O modules.

D

5 / 1

D

5.1.2 Features

The PIDF OFB is a corrector that comprises the features listed below:

• Direct or reverse action,

• Derivative action applied to the process variable or deviation,

• Feed-forward input,

• Output range 0-100 in floating point notation,

• Higher and lower alarms on the process variable with hysteresis compensation,

• Higher and lower alarms on the deviation with hysteresis compensation,

• Higher and lower limiting of the set point,

• Higher and lower limiting of the automatic output signal,

• Anti-reset windup,

• Manual and automatic operating mode selection,

• Local and remote set point selection,

• Input forcing (for debug/set-up actions),

• Limitation of output signal rate of change,

• Output bias,

• Deadband,

• Continuous or pulse width modulated output,

• Tracking,

• Optional following signal,

• Cascade handling,

3 INPUTS

PIDF OFB

4 OUTPUTS

The PIDF OFB comprises:

• 3 input parameters

• 4 output parameters

• 47 internal data

• 29 internal constants

47 INTERNAL

DATA

29 INTERNAL

CONSTANTS

5 / 2

5.1-3 PIDF OFB Functional Description

PIDF

PV

RSP

FF

ERROR

STATUS

OUTP

PIDF OFB 5 constantes internal constants

Simplified diagram of the PIDF OFB

FEED-

FOWARD

FF

DU SIGNAL

Pre-processing

FEED FORWARD

CONSIGNE

RSP

PRETRAITEMENT

Set Point

DE LA

CONSIGNE

–

+

Action

Derived dérivée

Action

MESURE

PV

PRETRAITEMENT

PV

DE LA

MESURE

AUTO

MANU

+

+

TRAITEMENT

Command

DE LA

COMMANDE

PRETRAITEMENT

OUTP

PW_0

PRETRAITEMENT

Pre-processing

SORTIE TOR

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5 / 3

5.1-4 Process Variable

PROCESS

VARIABLE

PIDFi,SP_NORM

+

DEV.

ε

PIDFi,PV

▼

SP

▲

PIDFi,PV_SUP

PIDFi,COMMAND

(bit 0)

PIDFi,PV_HL

LIMITER

ALARM

PIDFi,PV_INF

PIDFi,PV_LL

PIDFi,PV_SIM

PV

PIDFi,PV_USED

FORCED

PV

PID

D

• The process variable is copied to the PIDFi,PV internal data. It is then compared with the higher and lower limits PIDFi,PV_SUP and PIDFi,PV_INF and with the higher and lower alarm thresholds PIDFi,PV_HL and PIDFi,PV_LL.

• The user can force the process variable value by setting the LSB of command word

PIDFi,COMMAND (BIT 0).

• The process variable used PIDFi,PV_USED is equal to PIDFi,PV or to PIDFi,PV_SIM depending on the value of the command but.

5 / 4

PIDF OFB 5

Input Parameter

PV

Type

Floating

Access

(1)

Internal Data - Commands

Type Access

PV_SUP Floating (2)

Description

Process Variable.

Description

Process variable scale higher limit in physical units

(4).

PV_INF Floating (2) Process variable scale lower limit in physical units

(4).

PV_HL

PV_LL

PV_SIM

PV_USED

Floating

Floating

Floating

Floating

(3)

(3)

(2)

(1)

Process variable higher limit (4).

Process variable lower limit (4).

PV forced value used when setting-up the process control application. PV_SIM is used by the OFB in place of PV, when bit 0 of PIDFi,COMMAND is set to

Process variable used in the algorithm.

D

Important

The PV_SUP and PV_INF parameters are used for calculating the value of the parameters in physical units and for scaling RSP if the OFB is downstream in a cascade layout.

(1) Read by program and in adjust (data mode, etc.),

(2) Read by program and in adjust (data mode, etc.),

Written in adjust (data mode, etc.),

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.),

(4) Fallback value defined by the internal constant with the same name followed by the character $.

5 / 5

5.1-5 Set Point

MMX (or PL7-PMS2 in Software Workshop)

100% PV_SUP

PIDFi,SP_USED

SCALING

Operator

Set Point

Application

Set Point

RSP

PIDFi,RSP

0 PV_INF

Y

PID in cascade?

▲

RSP

N

PIDFi,SP

Y

Store

Set Point

▲

REM

LOC

N

Remote Set Point

AND

Following Set Point

N

▲

PIDFi,SP_MAX

LIMITER

PIDFi,SP_MIN

MAN. Mode

AND

TRACKING option

Y

▲

-

▲ +

Dev.

D

REM

→

LOC Switchover

▲

Measure.

LOC

→

REM Switchover

Selecting a local or a remote set point

• The set point is local, internal to the OFB (PIDFi,SP_USED) if the PIDFi,SP_RSP bit is set to 0, else the RSP input to the OFB will be taken as the set point (remote set point).

The set point range is then limited before being applied to the PID.

Following set point

• The following set point is used to avoid any sudden change to the set point when changing from a remote set point to a local set point (PIDFi,RSP copied to PIDFi,SP).

This function is enabled by the SP_FOLW bit:

SP_FOLW = 0 no following set point (by default)

SP_FOLW = 1 following set point.

Default operation

• The local set point PIDFi,SP is used and copied to PIDFi,SP_USED.

TRACKING mode

• To avoid sudden changes in the command when performing a MAN.

→

AUTO.

changeover, it is possible to set the local set point to match the process variable, by enabling the TRACKING bit.

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PIDF OFB 5

Input Parameter

RSP

Type

Floating

Access

(1)

Description

Remote Set Point.

By default RSP = 1.0 E+30 (input not used).

Internal Data - Commands

SP_RSP

Type

Floating

Bit

Access

(1)

(3)

Description

Set point memory.

Type of set point used. If SP_RSP = 0, the set point

SP_USED is used. If RSP = 1, the remote set point

RSP is used.

SP_MAX

SP_MIN

Floating

Floating

(3)

(3)

Higher set point limit (4).

Lower set point limit (4).

By default SP_MIN$ = -1.0 E+6

Internal Data - Information

SP_NORM

Type

Floating

Access

(2)

Description

Effective standardized set point.

By default SP_NORM = SP_USED converted (con-

D

SP_USED

SP_FOLW

TRACKING

Floating

Bit

Bit

(3)

(3)

(3)

Set point used in the algorithm used as set point.

By default SP_USED = PV (set point = process

Following set point selection bit (4).

In MAN. mode, when this bit is set to 1, the set point is set to the process variable (4).

By default TRACK$ = 0

(1) Read by program and in adjust (data mode, etc.),

(2) Read by program and in adjust (data mode, etc.),

Written in adjust (data mode, etc.),

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.),

(4) Fallback value defined by the internal constant with the same name followed by the character $.

5 / 7

D

5.1-6 PID Action

The output value is calculated from the process variable and the set point expressed as a percentage of the full scale range (standard format).

SET POINT

SP_USED

MESURE

PV_USED

-

▼

+ ▲

PV_SUP 100%

SCALING

PIDFi,SP_NORM

PV_INF 0

PIDFi,DEV

PIDFi,TI

∫

Integral

PIDFi,DEV_HL

-

▼ Input

ALARM

PIDFi,DEV_LL

+

▲

Derived action on deviation

PIDFi,TD

PV_SUP 100% d dt

SCALING

PV_INF 0

Derived action on PV

Derivation

PIDFi,PV_DEV

+

P.I.D. CORRECTOR

▼

+

▲

+

K

FEED-

FORWARD

Output

+

▼

+

Output value between

0 & 100%

• A mixed structure corrector is used, its transfer function, in the case of derivative action on the deviation is:

S (p) 1

= KP 1 + +

ε

(p) TI x p

TD x p

1 + (TD/KD) x p

With KP = Proportional gain

TI = Integral time

TD = Derivative time

The expression 1 + (TD/KD) x p gives the filtering of the derivative action. The value of

KD (max. gain of the derivative action) is set to 10.

Compatibility with the PID OFB (V4)

The algorithm is the same, but the parameters are in floating point notation. The settings of a V4 level OFB using the standard 0-10,000 range become 0-100 range values for the PIDF OFB:

• KP(F) = KP/100

• TI(F) = TI/10

• TD(F) = TD/10

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PIDF OFB 5

Internal Data - Commands

DEV_HL

Type

Floating

Access

(3)

DEV_LL

KP

Floating

Floating

(3)

(3)

TI

TD

Floating

Floating

(3)

(3)

Description

Higher threshold on calculated deviation (4).

Lower threshold on calculated deviation (4).

PID corrector gain. Its value is in the range [+0.01;

+100.0] (4).

Integral time of the PID corrector, in seconds.

Its value is in the range [0.0; +20000.0] (4).

Derived time of the PID corrector, in seconds.

Its value is in the range

[0.0; +20000.0] (4).

By default TD$ = +0.0

Internal Data - Information

DEV

Type

Floating

Access

(1)

Description

Included the deviation PV_USED - SP_USED, in physical units.

By default DEV = 0.0 (no deviation).

Internal Constants - Structure Variables

PV_DEV

Type

Bit

Access

(1)

Description

Type of derived action.

If PV_DEV = 0, from PV,

If PV_DEV = 1, from deviation.

By default PV_DEV = 0 (from PV).

D

(1) Read by program and in adjust (data mode, etc.),

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.),

(4) Fallback value defined by internal constant with the same name followed by the character $.

5 / 9

5.1-7 Feed-Forward Compensation

FORCED

FEED-FORWARD

PIDFi,FF_SIM

FEED-

FORWARD

PIDFi,FF

PIDFi,COMMAND

(BIT 2)

FF_SUP OTFF_SUP

SCALING

PIDFi,OUT_FF

FF_INF OTFF_INF

PID

PID Output

+

▼

+

D

In a standard PID set-up, the corrector reacts to variations of the process output (closed loop process control). Therefore, if any interference occurs, the corrector will only react when the process variable starts to deviate from the set point. The feed-forward function is used to compensate for a measurable interference as soon as it occurs. This function, in an open loop, anticipates the effect of the interference: the term "predictive process control" applies.

Example: To control the temperature level PV2, the output from the secondary circuit of a heat exchanger. A PID loop controls the hot air inlet control as a function of PV2 and the set point SP. The cold water temperature acts as a measurable interference with this process control set-up.

Using the feed-forward function makes it possible to react as soon as the cold water temperature varies and not once the temperature level PV2 has dropped.

▼

SP

+

PV

▼

PID

FF +

+ ▼

Transfer

Function

▲ ▼

Qc

Steam

▼

Control valve

Interference

TT1

TT2

▲

PV2

Condenser

5 / 1 0

PIDF OFB 5

Effect of the feed-forward input on the corrector command

Derived from the following formula:

OUT_FF =

(FF – FF_INF) x (OTFF_SUP – OTFF_INF)

+ OTFF_INF

(FF_SUP – FF_INF)

Input parameter

FF

Type

Floating

Access

(1)

Description

Process control loop feed-forward input.

By default FF = 1.0 E+30 (input not used).

Internal command data

Type

FF_SIM Floating

Access

(2)

FF_SUP

FF_INF

OTFF_SUP

Floating

Floating

Floating

(2)

(2)

(2)

Description

Forced value of input FF. FF_SIM is used by the

OFB in place of FF, when bit 2 of PIDFi,COMMAND is set to 1.

Higher limit of the FF range (4).

Lower limit of the FF range (4).

Value of the contribution of FF, corresponding to the maximum interference.

Its value is in the range [-100.0; +100.0] (4).

D

OTFF_INF Floating (2) Value of the contribution of FF, corresponding to the minimum interference.

Its value is in the range [0.; +100.0] (4).

By default OTFF_INF$ = 0.

The default values of FF_SUP, FF_INF, OTFF_SUP and OTFF_INF as selected so that the 0 value of the feed-forward input is neutral (no effect on the output).

(1) Read by program and in adjust (data mode, etc.),

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.),

(4) Fallback value defined by internal constant with the same name followed by the character $.

5 / 1 1

D

Internal Data - Information

OUT_FF

Type

Floating

Access

(1)

Description

Feed-forward output.

(1) Read by program and in adjust (data mode, etc.)

With the following assumptions:

• Condenser output temperature (cold water temperature) varies between 5

°

C and

25

°

C, with an average level of 15

°

C,

• A variation

∆

T of this temperature level is fully reflected in the exchanger output temperature,

• To compensate for any increase (or decrease) in the temperature output from the exchanger of 5

°

C, it is necessary to close (or open) the steam control valve by 10%,

Therefore the parameters of the feed-forward input are set so that the effect of the cold water temperature on the steam flow is:

• Null at 15

°

C,

• A ratio of 10% / 5

°

C between 5 and 25

°

C. This is shown as:

∆

Output %

▲

+20

+10

0

-10

-20

5 10 15 20 25

Cold water temperature (

°

C)

Therefore the settings used are:

FF_SUP at 25

°

C

FF_INF at 5

°

C

OTFF_SUP at 10%

OTFF_INF at -10%

5 / 1 2

PIDF OFB 5

5.1-8 Command Processing

FEED-

FORWARD DEAD-BAND

DIRECT-

REVERSE

PIDFi, OUTRATE

PID +

+

+

PIDFi, OUT_MAX

+

PIDFi, OUT_MIN

PIDFi, DBAND PIDFi, DIR_REV

OUTBIAS

PIDFi, OUTBIAS

• Using Outbias means that when neither feed-forward nor integral inputs are used, operating precision is maintained.

• The command signal is then restricted by the limiter.

• A check on the amplitude variation of the command is performed by the OUTRATE variation limiter.

• Deadband is used to avoid premature actuator wear by avoiding small variations in position at the end of travel.

• The direct/reverse selection is used to change the direction of the corrector action to match that of the actuator/process system.

D

Internal Data - Commands

OUTBIAS

Type

Floating

Access

(3)

Description

Static deviation compensation when no integral action or feed-forward input is used. Its value is in the range [0.0; +100.0] (4).

DBAND Floating (3)

OUT_MAX

OUT_MIN

Floating

Floating

(3)

(3)

Deadband. If the output variation is less than DBAND, the action remains unchanged. Its value is in the range [0.0; +100.0] (4).

Higher output limit. Its value is in the range [0.0;

+100.0] (4).

Lower output limit. Its value is in the range [0.0;

+100.0] (4).

By default OUT_MIN$ = 0.0 (no lower limit).

(3) Read program and adjust (data mode, etc.),

Written by program and adjust (data mode, etc.).

(4) Fallback internal constant with the same name followed by the character $.

5 / 1 3

Internal Data - Commands (continued)

DIR_REV

Type

Bit

Access

(2)

Description

PID action.

If DIR_REV = 0, PID action is direct.

If DIR_REV = 1, PID action is reversed (4).

OUTRATE Floating (3) Limit to output variation between two samples. Its value is in the range [0.0; +100.0] (4).

By default OUTRATE$ = +100.0 (no limit).

(2) Read by program and in adjust (data mode, etc.),

Write in adjust (data mode, etc.),

(3) Read by program and in adjust (data mode, etc.),

Write by program and in adjust (data mode, etc.).

(4) Fallback value defined by internal constant with the same name followed by the character $.

D

_____________________________________________________________________

5.1-9 Width Modulated Output

The width modulated output is active when the OUT_TYPE bit is set to 1. By default, this bit is set to 0 (width modulated outputs set to 0).

The width modulated output is a function of the analog output and the modulation period

TCYCLE. The ratio (width modulated output activation time) / (modulation period) corresponds to the percentage of the corresponding analog output.

Width modulated output PW_O

▲

Width modulation at 33%

Time

TCYCLE

The width modulated output PW_O is updated by the PIDF OFB. The activation time of this output is therefore a multiple of the period of the task containing the PIDF OFB. This restriction determines the modulation resolution that is equal to the ratio (task period)/

(modulation period). For example: if the maximum acceptable resolution is 5% and if the process control application is running in a 500 ms auxiliary task, the minimum modulation period is 10 s. The TCYCLE modulation period expressed in seconds, is set to 20 s by default (TCYCLE = 20.0).

5 / 1 4

PIDF OFB 5

5.1-10 Selecting Corrector Operating Mode and Control Signal Processing

AUTO

PIDFi, OUTP

PIDFi, MAN_AUTO

COMMANDE

COMMAND

MANUELLE

PIDFi, OUT_MAN

MANU

Choix de la sortie

à commander

PIDFi, OUT_TYPE

PIDFi, PW_0

• By default the corrector is set for Manual mode operation and the control output used is the analog output.

• The PIDFi, MAN_AUTO bit selects the corrector operating mode (Manual or Auto).

Output parameters

OUTP

Type

Floating

Access

(1)

Description

PID analog output. OUTP is the result of the algorithm (in AUTO mode) or the manual output value (in

MAN. mode). Its value is in the range [0.0; +100.0].

By default OUTP = OUT_MAN (manual control

D

PW_O Bit (1) PID analog output taking the form of an image of

OUTP.

By default PW_O = 0 (null output).

(1) Read by program and in adjust (data mode, etc.).

5 / 1 5

Internal Data - Commands

OUT_MAN

Type

Floating

Access

(3)

MAN_AUTO Bit (3)

Description

Manual output value from the control loop.

Its value is in the range [0.0; +100.0].

PID operating mode.

If MAN_AUTO = 0, PID in manual mode.

If MAN_AUTO = 1, PID in automatic mode.

By default MAN_AUTO = 0 (manual mode).

Internal Constants - Structure Variables

OUT_TYPE

Type

Bit

Access

(1)

Description

Activates output PW_O. If OUT_TYPE = 0, PW_O inactive (PW_O = 0). If OUT_TYPE = 1, output

PW_O is width modulated.

By default OUT_TYPE = 0 (PW_O inactive).

D

(1) Read by program and in adjust (data mode, etc.).

(3) Read by program and in adjust (data mode, etc.),

Write by program and in adjust (data mode, etc.).

5 / 1 6

PIDF OFB 5

5.1-11 Cascade Set-up with two Correctors

A cascade of PIDF correctors is shown in the diagram below:

Mesure 2

Mesure 1

Consigne

Externe

PV

RSP

FF

PIDF1

ERROR

STATUS

OUTP

PW_0

PV

RSP

FF

PIDF2

ERROR

STATUS

OUTP

PW_0

The Upstream OFB controls OUTP in the range [0.0; 100.0].

The Downstream OFB reads this information from the RSP input and converts its to the same scale as its own PV measurement value (measure 2).

The SP_USED internal data is expressed in physical units.

The Upstream OFB (PIDF1) must be executed before the Downstream OFB (PIDF2):

< Execute Upstream OFB

! EXEC PIDF1(MES1;; => ;;;)

< Execute Downstream OFB

! EXEC PIDF2(MES2; PIDF1,OUTP; => ;;;)

D

Avoiding "bumps" in a cascade

"Bumps" occurs in a cascade when the cascade is closed (the downstream corrector switches from a local to a remote set point).

To avoid "bumps", a mechanism is used to change the Upstream corrector over to pseudo manual mode when the downstream corrector changes to the local set point.

This mechanism uses the LINKED and BUMPLESS internal data, with:

• LINKED for the Upstream OFB = SP_RSP for the Downstream OFB,

• BUMPLESS for the Upstream OFB = SP_NORM for the Downstream OFB, in the range [0.0; 100.0].

To control a cascade, the next three lines must be added to the PL7-3 program, after the

Downstream PID execution instruction, so that the OFB knows that it is used in cascade and to ensure a smooth bumpless transition.

! PIDF2,SP_RSP

→

PIDF1,LINKED

! PIDF2,SP_NORM

→

PIDF1,BUMPLESS

! SET PIDF2,COMMAND,D

5 / 1 7

Internal Data

BUMPLESS

Type

Floating

Access

(1)

Description

If Upstream OFB in a cascade, BUMPLESS =

LINKED Bit (1) If Upstream OFB in a cascade, LINKED = SP_RSP for Downstream OFB in the cascade.

(1) Read by program and adjust (data mode, etc.).

Note

A multiple cascade of n elements is the same as an association of n-1 cascades of two corrector

OFBs.

D

_______________________________________________________________________

5.1-12 Man-Machine Interface Related Parameters

Internal Data - Commands

LIBELLE

Type

Message

Access

(2)

Description

String of up to 9 characters containing the name of the loop controlled by the OFB (specific man-machine interface data) (4).

UNIT Message (2) String of up to 6 characters that contains the type of physical unit selected for the variable controlled by the OFB (specific man-machine interface data) (4).

By default UNIT$ = UNITS.

(2) Read by program and adjust (data mode, etc.),

Write in adjust (data mode, etc.).

5 / 1 8

PIDF OFB 5

5.1-13 Parameters Linked to OFB Execution

Internal Data -Commands

Type Access

T_OFB Floating (2)

Description

PIDF OFB processing period in seconds. Its true value is automatically adjusted to the closest multiple of the period if the task in which the PIDF OFB is executed (if the declared T_OFB is 800 ms and the period of the

AUX0 task is 300 ms, true T_OFB will be 900 ms).

Its value is in the range [+0.02; +1.0 E+6] (4).

T_CYCLE Floating (2) Width modulation period in seconds.

Its value is in the range [+0.02;

+1.0 E+6] (4).

FORCE Bit (3) FORCE = 1 requires execution of the algorithm in the next cycle.

By default FORCE = 0 (no forcing).

Internal Data - Information

READY

Type

Bit

Access

(1)

Description

Bit linked to the internal counter that controls sequencing of OFB execution. READY is set to 1 when the counter indicates that the OFB will be executed during the next cycle.

This function lets the user link a number of processing actions to perform (on the PV or the SP) when the

OFB is actually executed.

By default READY = 0.

D

(1) Read by program and in adjust (data mode, etc.).

(2) Read by program and in adjust (data mode, etc.),

Written in adjust (data mode, etc.).

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.).

5 / 1 9

D

5.1-14 Error Processing

Manual mode output

Set Point level

Automatic mode

Output rate of change limit exceeded

Null FF input

Output deviation

Internal data out of range

Internal data

Incoherent input parameter

Processing performed by the OFB

No limit,

The OFB continues normal processing.

SP = closest limit value,

The OFB continues normal processing

Output = limit value (MIN or MAX as appropriate),

The OFB continues normal processing.

Output rate of change limit

(OUTP n

= OUTP n-1

+/- OUTRATE),

OUTP output calculated without feed-forward,

STATUS,13 and ERROR are set to 1.

PID output = last output applied,

The OFB continues normal processing.

The OFB assigns a limit value (MIN or MAX as appropriate),

Internal data min = internal data max,

The OFB continues normal processing.

Output frozen,

STATUS,F is set to 1.

5 / 2 0

PIDF OFB 5

5.1-15 OFB Reports

Status Word (output)

STATUS

Type

Word

Access

(1)

Description

OFB report.

(1) Read in adjust (data mode, etc.).

The PIDF OFB comprises a single status word as an output parameter, called STATUS:

Bit 0 = 1 : Can only run on a PMX PLC (error)

Bit 1 = 1 : Calculation error

Bit 2 = 1 : Low PV threshold exceeded (error)

Bit 3 = 1 : High PV threshold exceeded (error)

Bit 4 = 1 : Low Dev. threshold exceeded (error)

Bit 5 = 1 : High Dev. threshold exceeded (error)

Bit 6 = 1 : Low SP threshold reached (information)

Bit 7 = 1 : High SP threshold reached (information)

Bit 8 = 1 : Low output limit reached in automatic mode (information)

Bit 9 = 1 : High output limit reached in automatic mode (information)

Bit 10 = 1 : Low output limit exceeded in manual mode (information)

Bit 11 = 1 : High output limit exceeded in manual mode (information)

Bit 12 = 1 : Output rate of change limit reached (information)

Bit 13 = 1 : Null FF input scale (error)

Bit 15 = 1 : Incoherent input parameter: data not in floating point notation (error)

D

MONITOR Word

MONITOR

Type

Word

Access

(2)

Description

Word intended mainly for use by the Monitor 77 supervision system.

By default MONITOR = 0.

(2) Read by program and adjust (data mode, etc.),

Write by program.

Bit 0 = SP_RSP status

Bit 1 = MAN_AUTO status

Bit 5 = Reserved

Bit 6 = 1 : PV lower limit exceed

Bit 7 = 1 : PV higher limit exceed

Bit 8 = 1 : Dev. lower limit exceed

Bit 9 = 1 : Dev. higher limit exceed

Bit 10 to bit 15 : Available to the user for returning discrete type information (alarm, operating mode, etc.).

5 / 2 1

D

SUPERVIS character table: Reserved for the system.

COMMAND Word

The COMMAND word serves two purposes for the PIDF OFB: to determine the forced input parameters (8 LSB) and the PID operating mode (alarms enabled or inhibited):

Bit 0 = 1 : PV input forcing (PV_SIM used in place of PV)

Bit 1 = 1 : Ignored

Bit 2 = 1 : FF input forcing (FF_SIM used in place of FF)

Bit 8 = 0 : PV lower threshold disabled

= 1 : PV lower threshold enabled

Bit 9 = 0 : PV higher threshold disabled

= 1 : PV higher threshold enabled

Bit 10 = 0 : Dev. lower threshold disabled

= 1 : Dev. lower threshold enabled

Bit 11 = 0 : Dev. higher threshold disabled

= 1 : Dev. higher threshold enabled

Bit 12 = 0 : Output rate of change limit disabled

= 1 : Output rate of change limit enabled

Bit 13 = 1 : PID downstream from a cascade

By default: COMMAND = H'1F00' (no forcing, error bits enabled and no cascade loops used).

5 / 2 2

PIDF OFB 5

__________________________________________________________________________________________

5.1-16 Reaction to a PLC Power Return

Hot Restart

The PIDF OFB restarts in the same state as prior to the power break:

• Setpoints and adjustment values are identical to those used prior to the power break.

The PLC's real-time clock can be used to determine the duration of the power break, allowing the user to program a failure and reinitialization sequence in the event of a long duration power break.

Cold Restart

The PIDF OFB is initialized in the following state:

• MAN, LOCAL mode (internal set point),

• Output set to 0,

• Set point aligned with the measurement value (refer to the note),

• Adjustment values equal to the default value defined in the INTERNAL CONSTANTS

(where applicable),

Note

This usually results in a set point value of 0 given that TSX AEM modules output a null measurement value during the self-test process.

STRUCTURE

CONSTANTS

INTERNAL

CONSTANTS

PV_DEV

OUT_TYPE

OUT_RANGE

INTERNAL

DATA

INHIB

SP

OUT_MAN

SP_RSP

MAN_AUTO

DIR_REV$

1

2

DIR_REV

D

INTERNAL

DATA

INITIALIZATION

VALUES

.

.

.

.

.

.

.

KP$

.

.

OUTRATE$

1

2

.

.

.

.

.

.

.

KP

.

.

OUTRATE

COMMANDS

STATUS1

PV_USED

SP_USED

DEV

DATA

READY

Shaded areas identify the values used by the PIDF OFB.

1

Effect of a cold restart,

2

Effect of the SAVE function (refer to Sub-section 8).

__________________________________________________________________________________________

5 / 2 3

D

__________________________________________________________________________________________

5.1-17 Accessing Variables

• The Input/Output parameters cannot be directly modified from a terminal. To modify an input parameter value, it is essential to assign a PL7-3 variable (Program mode,

[PARAM] function key),

• The internal constants can be modified using the [SAVE] key accessible from the

Man-Machine Interface or from PL7-3, either in Program mode ([CONTENT] function key) or in Constants mode,

• Internal data (commands) can be modified from a terminal from PL7-3 in Data mode or by using SYSDIAG software. Internal data can also be modified from the PLC program (e.g. SET PIDF0,SP_RSP; DW102

→

PIDF0,PV_HL).

• All of the I/O parameters, all internal data and all internal constants can be read either from the terminal or from the PLC program (e.g.: PIDF0,STATUS

→

W110; IF PIDF0,

READY THEN ...).

FTX 507

PL7-3

Program Mode

X-TEL

SYSDIAG

PL7-3

Data Mode

CONTENT PARAM

PROGRAM

DW200

DW202

PV

RSP

FF

PIDF0

ERROR

STATUS

OUTP

PW_O

DW204

! PIDF0,STATUS

→

INTERNAL

CONSTANTS

.

.

.

KP$

.

.

.

OUTRATE$

INTERNAL

DATA

COMMANDS

! SET PIDF0,SP_RSP

! DW102

→

PIDF0,PV_HL

INFORMATION

! IF PIDF0,READY THEN

__________________________________________________________________________________________

5 / 2 4

PIDF OFB 5

__________________________________________________________________________________________

5.1-18 Performance Levels

PIDF OFB memory requirements

5808 words regardless of the number of times it is used

Data Field

208 words each time it is used

PIDF OFB execution time (per cycle)

Constants Field

64 words each time it is used

9.8 ms

PMX 67-40

4.4 ms

PMX 87-40

3.4 ms

PMX 107-40

3 ms

D

__________________________________________________________________________________________

5 / 2 5

__________________________________________________________________________________________

5.2

Setting-up the PIDF OFB

5.2-1 General

Reminders:

Once all of the preliminary (hardware and software) configuration operations have been performed, creating a control loop application requires writing a program corresponding to:

• Measurement acquisition by the sensors,

• PIDF algorithm execution,

• Sending commands to the actuators.

PMX V5 PLC

D

Measurement

Acquisition

Actuator

Control

Process

__________________________________________________________________________________________

5 / 2 6

PIDF OFB 5

__________________________________________________________________________________________

5.2-2 Measurement Acquisition

The 4 or 8 channel TSX AEM analog input modules perform the conversion from electrical input level signal to a 0 - 10000 standard format that must be converted to floating point notation using an SCLF OFB prior to processing by the PIDF OFB.

Eight types of module cover the range of standard applications most often encountered in the acquisition of continuous input level signal:

• TSX AEM 411 4 isolated high level channels (voltage or current input),

• TSX AEM 412 4 isolated low level channels (thermocouple or voltage input),

• TSX AEM 413 4 isolated low level channels (Pt 100 probe or voltage),

• TSX AEM 811 8 isolated high level channels (voltage or current input),

• TSX AEM 821 8 high level high speed channels (voltage or current input),

• TSX AEM 1601 16 non isolated high level channels (voltage input),

• TSX AEM 1602 16 non isolated high level channels (current input),

• TSX AEM 1613 16 non isolated low level channels (Pt 100 probe input).

The choice of an input module depends on the type of input sensors used with it.

D

Using the measurements

How the measurements are used depends on the type of module used. A quick reminder on measurement data acquisition methods is given below. For more information on accessing these measurements, refer to the appropriate user's documentation:

• For TSX AEM 411/412/413 modules:

TSX AEM User's Manual (TSX D43 727), Section 7,

• For TSX AEM 811 modules:

TSX AEM 811 User's Manual (D23 001E), Section 7,

• For TSX AEM 821 modules:

TSX AEM 821 User's Manual (TSX D23 006E), Section 4,

• For TSX AEM 1601/1602 modules:

TSX AEM 1601/1602 User's Manual (TSX DM AEM 16E), Section 4,

• For TSX AEM 1613 modules:

TSX AEM 1613 User's Manual (TSX DM AEM 1613E), Section 4.

__________________________________________________________________________________________

5 / 2 7

__________________________________________________________________________________________

Brief reminders on measurement acquisition

TSX AEM 4xx or TSX AEM 811/821 modules with up to 4 channels:

No specific programming required.

IW4,3

SCLF0 PIDF0

DW60

DW60

PV

RSP

FF

TSX AEM 811 module with more than 4 channels:

Programming:

Master task, run text block: EXCHG TXT2

AEM 811

D

TXT2

W20

Measure. 0

W22

SCLF1

DW62

DW62

PIDF1

PV

RSP

FF

Measure. 7

TSX AEM 821 module with more than 4 channels:

Auxiliary task programming:

! READEXT(I5;W30;W50)

AEM 821

W30

Measure. 0

W34

SCLF2 PIDF2

DW64

DW64

PV

RSP

FF

Measure. 7

__________________________________________________________________________________________

5 / 2 8

PIDF OFB 5

__________________________________________________________________________________________

Coherence with the data output mode

It is up to the user to ensure coherence between the data output mode defined in the TSX

AEM module configuration and the MIN/MAX limits of the SCLF and PIDF OFBs. To do this, it is recommended that the user select:

• Standard 0/10000 range for TSX AEM 411, 811, 821 (in normal mode), TSX AEM

1601 and 1602 modules,

• "User" range for TSX AEM 412, 413 and 1613 modules. This mode provides a 0/10000 measurement range over the temperature range defined by the user.

Using this approach, a standard output is obtained regardless of the module used.

AEM

SCLFi

0/10000 meas. PV

PIDFi

D

Output mode

AEM HL (1): Standard SCLFi,INP_SUP = 10000

AEM LL (2): User SCLFi,INP_INF = 0

SCLFi,OUT_SUP = MAX PHYS

SCLFI,OUT_INF = MIN PHYS

PIDFi,PV_SUP = MAX PHYS

PIDFi,PV_INF = MIN PHYS

Note

If TSX AEM 821 in simplified mode

SCLFi,INP_SUP = 4000

(1) TSX AEM 411/811/821/1601/1602

(2) TSX AEM 412/413/1613

__________________________________________________________________________________________

5 / 2 9

__________________________________________________________________________________________

Examples

1

High level

To acquire a flow measurement in 0/10 V range for 0 to 5.6 m 3 /h.

TSX AEM 411

0/10 V

5.6

PIDFi

0/10000

SCLFi

10000 5.6

0 0.

0.

Standard

D

2 Low level

For a temperature measurement obtained using a Pt 100 probe with an overall range of -220/880

°

C, but using only the 150/350

°

C part of the range.

Pt 100

TSX AEM 413

MAXU = 3500 (*)

SCLFi

10000

0/10000

350.

0 150.

MINU = 1500

User

(*) MAXU and MINU are expressed as integers in 1/10

°

C.

350.

PIDFi

150.

__________________________________________________________________________________________

5 / 3 0

PIDF OFB 5

__________________________________________________________________________________________

5.2-3 PIDF OFB Programming

The PIDF OFB structure lets the user easily place control loop functions in the sequential program and take advantage of all of the features of the PL7-3 programming language to create traditional control loop applications.

The PIDF OFB is programmed like any other standard PL7-3 function block in one of the periodical tasks in the PLC (AUX0 is recommended), in the selected program module.

Parameter assignment (reminders)

• I/O parameters:

The PIDF OFB I/O parameters must be assigned to PL7-3 variables. The PV and

OUTP parameters are always required, all others are optional.

They can be read but not written in Data mode. Any change in assignment must be performed in Program mode.

• Internal data:

Internal data can be read and written:

• From the programming terminal in Data mode,

• By program.

• Internal constants:

The internal constants can be accessed in Program mode via the [CONTENT] dynamic soft key or in Constants mode.

D

Syntax:

EXEC PIDFi(Process Variable;Remote Set Point;Feed-forward=>error bit;status word0;analog output; discrete output).

PIDF OFB execution must not be conditional.

Example 1: Single loop

!

!

!

EXEC SCLF1 (IW4,3 =>)

EXEC PIDF1(SCLF1,OUTP;DW72; => B12;W8;)

EXEC ISCLF1 (PID1,OUTP => OW7,3)

With:

• IW4,3 = TSX AEM module measurement value,

• DW72 = Remote Set Point value,

• B12 = Error bit (optional),

• W8 = Status word 0 (optional),

• OW7,3 = Analog output.

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5 / 3 1

__________________________________________________________________________________________

PARAM CONTENT

Allows access to

I/O parameters

Allows access to internal constants

D

Example 2: Cascade loop control

The cascade is obtained by stringing PIDF OFBs together. Execution of the OFB representing the external loop precedes that of the OFB representing the internal loop.

There are two ways to program a cascade loop:

• Directly, leaving open the action of the preceding block but setting the instructions for the following block:

! EXEC SCLF1 (IW4,3 => DW30)

! EXEC SCLF2 (IW4,4 => DW32)

! EXEC PIDF1 (DW30;; => ;;;)

! EXEC PIDF2 (DW32;PIDF1,OUTP; => ;; DW34;)

! EXEC ISCLF2 (DW34 => OW6,3)

Important, in Debug mode, the open output PIDF1 cannot be displayed in real-time.

• Indirectly, using a variable linked to the action of the preceding block and the set point value of the following block:

! EXEC SCLF1 (IW4,3 => DW30)

! EXEC SCLF2 (IW4,4 => DW32)

! EXEC PIDF1 (DW30;; => ;;DW36;)

! EXEC PIDF2 (DW32; DW36; => ;;DW34;)

! EXEC ISCLF2 (DW34 => OW6,3)

To benefit from automatic cascade loop control, i.e. to ensure a smooth bumpless transition when the loop is "closed", add the following three lines after executing the

PIDF2 OFB:

! PIDF2; SP_RSP -> PIDF1, LINKED

! PIDF2, SP_NORM -> PIDF1, BUMPLESS

! SET PIDF2, COMMAND, D

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5 / 3 2

PIDF OFB 5

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Example 3: Mixed process control (combining PID control and feed-forward action)

The FF parameter in the PIDF OFB can be used to superimpose on the output value calculated by the PID algorithm, a value calculated from an external value to anticipate its variations.

< CALCULATE THE ANTICIPATION VALUE

! IW4,5 - 5000) * W52/100

→

W53

! EXEC SCLF3 (W53

→

DW54)

< EXECUTE THE ALGORITHM

! EXEC SCLF4 (IW4,4 => DW56)

! EXEC PIDF3(DW56;;DW54 => ;;DW58;)

! EXEC ISCLF3 (DW58 => OW6,4)

D

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5 / 3 3

D

__________________________________________________________________________________________

5.2-4 Updating Outputs

The control signal to the process is sent either using TSX ASR analog output module

(continuous output from the PIDF OFB) or using TSX DST discrete output modules

(width modulation output from the PIDF OFB).

If the analog output solution is selected, the user can select one of the modules listed below:

• TSX ASR 200: 2 isolated channels, 12 bit resolution (bipolar voltage or current),

• TSX ASR 401: 4 isolated channels, 11 bit resolution + sign (voltage

±

10 V),

• TSX ASR 402: 4 isolated channels, 12 bit resolution (4 - 20 mA current range with power supply),

• TSX ASR 403: 4 isolated channels, 12 bit resolution (4 - 20 mA, current range and external power supply),

• TSX AST 200: 2 channels, unipolar or current operation, isolated from the PLC bus,

8 bit resolution.

The choice of an input module depends on the type of input sensors used with it.

For more information on using these modules, refer to the appropriate TSX AST/ASR

Analog Output Modules User's Manual (TSX D23 007 E), Sections 3 and 4.

Brief reminders on analog output updating

TSX ASR 200 module

Programming:

PIDF3 ISCLF3

OUTP

DW60

DW60

OW5,0

TSX ASR 200

ISCLF3,OUT_SUP = 4000

ISCLF3,OUT_INF = 0

ISCLF3,INP_SUP = 1000

ISCLF3,INP_INF = 0

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5 / 3 4

PIDF OFB 5

__________________________________________________________________________________________

TSX ASR 4.. module

Channel 0 programming:

< ASR 401 configured for percentage of FSR

H'00F0'

→

OW5,1

PIDF3 ISCLF3 TSX ASR 4..

OW5,3

OUTP

DW60

DW60

ISCLF3,INP_SUP = 100

ISCLF3,INP_INF = 0

ISCLF3,OUT_SUP = 10000

ISCLF3,OUT_INF = 0

TSX AST 200 module

Programming:

PIDF3

OUTP

DW60

DW60

ISCLF3

W50

TSX AST 200

D

ISCLF3,INP_SUP = 100

ISCLF3,INP_INF = 0

ISCLF3,OUT_SUP = 250

ISCLF3,OUT_INF = 0

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5 / 3 5

__________________________________________________________________________________________

5.2-5 Debug - Adjust

Adjusting the set-up of a process control loop is normally performed using a manmachine interface terminal (via the TREND and TUNE screens). For more information, refer to Divider F.

All of the parameters of the PIDF OFB can also be displayed in Data modes.

Display screen example:

D

The ALT O key combination displays a list of the internal parameters of the OFBs declared in the configuration. In the case of the PIDF OFB, this key can be used as an on-line help function:

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5 / 3 6

PIDF OFB 5

__________________________________________________________________________________________

5.2-6 Suggestions for Use

To obtain best control loop results, always select the:

• Measurement acquisition rate for TSX AEM modules,

• Sampling period (OFB parameter T_OFB) compatible with the process time constant.

Measurement acquisition rate

The acquisition time is 100 ms per channel except for TSX AEM 821 modules that take

6 ms + 2.5 ms per channel and the TSX AEM 1613 module that takes 260 ms + 65 ms per channel).

Determining the T_OFB parameter

The T_OFB parameter contains the PIDF OFB sampling period value.

The default value (0.3 s) covers most of the possible applications where the process has a response time of a few seconds. If a fast process must be controlled (time constant of around a second), the value of T_OFB may be reduced. If the process is very slow, the T_OFB parameter can be increased.

D

Reminder: T_OFB is automatically adjusted to the closest possible multiple of the period of the task in which the OFB is executed.

The value of T_OFB must be selected according to the process allowing for the following rule:

T_OFB

≤

fastest time constant / 10

Example:

For a process with a time constant of 5 seconds, T_OFB must not exceed 500 ms.

If the OFB is in a 300 ms auxiliary task and the user imposes parameter T_OFB at 1 second, the OFB automatically calculates the new T_OFB value as 0.9 s (the multiple of 0.3 s that is closest to 1 second).

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5 / 3 7

D

__________________________________________________________________________________________

Selecting the task to execute process control in

It is up to the user to select the task. It is recommended that the AUX0 task be reserved for such applications.

Important

The PIDF OFB works from measurement values provided by the TSX AEM modules.

However, when the PLC is powered-up the modules perform a self-tests sequence that lasts a few seconds, during which time the measurement values are not significant.

It is up to the user to eliminate the risk of using these erroneous measurement values and only transfer the measurement value from the module to the control loop when it is operational:

AEM ASR

SCLF0 PIDF0 ISCLF0

PV

Measure. OK

OUT

This is programmed as follows:

! IF AEMLD0,READY THEN IW4,3 -> W70

! EXEC SCLF0(W70 => DW120)

! EXEC PIDF0(DW120;; => ;;DW122;)

! EXEC ISCLF0(DW122 => OW6,3)

To avoid running the process control loop with an invalid measurement value, condition measurement value transfer to the module being operational, OK, running and the measurement value being correct. This is programmed, for example, for channel 0 of a

TSX AEM 41x/811/821 module as follows:

! IF AEMLD0,READY • NOT I4,3 • IW2,0,C • IW2,1,8 THEN ...

Therefore if the process variable is equal to the set point value before a power break or an error, the output from the PIDF corrector will remain constant.

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5 / 3 8

SCLF OFB 6

6.1

General

The SCLF OFB converts an integer analog value (usually obtained from a TSX AEM xxx module) into a floating point value (usually into physical unit values for use by the PIDF

OFB).

The INP input value is in the range INP_INF and INP_SUP.

The output value is in the range OUT_INF and OUT_SUP.

OUTP (floating)

INP (inte-

Filtering ger)

The analog value can be filtered, once converted into a floating point notation.

INP

Conversion

I

→

F

INPF

Filtering

INFF

Scaling

OUTP

A low pass, first order filter with the following equation is used:

INFF

(n)

= FC * INFF

(n-1)

+ (1-FC) * INPF

(n) with: and

INFF filtered value at instant n

FC filtering factor between 0.and 1. (0. by default)

INPF

(n)

raw input value at instant n

This formula corresponds to a first order filter with a time constant:

τ

Task Period

= -

Ln (FC)

For example for a task with a period of 300 ms and a filtering factor of 0.9, the equivalent time constant is 2.8 s.

D

6 / 1

6.2

SCLF OFB Presentation

Input parameter

INP : word

Internal data

Internal constants

INHIB : bit

COMMAND : word

INP_SIM : word

FC : dwor

INP_SUP : word

OUT_SUP : dwor

STATCALC : word

FC$ : dwor

INP_SUP$ : dwor

OUT_SUP$ : dwor

SCLF

ERROR : bit

STATUS : word

OUTP : dwor

INP_INF : word

OUT_INF : dwor

INP_INF$ : dwor

OUT_INF$ : dwor

Output parameters

_______________________________________________________________________

6.3

Parameter Description

D

Input parameter

INP

Type

Word

Access

(1)

Description

Integer analog value to convert into floating point notation. Its value is between [INP_INF; INP_SUP].

By default INP = INP_INF

Output parameters

OUTP

Type

Floating

ERROR

STATUS

Bit

Word

Access

(1)

(1)

(1)

Description

Analog value converted into floating point notation.

Its value is between [OUT_INF; OUT_SUP].

This bit goes to 1 when an error is detected. The output from the OFB contains an incorrect value.

Reading the STATUS parameter indicates the type

OFB operation report. Each bit in this word indicates a type of error and is only reset to 0 when the cause of the error has ended.

The content of this word is given in detail in the next section.

(1) Read by program and in adjust (data mode, etc.).

6 / 2

SCLF OFB 6

Internal data

INHIB

COMMAND

INP_SIM

FC

INP_INF

INP_SUP

OUT_INF

OUT_SUP

STATCALC

Type

Bit

Word

Word

Floating

Word

Word

Access

(3)

Description

Set to 1, this bit inhibits the OFB alarms by forcing the

ERROR bit to 0.

(3)

(2)

(3)

(2)

When bit 0 of this word is set to 1, the INP input is

Forced value of INP used when setting-up the process control application. INP_SIM is used by the

OFB in place of INP, when bit 0 of SCLF,COMMAND is at 1.

Filtering factor of INP. Its value is in the range

[0.0; +1.0] (4)

Lower limit of the range used to express INP.

Its value is in the range [-32768; +32767] (4).

(2) Higher limit of the range used to express INP.

Its value is in the range [-32768; +32767] (4).

Lower limit of the range used to express OUTP (4).

D

Floating

Floating

Word

(2)

(2)

(1)

Higher limit of the range used to express OUTP (4).

Calculation report. This word contains the result of the operations in floating point format.

(1) Read by program and in adjust (data mode, etc.),

(2) Read by program and in adjust (data mode, etc.),

Written in adjust (data mode, etc.).

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.).

(4) Fallback value defined by the internal constant with the same name followed by the character $.

6 / 3

6.4

Status Word

If an error occurs or in the event of incorrect execution (ERROR = 1), this word provides a report on OFB operation. Each bit corresponds to an error and it is only reset to 0 when the cause of the error is removed.

Bit 0 = 1 : Can only be run on a PMX

Bit 1 = 1 : Calculation error

Bit 2 = 1 : Null input scale

Bit 3 = 1 : Null output scale

Bit 4 = 1 : INP_SUP exceeded

Bit 5 = 1 : INP_INF exceeded

Bit15 = 1 : Incoherent input parameter (non floating point data)

D

___________________________________________________________________________

6.5

Performance Levels

Memory requirements

1264 words regardless how often it is used

Data Field

48 words each usage

Constants Field

16 words each usage

SCLF OFB execution time (per cycle)

1.8 ms

PMX 67-40

0.8 ms

PMX 87-40

0.6 ms

PMX 107-40

0.5 ms

6 / 4

SCLF OFB 6

6.6

Example of Use

Conversion of a measurement value provided by a TSX AEM module for use by a PIDF

OFB.

AEM

SCLF PIDF

INP OUTP PV

Standard mode

INP_SUP = 10000

INP_INF = 0

OUT_SUP = PIDFi,PV_SUP

OUT_INF = PIDFi,PV_INF

D

6 / 5

D

6 / 6

ISCLF OFB 7

7.1

General

The ISCLF OFB converts a floating point analog value (from the process control algorithm) into an integer value (usually intended for use by an analog output module).

The INP input value is in the range INP_INF to INP_SUP.

The output value is in the range OUT_INF to OUT_SUP.

OUTP (integer)

OUTP

INP (floating)

INP

______________________________________________________________________

7.2

ISCLF OFB Presentation

D

ISCLF

Input parameter

INP : word ERROR : bit

STATUS : word

OUTP : dwor

Output parameters

Internal data

Internal constants

INHIB : bit

COMMAND : word

INP_SIM : word

INP_SUP : dwor

OUT_SUP : word

STATCALC : word

INP_SUP$ : dwor

OUT_SUP$ : word

INP_INF : dwor

OUT_INF : word

INP_INF$ : dwor

OUT_INF$ : word

7 / 1

7.3

Parameter Description

Input parameters

INP

Type

Word

Access

(1)

Description

A floating point analog value to convert to an integer.

Its value is in the range [INP_INF; INP_SUP].

By default INP = INP_INF

D

Output parameters

Type

OUTP Floating

ERROR

STATUS

Bit

Word

Access

(1)

(1)

(1)

Description

An analog value converted to an integer. Its value is in the range [OUT_INF; OUT_SUP].

This bit changes to 1 when an error is detected. The output from the OFB contains an incorrect value.

Reading the STATUS parameter will let the user

A status report on the operation of the OFB. Each bit in this word indicates a type of error and it is only reset to 0 when the cause of the error has disappeared. The content of this word is detailed in the next sub-section.

(1) Read by program and in adjust (data mode, etc.).

7 / 2

ISCLF OFB 7

Internal data

INHIB

COMMAND

INP_SIM

INP_INF

INP_SUP

OUT_INF

OUT_SUP

STATCALC

Type

Bit

Word

Floating

Floating

Word

Floating

Floating

Word

Access

(3)

(3)

(2)

Description

Set to 1, this bit inhibits the OFB alarms by forcing the

ERROR bit to 0.

When bit 0 of this word is set to 1, the INP input is

Forced value of INP used when setting-up the process control application. INP_SIM is used by the

OFB in place of INP, when bit 0 of SCLF,COMMAND is at 1.

Lower limit of the range used to express INP (4).

(2)

(2)

(2)

(2)

(1)

Higher limit of the range used to express INP (4).

Lower limit of the range used to express OUTP.

Its value is in the range [-32768; +32767] (4).

Higher limit of the range used to express OUTP.

Its value is in the range [-32768; +32767] (4).

Calculation report. This word contains the result of the operations in floating point format.

D

(1) Read by program and in adjust (data mode, etc.),

(2) Read by program and in adjust (data mode, etc.),

Written in adjust (data mode, etc.).

(3) Read by program and in adjust (data mode, etc.),

Written by program and in adjust (data mode, etc.).

(4) Fallback value defined by the internal constant with the same name followed by the character $.

7 / 3

7.4

Status Word

If an error occurs or in the event of incorrect execution (ERROR = 1), this word provides a report on OFB operation. Each bit corresponds to an error and it is only reset to 0 when the cause of the error is removed.

Bit 0 = 1 : Can only be run on a PMX

Bit 1 = 1 : Calculation error

Bit 2 = 1 : Null input scale

Bit 3 = 1 : Null output scale

Bit 4 = 1 : INP_SUP exceeded

Bit 5 = 1 : INP_INF exceeded

Bit15 = 1 : Incoherent input parameter (non floating point data)

D

___________________________________________________________________________

7.5

Performance Levels

Memory requirements

1048 words regardless how often it is used

Data Field

40 words each usage

Constants Field

16 words each usage

ISCLF OFB execution time (per cycle)

1.5 ms

PMX 67-40

0.6 ms

PMX 87-40

0.5 ms

PMX 107-40

0.4 ms

7 / 4

ISCLF OFB 7

7.6

Example of Use

Conversion of the output of the PIDF OFB for transfer to a TSX ASR module.

ASR 401

PIDF ISCLF

OUTP INP OUTP

INP_SUP = 100.

INP_INF = 0.

OUT_SUP = 10000

OUT_INF = 0

D

7 / 5

D

7 / 6

SAVE OFB 8

8.1

General

The SAVE OFB is used, once set-up is performed, to save process control OFB parameters: transferring the contents of internal data to the internal constants. This way, after a power break, process control OFBs will restart with the values defined during the set-up phase and not using the default values.

Although implicitly programmed, this OFB must be configured in PL7-3 (configuration of one and only one OFB).

It is run after the user selects the SAVE dynamic function key from the TREND adjustment screen (refer to the description of the Man-Machine Interface).

TREND SCREEN

TUNE SCREEN

Internal data

•

•

•

KP

TI

TD

•

OUTRATE

SAVE

OFB

Internal constants

KP$

TI$

TD$

•

•

•

•

OUTRATE$ Cold

restart

This operation is required to ensure that in the event of a cold restart of the PLC, the PIDF

OFB is run using the last adjustment values selected.

D

8 / 1

D

8 / 2

Appendix 9

__________________________________________________________________________________________

9.1

PID Parameter Set-up Method

There are a number of ways to set-up and adjust the parameters of a PID control loop.

In this sub-section the Ziegler and Nichols method is described with two variations:

• Closed loop adjustment,

• Open loop adjustment.

Closed loop adjustment

The principle requires the use of proportional control (I = 0, D = 0) to excite the process by increasing the gain until it starts to oscillate after applying a step to the instruction value used by the PID corrector.

Once this is achieved, simply increase the value of the critical gain (Kpc) that caused the undamped oscillation and the oscillation period (Tc) to deduce the values required for an optimal setting of the regulation system.

Measure

D

Tc t

Depending on the type of process control used (PID or Pi), the correction factors are set to the values listed below:

Kp Ti Td

PID

Kpc

1.7

Tc

2

Tc

8

PI

Kpc

2.22

Tc

2

With:

• Kp = Proportional gain,

• Ti = Integral time,

• Td = Derivative time.

This type of adjustment ensures a highly dynamic control that may result in range overrun when a change of set point is made. If this occurs, reduce the gain value until the system reacts as required.

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9 / 1

__________________________________________________________________________________________

Open loop adjustment

With the process control system in manual mode, apply an increment to the output and consider the initial reaction of the process to that of a pure delay integrator.

Output

∆

S t

Integrator Process response

Measure

D

∆

M =

∆

S

Tu Tg t

The intersection of the line representing the integrator and the time axis determines the time value Tu.

The time value Tg is then defined as the time required by the controlled variable

(measurement) to vary by the same amplitude (as a % of the full scale range) as the output from the process controller.

Depending on the type of process control used (PID or Pi), the correction factors are set to the values listed below:

Kp Ti Td

PID

≤

1.2 Tg/Tu

≥

2 * Tu 0.5 * Tu

PI

≤

0.9 Tg/Tu 3.3 * Tu

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9 / 2

Appendix 9

__________________________________________________________________________________________

This type of adjustment ensures a highly dynamic control that may result in range overrun when a change of set point is made. If this occurs, reduce the gain value until the system reacts as required.

The benefit from using this method come from it requiring no hypothese about the type or order of the process to control. It applies equally to stable or true integrator processes.

It is especially useful when using slow processes (such as those found in glass manufacturing applications) as the user need only have the start of the answer in order to set the values of factors Kp, Ti and Td.

D

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9 / 3

D

__________________________________________________________________________________________

9.2

PID Parameter Influence and Effects

Proportional Action

Proportional action lets the user affect the response time of the process. The higher the gain, the faster the response time, the lower the static error (in purely proportional terms), but the more the stability is reduced.

Therefore a compromise must be found between speed and stability.

Influence of proportional action on the response of the process to a step:

% Kp too high

Kp correct

∆ c

Kp too low t

Note

These responses are those of an unstable process. For a stable process, the static error decreases when Kp increases.

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9 / 4

Appendix 9

__________________________________________________________________________________________

Integral Action

The integral action lets the user cancel the static error (difference (error) between the measurement and instruction values). The higher the integral action (Ti reduced), the faster the response but the lower the stability.

Again a compromise must be found between speed and stability.

Influence of integral action on the response of the process to a step:

% Ti too low

Ti correct

∆ c

Ti too high

D t

Reminder: Ti lower implies a higher integral action.

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9 / 5

D

__________________________________________________________________________________________

Derivative Action

The derivative action anticipates process response. It adds a term to the equation that takes into account the speed of error variation. This is used to anticipate by accelerating the response of the process when the error increases and slowing the response when the error diminishes. The higher the derivative action (Td high), the faster the response.

Again a compromise must be found between speed and stability.

Influence of derivative action on process response to a step:

%

Td too low

∆ c

Td correct

Td too high t

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9 / 6

Appendix 9

__________________________________________________________________________________________

9.3

PID Process Control Limits

If the process is compared with a pure delay first order of a transfer function:

Ke

-

τ p

H (p) =

1 +

θ p

With:

•

τ

= Model delay,

•

θ

= Model time constant,

The performance level of the regulation system are a function of the ratio

θ

/

τ

.

PID process control is perfectly suited to the following condition:

2

≤

θ

τ

≤

20

For

θ

/

τ

< 2, i.e. fast process control loops (

θ

low) or for control systems with a high delay

(

τ

high) PID control loops are unsuitable, more sophisticated algorithms are required.

For

θ

/

τ

> 20, discrete control is adequate.

D

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9 / 7

D

__________________________________________________________________________________________

__________________________________________________________________________________________

9 / 8

________________________________________________________

Man-Machine Interface Design E

___________________________________________________________________________

Section Page

__________________________________________________________________________________________________

Configuring the Man-Machine Interface

1.1

Program Configuration Methodology

1.2

Selecting the Module to Program

1.3

Declaring the Regulation Option in PL7-MMI 37

1.4

Configuring the Regulation Task in PL7-MMI 37

1/1

1/2

1/3

1/4

__________________________________________________________________________________________________

Creating a Man-Machine Interface Application

2.1

Application Creation Methodology

2.2

Creating Screen Backgrounds (Static Screens)

2.2-1 Introduction

2.2-2 Ready-made Symbols

2.2-3 Creating the Menu Screen

2.2-4 Creating Control Screens

2.2-5 Exiting the Graphic Editor

2/1

2/2

2/2

2/2

2/4

2/5

2/6

2.3

Defining Animations

2.3-1 Introduction

2.3-2 Animating a Symbol

2.3-3 Animating a Function Key

2.3-4 Animating the Alarm Banner Line

2.3-5 Modifying the Value Display Format

2.3-6 Modifying the Set Point Increment Value

2.3-7 Testing the Animations

2.3-8 Input Selection for Symbols and Symbol Elements

2.3-9 Modifying an Animation in a Multiplexed

Selection Screen

2.3-10 Saving Animations and Exiting the

Animation Editor

2.3-11 Animation Corresponding to an SCL OFB

2.3-12 Animation Corresponding to an ISCL OFB

2/7

2/7

2/7

2/10

2/11

2/12

2/14

2/15

2/16

2/18

2/18

2/19

2/20

E

The user must follow the chronological order when performing the various operations required to create a process control man-machine interface application.

Failure to follow the chronological order or omitting a required operation will cause errors in the application.

___________________________________________________________________________

E / 1

E

________________________________________________________

Man-Machine Interface Design E

___________________________________________________________________________

Creating a Man-Machine Interface Application

2.4

Defining the Process Control Password

2.5

Generating Executable Files and Selecting Tasks

2.6

Transferring Files to the Module

2.7

Appendix

2.7-1 Process Control Front Panel Symbol Animation

2.7-2 Application Comprising More Than 32 PID/20 PIDF

Controllers

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Configuring the Man-Machine Interface 1

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1.1

Program Configuration Methodology

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To correctly configure the man-machine interface program, the following requirements must be met:

• First, ensure that the man-machine interface program was installed on the station after the installation of PL7-3,

• Second, ensure that the following operations are performed in the sequence listed below.

1 Run PL7-MMI 37 by double clicking on the corresponding icon,

2

Select the module that will execute the application: PCM_1 to PCM_4 (refer to Subsection 1.2),

3 Declare the REGULATION option in PL7-MMI 37 (refer to Sub-section 1.3),

4

Configure the REGULATION option in PL7-MMI 37, to generate the symbol data base that will be transferred to the cartridge (refer to Sub-section 1.4),

5 Quit the Task Manager. The system is now ready for the user to create a manmachine interface REGULATION application.

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1.2

Selecting the Module to Program

The module is selected from the dialog box shown below. It is displayed automatically when the MMI icon is selected. The dialog box lets the user define module characteristics.

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• Select a module to program from the four available (PCM_1 to PCM_4). Each module has its own dedicated MMI OFB. The user must therefore declare in the PL7-3 configuration, as many MMI OFBs as there are modules (e.g. if module PCM_3 is selected, 3 MMI OFBs must be declared in the PL7-3 configuration),

• Select the language for the keyboard connected to the TSX PCM 37 station. For the

Control Man-Machine Interface keyboard TPMX KB 1, select United States,

• Graphic image resolution: 640 x 350 pixels,

• Multi-console. Select this box if multiple consoles are chained together,

• Physical address of the man-machine interface in the PLC. This address is the same as the one declared when the configuration was defined in XTEL-CONF,

• For module versions V1.4 and higher, configure the screen saver to take effect after a specified period of inactivity, using the Delay (in minutes) field.

• Description of the control man-machine interface application (up to 80 characters in length). The description comments are optional.

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Configuring the Man-Machine Interface 1

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1.3

Declaring the Regulation Option in PL7-MMI 37

This operation is required to identify the Regulation function as a task recognized by the

PL7-MMI 37 design program. To declare the function:

• Pulldown the Utilities menu from the action bar in the PL7-MMI 37 primary window and select Add options. This will display a list of available options:

• Select two lines REGULATION1 and REGULATION2. Once selected, the two lines are highlighted in reverse video,

• Validate the selection made. This starts installation of the option in PL7-MMI 37 and starts the transfer to XTEL-SDBASE of the 32 PID and 20 PIDF symbols. A dialog box lets the user follow the progress of these operations,

• When a new dialog box tells the user that installation is complete, press <Enter>, then quit PL7-MMI 37 by selecting the Exit menu.

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1.4

Configuring the Regulation Task in PL7-MMI 37

This operation lets the user generate the symbol data base that will be transferred to the man-machine interface module for use by the Regulation function. The following procedure should be followed:

• Pulldown the Create menu from the action bar of the PL7-MMI 37 primary window and select Configuration Manager CM. The following screen is displayed:

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• Select REGULATION by double clicking on the corresponding line. This displays the

Regulation screen.

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Configuring the Man-Machine Interface 1

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• Pulldown the Utilities menu and select Import. This displays a dialog box that reminds the user which application directory is selected. This is the directory that

Regulation task specific symbols will be imported into,

• Validate the action to start importing files and fill-in the list of variables,

Warning

Symbols must only be imported once.

• Use the Exit, menu to exit the Regulation function and then the Configuration Manager and return to the PL7-MMI 37 primary window. The user can now create a Regulation function man-machine interface application (refer to Section 2).

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Creating a Man-Machine Interface Application 2

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2.1

Application Creation Methodology

A Regulation function, man-machine interface application comprises a number of animated screens that can be accessed by the operator of the automation application used with process control applications. The screens listed below are required for all applications and must always be present:

• MENU: This screen is required for all applications, as it is the first one displayed. It lets the user access the Control and Adjust screens,

• CONTROL: These screens provide the user with a real-time view of the application and allow the user to act on them:

- Display process control unit front panels,

- Display alarm banner lines, generated by the Alarms function (optional),

- Modify process control parameters,

- Access to other screens,

• TREND: This screen displays trending curves for each selected process controller. It lets the user access process controller parameters for adjusting the process control loop. This screen was designed by Telemecanique and should never be

changed during the application design phase,

• TUNE: This screen displays the parameter settings for the selected process controller. Like the TREND screen, this screen was designed by Telemecanique and

should never be changed during the application design phase.

Creating a process control man-machine interface application comprises creating the

MENU screen and (one or more) process control screens. Once this is done, the files must be transferred to the TSX PCM 37 module. This operation requires seven consecutive phases (for further information, refer to the PL7-MMI 37 documentation,

TXT DM PL7 M37 V5E):

1 Run PL7-MMI 37, by double clicking on its icon. This displays the Module Selection screen. Select the module that will be used to run the application: PCM_1 to PCM_4

(refer to Sub-Section 1.2),

2 Create screen backgrounds (or static pictures) for the MENU and CONTROL screens (refer to Sub-Section 2.2),

3 Define the animation for the created screen backgrounds (refer to Sub-Section 2.3),

4

Define the Control (Regulation) password,

5 Generate files for transfer to the man-machine interface module (refer to Sub-

Section 2.5),

6 Transfer the files to the man-machine interface module (refer to Sub-Section 2.6),

7 Document the application (optional).

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2.2

Creating Screen Backgrounds (Static Screens)

2.2-1 Introduction

The Graphic Editor GED, accessed via Graphics Editor GED in the Create menu lets the user draw color screen backgrounds. In addition to the features provided by the editor (refer to Divider A, Section 2 of the PL7-MMI 37 documentation), three ready made drawn and animated screens are provided:

• FAV for the front panel of a PID controller, using a PID OFB,

• FAV1 for the front panel of a PID controller, using a PIDF OFB,

• PFAV a small version of the front panel of a process controller, using a PID OFB,

• PFAV1 a small version of the front panel of a process controller, using a PIDF OFB,

• TOUCHES and TOUCHES1 that provide all of the keys required for controlling an application.

Attention

The FAV, FAV1, PFAV, PFAV1, TOUCHES and TOUCHES1 symbols should not be modified.

Due to the multiplexing used, a control screen can only comprise front panels of the same type: FAV or FAV1. In addition, it is necessary to use the

TOUCHES symbol with FAV front panels and the TOUCHES1 front panel with

FAV front panels.

As the small versions of the front panels are not multiplexed, it is possible to use PFAV and PFAV1 symbols in the same screen.

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2.2-2 Ready-made Symbols

Process Controller Front Panel: FAV or FAV1

1

Control loop name,

2 Process Variable bargraph,

3 Instruction bargraph,

4 Output level bargraph,

5

Type of physical units,

6 Instruction status: LOCal or REMote,

7 Process controller operating mode:

MANual or AUTomatic,

8 Process Variable value in physical units,

9 Instruction value in physical units,

&

Output value as a percentage,

Measurement scale range.

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Creating a Man-Machine Interface Application 2

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Small process controller front panel: PFAV or PFAV1

1 Control loop name,

2 Process Variable bargraph,

3 Set Point bargraph,

4 Output level bargraph,

5 Instruction status: LOCal or REMote,

6 Process controller operating mode:

MANual or AUTomatic.

Function keys required for application control: TOUCHES or TOUCHES1

1 S1 ALARM

2

S2 ALACK

3 S3 MUTE

4 S4 TREND

5

S5

6 S6

7 S7 L/R

8 S8 M/A

9

S9 SP

& S10 OUT

S11 -

"

S12 +

: Calls the Alarms task,

: Remote error acknowledgment,

: Warning buzzer control linked to alarms,

: Calls the adjustment view,

: Not used,

: Not used,

: Selects Set Point type field for the currently selected process

controller and modifies its value (LOC or REM),

: Selects Operating Mode field for the currently selected process

controller and modifies its value (MAN or AUT),

: Selects Set Point field for the currently selected process controller,

: Selects Output field for the currently selected process controller,

: Decrements the value of the selected field (Set Point or Output),

: Increments the value of the selected field (Set Point or Output).

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2.2-3 Creating the Menu Screen

This screen is required in all applications and must let the user access the control and adjust screens. The graphic design of this screen and its wording are left to the application designer to define, within the limits of the features supported by the Graphics

Editor GED. The procedure described below is an example showing how a Menu screen can look:

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The Sub-section numbers in brackets refer to Divider A of the User's Manual describing the Graphics Editor GED for PL7-MMI 37 (TXT DM PL7 M37 V5E).

1 Define the screen background color. To do this:

• Select the background color ( Sub-Section 2.22),

• Replace the background color with the selected color ( Sub-Section 2.4).

2

Draw the graphic objects: Two control buttons, the title window, etc. ( Sub-Sections

2.7 and 2.17).

3

Define the color of the graphic objects drawn ( Sub-Section 2.11).

4 Define and place the text ( Sub-Section 2.9).

5 Save the Menu screen ( Sub-Section 2.6).

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Creating a Man-Machine Interface Application 2

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2.2-4 Creating the Control Screens

This type of screen must always be created as it is absolutely necessary. It is only possible to adjust process control loops where an FAV or FAV1 symbol has been drawn, animated and multiplexed.

This screen uses both ready made predefined symbols previously described and graphic objects that are created by the designer.

The predefined symbols in the symbols library (FAV, FAV1, PFAV, PFAV1, TOUCHES and TOUCHES1) must never be modified (except for the modifications described in

Sub-sections 2.3-5 and 2.3-6). The drawings used for other graphic objects and the positioning on-screen of all objects (including symbols) is up to the application designer.

An application control screen must comprise the following elements:

1 The TOUCHES symbol that displays the commands required for PID application control (using FAV) or the TOUCHES1 symbol that displays the commands required for PIDF application control (using FAV1),

2 One or more FAV or FAV1 symbols that display the status of the process control loops.

It is only possible to display a maximum of four FAV or FAV1 symbols per screen. If the number of loops to display exceeds four (up to a maximum of 32 PID and/or 20

PIDF control loops), it is necessary to create more than one control screens. A single

control screen can only contain one type of symbol: FAV or FAV1,

3 A key that returns the user to the Menu screen (or to the previous screen),

4 A field required for multiplexing the various process control front panels. In operation, this screen is used for local entry of Set Point and Process Variable parameters,

5 An optional field, for displaying a copy of the Alarm task banner line. So that all alarm information can be displayed in normal operation, this field should cover the entire width of the screen.

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3

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The Sub-section numbers in brackets refer to Divider A of the User's Manual describing the Graphics Editor GED for PL7-MMI 37 (TXT DM PL7 M37 V5E).

1

Define the screen background color. To do this:

• Select the background color ( Sub-Section 2.22),

• Replace the background color with the selected color ( Sub-Section 2.4),

2 Retrieve the TOUCHES or TOUCHES1 symbol ( Sub-Section 2.10),

3 Retrieve the FAV or FAV1 symbol ( Sub-Section 2.10). Repeat this operation as many times as there are front panels to draw.

Attention:

The activation of symbols in operation will take place in the order in which they were created.

If the ERASE or SYMBOL (COPY, REPLACE, OVERLAY, etc.) functions are used to modify the location of the symbols, the Animation Editor must be used to delete all references to symbols that no longer exist graphically. To perform this operation, use the Cancel action in the Library menu in the Animation

Editor ANT.

4 Draw the other graphic objects: One control button, the multiplexing field and the alarm banner line ( Sub-Sections 2.7 and 2.17),

5

Define the color of the graphic objects drawn in step

4

( Sub-Section 2.11),

6 Define and place the text ( Sub-Section 2.9) for the graphic objects drawn in step 4

( Sub-Section 2.9),

7

Save the screen, e.g. OVEN_4 ( Sub-Section 2.6).

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2.2-5 Exiting the Graphic Editor

This operation uses the EXIT action ( refer to Sub-Section 2.4).

Attention

This operation does not automatically save the generated screens.

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Creating a Man-Machine Interface Application 2

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2.3

Defining Animations

2.3-1 Introduction

The Animation Editor ANT, is accessed by selecting Animation Editor ANT in the

Create menu. It lets the user define animation on a static screen that has been drawn previously under GED. Since animation is attached to a static screen, the first action is to open the corresponding screen. To do this pull down the File menu in the Animation

Editor ANT and select the Open action. Doing this displays a dialog box that lists all of the files to animate. Select the file to open, e.g. OVEN_4 or MENU and validate the selection made.

Note

If the VALUE internal data in the ISCL OFB is used, it must be declared only in write.

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2.3-2 Animating a Symbol

The FAV, FAV1, PFAV, PFAV1, TOUCHES or TOUCHES1 symbols are part of a library of symbols, but they are not part of the current application. To include them, follow the procedure below:

FAV, FAV1, PFAV or PFAV1 Symbols

1 Pull down the Library menu and select Use. The next dialog box that lists the symbols available for the currently displayed screen will be displayed:

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2 Select the symbol to animate: e.g. FAV, then validate the selection. A message is displayed to remind the user of the functions of the buttons and the mouse:

• The right mouse button selects the next symbol when there are a number of symbols of the same type in the screen (e.g. more than one FAV symbols),

• The left mouse button lets the use define the animation to use for the selected symbol.

Click on the OK button to delete the dialog box. The first symbol of the selected type is framed with a dotted line.

3 Move the dotted line until it surrounds the symbol to animate by clicking on the right mouse button.

4 Start the definition of the animations required for the selected symbol by clicking on the left mouse button. The following dialog box is displayed:

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5 Define the $ character, i.e. the number of the PID program that is assigned to the selected front panel. Validate the entries made. Once this is done, the user can define the animation required for the symbol. Up to 32 FAV and/or 20 FAV1 symbols can be used in the application. Each FAV symbol is assigned to a PID OFB and each

FAV1 symbol is assigned to a PIDF OFB, selected from those defined in the PL7-3 configuration.

6 Once animations are defined for the first FAV symbol, repeat steps 1 to 5 for each of the other symbols of the same type.

Note

If two $ symbols are assigned to the same process controller front panel, multiplexing is impossible.

The user must then delete all existing animations (using Edit/Delete), then redefine the screen animation.

For more information on FAV, FAV1, PFAV and PFAV1 symbol animation, refer to the Appendix,

Sub-section 2.7-2.

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Creating a Man-Machine Interface Application 2

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TOUCHES or TOUCHES1 Symbol

1

Pull down the Library menu and select Use. The complete list of symbols available is displayed.

2 Select a symbol to animate, in this case TOUCHES, then validate the selection made. Read the message reminding the user of the function of the mouse button and click on OK. The TOUCHES symbol is displayed surrounded by a dotted line.

3 Start the procedure to define animations for the selected TOUCHES symbol by clicking on the left mouse button.

Note

Use of the Library/Create or Library/Delete action is not allowed when using predefined symbols:

FAV, FAV1, PFAV, PFAV1, TOUCHES or TOUCHES1.

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2.3-3 Animating a Function Key

This type of animation lets the user assign a change of screen to a keyboard function key. The assignment procedure is as follows:

1 Select the graphic object to animate by positioning the cursor on it and clicking on the left mouse button. The selected object is displayed surrounded by four selection points.

2 Pull down the Animate menu and select Function Key.... The following dialog box is displayed:

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3 Enter the Variable field: DISPLAY. This predefined variable lets the user select the current screen.

4

Enter the Value field: MENU or OVEN_4. This field gives the name of the screen which is assigned to the DISPLAY variable and thereby becomes the current screen.

5

Define the action assigned to the selected keyboard function key: SET. This action assigns the screen defined by the Value screen to the variable defined in the Variable field.

6 Define the keyboard key assigned to the SET action: F1 or F2.

7 Validate the selections and entries made.

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Creating a Man-Machine Interface Application 2

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2.3-4 Animating the Alarm Banner Line

Animating the alarm banner line is done by assigning the ALARMS task alarm banner line to the field drawn using GED. Proceed as follows:

1 Select a graphic object to animate by positioning the cursor on it and clicking on it with the left mouse button. The object will remain displayed with four selection points around it.

Attention

The position of the cursor when the object is selected is that of the lower left

corner of the first character of the alarm message.

2 Pulldown the Animate menu and select Output Text.... The following dialog box is displayed:

3 Type the name of the variable ALBANNER in the appropriate field. This predefined variable lets the user assign the ALARMS task alarm banner to the selected graphics field.

4 Select the background color. The selected color must be the same as that of the banner drawn in GED.

5 Select the character color. The message displayed by the alarm banner line will be displayed in this color.

6

Validate the selections made.

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2.3-5 Modifying the Value Display Format

Each process control front panel display shows the process variable, set point and output values of the corresponding PID. A default display format is used to display this information:

• 5 characters (xxx.x) for the process variable,

• 5 characters (xxx.x) for the set point,

• 5 characters (xxx.x) for the output value.

As the process variable and set point values are displayed in physical units, it is possible to modify their display format. However, to ensure that the display format remains comparable, this change must be made for both measurement values. Use the following procedure:

1 Select the value display field to modify. To do so, place the cursor on this field and click on the left mouse button. The selected value is displayed with four selection points around it and an icon is displayed to show that the object is already animated.

Caution

The position of the cursor when the selection is made is that of the lower left

corner of the first character displayed.

2 Pulldown the Animate menu and select Numerical Output..., this will display a dialog box. For example the dialog box shown below:

Note

Double-clicking in the display field will display the dialog box without calling-it up via the Animate

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Creating a Man-Machine Interface Application 2

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3 Place the cursor on the first character in the Format field, then click on and hold down the left mouse button and drag the mouse cursor to select all of the characters. All selected characters will be highlighted in reverse video.

4 Clear the Format field by pressing the <Del> or <Backspace> keys.

5 Define the new format by entering a row of nines (up to 6 characters allowing for the sign and decimal point). E.g. 99.9 or 999999.

6 Validate the new animation parameters.

Note

The display format used for the output value should not be modified.

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2.3-6 Modifying the Set Point Increment Value

During normal operation, the user can locally modify the set point value or the process control output value either by entering a new value or by incrementing or decrementing the current value (using keys S12 + or S11 -). The default increment is 0.1, but this value can be modified only for the set point increment. Use the following procedure:

1 Using the mouse to position the cursor, click on the left mouse button to:

• When using a FAV front panel:

- Select the "loop" in the letter P in PV to modify its incrementation value,

- Select the "loop" in the letter P in SP to modify its decrementation value.

• When using a FAV1 front panel:

- Select the "center" (*) of the letter S in SP to modify its incrementation value,

- Select the "vertical" (*) of the letter P in SP to modify its decrementation value.

Once this is done the object is displayed with 4 selection points around it and an icon is displayed showing that the object is already animated.

(*) These selection fields can also be selected from the Edit menu, Find symbol function that displays a list of symbols used. Select from the list the corresponding symbol: R1SPi [selxxx] and confirm the selection. The selection field is then framed with four points and an icon is displayed showing that the element is already animated.

2 Pulldown the Animate menu and select Function Key..., this displays a dialog box.

E.g. the dialog box displayed below for the OFB PID1 set point:

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3 Place the cursor on the first character in the Value field, then press the left mouse button and drag the mouse cursor to select all of the characters. They are highlighted in reverse video.

4 Clear the Value field by pressing the <Del> or <Backspace> keys.

5 Enter the new incrementation value. E.g. 0.5 or 10.

6 Validate the new animation parameters.

2.3-7 Testing the Animations

This test is not required but recommended as it lets the user check that the displays are correctly located for normal operation. If a display is incorrectly positioned within the display field, the user must correct the corresponding animation taking care with the position of the cursor when selecting the object. The cursor position used corresponds in operation to the lower left corner of the first character displayed. To run a test of the animations:

1 Pulldown the Test menu and select Test.

2 Display the animations by clicking on the left mouse button. Refer to Sub-Section 3.14, Divider A of the PL7-MMI 37 documentation (TXT DM PL7 M37 V5E).

3 Quit the test function by clicking on the right mouse button.

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2.3-8 Input Selection for Symbols and Symbol Elements

Input selection is the last operation to perform on-screen. It is required for all screens that contain at least one FAV or FAV1 symbol.

It lets the user assign a single keyboard action: value entry, set point status selection or operating mode selection to more than one process control front panel display of the same type. This is done from a single common input: data entry field or keyboard key.

An animated screen can only contain a single set of multiplexed inputs.

Modification of a screen comprising input selection must always follow the

procedure described in Sub-section 2.3-9.

The number of symbols to multiplex (or number of occurrences) is given by the number of FAV or FAV1 symbols displayed (1 to 4). For each symbol, four elements must be multiplexed:

• The set point status selection field,

• The process controller operating mode selection field,

• The set point value entry field in local mode,

• Output value entry field in full-manual operating mode.

To define an animation of this type:

1 Select the graphic object reserved for multiplexing by placing the cursor on it and clicking on the left mouse button. The object will then be displayed with 4 selection points around it. In operation, this field is used to enter set point or output values.

Attention:

The position of the cursor when the object is selected becomes, in operation,

the position of the lower left corner of the first character entered.

2 Pulldown the Animate menu and select Input Selection....

3 Select the symbol to multiplex: FAV or FAV1, then confirm the selection made. The dialog box shown on the next page is displayed:

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4 Enter the name of the Input variable: Up to a maximum of 13 characters. Valid characters are:

• First character: A-Z, a-z, @, $, _ or #,

• Other characters: A-Z, a-z, 0-9, @, $, _ or #.

5

Select the entry field background color. This color must be the same as that selected in GED.

6 Select the color of the characters entered.

7 Select the keyboard key used to activate, in operation, the previous element of the selected symbol: UP (Cursor Up key).

8 Select the keyboard key used to activate, in operation, the next element of the selected symbol: DWN (Cursor Down key).

9

Select character size: 1,

& Confirm the selections and entries made.

Note

If the values to enter are already known, it is possible to define a minimum value (Min.) and a maximum value (Max.) in the corresponding fields. In operation, if the value entered by the operator is out of range, an error message is displayed by the task manager.

The Error Message field lets the user define a variable that when assigned to a text output type animation (same variable name), lets the user display multiplexer error messages in an error message banner line: e.g. the message displayed when the value entered is out of range. The banner line for the selected screen is drawn in GED and its text output animation is defined in ANT.

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2.3-9 Modifying an Animation in a Multiplexed Selection Screen

1st. case

Input selection animation is not yet defined. In this case it is possible to modify the animation of a previously animated object in the normal way (refer to PL7-MMI 37 documentation).

2nd. case

Input selection animation is already defined:

• If the animation to modify is not linked to the multiplexing (all objects except function keys S7, S8, S11 and S12), modify it in the normal way then create a new multiplexing type animation,

• If the animation to modify is linked to the input selection (function keys S7, S8, S11 and S12), it is absolutely necessary to delete all existing animations (Edit/Delete) them then redefine screen animation.

Remark

If this procedure is not followed, the modifications will not be accepted and the application will not be modified.

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2.3-10 Saving Animations and Exiting the Animation Editor

Before quitting a screen, the user must save any animations or modifications to animations made. To do this, pulldown the Files menu and select Store.

To quit the animation editor, pulldown the Exit menu and select Exit.

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2.3-11 Animation Corresponding to an SCL OFB (V4 Level PLC)

If the PLC application uses SCL function blocks for floating point display of a PL7-3 integer variable(1), the user must define a Digital Output type animation for each variable. Use the following procedure:

• Use GED to define an object reserved for this use in the screen where the display of the variables is required (a simple rectangle is sufficient),

• Use XTEL-SDBASE to declare the symbol assigned to the variable SCLi, OUTPUT

(that comprises the value to display in floating point format),

• Use ANT to define a Digital Output animation assigned to this variable (2).

Note

XTEL-SDBASE can be accessed from within ANT when the variable to animate is not defined.

Application to the example proposed in Sub-section 4.6, Divider C (linking ANT and

XTEL-SDBASE definition screens)

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(1) Only data from PID function blocks is automatically converted to floating point format for display. All other variables require the use of the SCL OFB.

(2) For more information on the procedure to follow, refer to PL7-MMI 37 documentation, Sub-Section 3.9, Divider A.

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2.3-12 Animation Corresponding to an ISCL OFB (V4 Level PLCs)

If the PLC application uses ISCL function blocks so that PL7-3 can use floating point values entered by the operator (1), the user must first define a Text Input type animation for each one.

Use the following procedure:

• Use GED to define an object reserved for this purpose in the screen where value entry is supported (a simple rectangle is adequate),

• Use XTEL-SDBASE to declare the symbol assigned to the ISCLi, VALUE variable (that receives the value entered by the operator),

• Use ANT to define an Input Text type animation assigned to this variable (2).

Reminder

The ISCLi, VALUE parameter must be declared as write only.

Note

XTEL-SDBASE can be accessed from within ANT when the variable to animate is not defined.

Application to the example proposed in Sub-section 5.6, Divider C (linking ANT and

XTEL-SDBASE definition screens)

(1) Only values destined for PID function blocks (set point, output, process variables) are automatically converted from floating point to integer notation. For all other variables, the ISCL OFB must be used.

(2) For more information on the procedures to follow, refer to PL7-MMI 37 documentation, Sub-section 3.10, Divider A.

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Creating a Man-Machine Interface Application 2

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2.4

Defining the Process Control Password

In operation, access to adjustment screens can be password protected. The password is defined during the application design phase using the following procedure:

1

Pulldown the Generate menu and select Password. The following dialog box is displayed:

2 Select Operation.

3 Perform the following operations in the sequence listed below:

• Enter the previous password,

• Enter the new password,

• Confirm the new password.

Data entry is restricted to 8 characters. Blank characters (spaces) are significant.

The default setting (before the first entry is made) comprises no password: "blank" password.

Attention

If a dedicated adjustment keyboard is used in normal operation, use numbers for the password.

4 Validate the entries made.

Note

The Operation password is entered in the same way as the Regulation password. It protects access to the module by transfer and control functions.

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2.5

Generating Executable Files and Selecting Tasks

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The file generation procedure is required to generate executable files for transfer to the man-machine interface module memory cartridge. Use the following procedure:

1

Pulldown the Generate menu and select Table Creation with or without a coherence check. If With Coherence is selected, the coherence check is performed between variables read from the XTEL-SDBASE data base by the PL7-3 application and the variables read by the man-machine interface application. The following dialog box is displayed to allow the user to follow the operations taking place:

E

2 When the message PROCESS FINISHED is displayed, click on the OK button to close the dialog box.

Task selection lets the user select the tasks used in the man-machine interface module.

This lets the user define a list of files that are representative of the application. To do this:

3 Pulldown the Generate menu and select Select Tasks, the dialog box shown on the next page is displayed:

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Creating a Man-Machine Interface Application 2

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4 Select the tasks required by the application by clicking on their name:

• ALARMS (not required),

• GRAPHIC (required),

• RUN MANAGER (required),

• FILE TRANSFER (not required),

• TIMERS (required),

• COMMUNICATION (required),

• REGULATION1 (required),

• REGULATION2 (required).

The selected tasks are highlighted in reverse video.

5

Validate the selections made.

Note

All of the required tasks must be active in normal operation (refer to the Run Manager screen description).

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2.6

Transferring Files to the Module

This operation lets the user transfer the process control man-machine interface application to the memory cartridge in the TSX PCM 37 module. To do this:

1

Pulldown the Transfer menu and select Up/Download. After correct data entry and validation with the operating password, the following dialog box is displayed:

E

2 Select APPLICATION to PCM MODULE.

3 Confirm the selection made.

Note

To transfer the application to the PCM module, the following requirements must be met:

• Terminal connected to the PLC via the PLC processor terminal port or a MAPWAY, ETHWAY,

FIPWAY or FIPIO network,

• Module stopped (Stop) and the main menu displayed on-screen,

• If the module is running (Run), ensure that the TENFT task is loaded in the module and active.

Before performing a transfer to a blank memory cartridge, it must first be formatted.

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Creating a Man-Machine Interface Application 2

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2.7

Appendix

2.7-1 Process Control Front Panel Symbol Animation

This Appendix is provided for user information only, as the symbol animation procedure is fully automatic. This information may be useful when resusing the variables from these symbols elsewhere than the pre-animated symbols.

Animating an FAV, FAV1, PFAV or PFAV1 symbol will animate the various fields within the symbol (11 for FAV or FAV1 and 5 for PFAV or PFAV1).

Each field is assigned an symbol (e.g. R1PV2 for the process variable of PIDF2), that designates a data object or constant of the PIDF OFB assigned to the FAV1 symbol.

Correspondence between symbols used by PL7-MMI 37 and the PID or PIDF OFB variables is ensured by XTEL-SDBASE. The correspondance table is generated when the Regulation option is declared (refer to Sub-section 1.3).

Example for the PID2 OFB

PID2,LIBELLE

PID2,UNIT

PID2,S_PV

PID2,S_SP

PID2,S_OUT

PID2,S_PVMAX

PID2,S_PVMIN

PID2,S_PVHL

PID2,S_PVLL

PID2,SP_RSP

PID2,MAN_AUTO

Symbol

Rlibel2

Runphy2

Rpvscl2

Rspscl2

Rouscl2

Rpvsup2

Rpvinf2

Rpvhl2

Rpvll2

Rtypsp2

Rtypma2

Description

Loop name

Physical unit

Process variable value

Set point value

Output value

Max. PV value

Min. PV value

PV high level alarm

PV low level alarm

Local/remote set point

MAN./AUTO. status

Example for the PIDF3 OFB

PIDF3,LIBELLE

PIDF3,UNIT

PIDF3,PV_USED

PIDF3,SP_USED

PIDF3,OUT_MAN

PIDF3,PV_SUP

PIDF3,PV_INF

PIDF3,PV_HL

PIDF3,PV_LL

PIDF3,SP_RSP

PIDF3,MAN_AUTO

Symbol

R1libl3

R1unit3

R1pv3

R1sp3

R1out3

R1pvs3

R1pvi3

R1pvhl3

R1pvll3

R1spr3

R1ma3

Description

Loop name

Physical unit

Process variable value

Set point value

Output value

Max. PV value

Min. PV value

PV high level alarm

PV low level alarm

Local/remote set point

MAN./AUTO. status

The symbols used by PL7-MMI 37 can also be reused without the pre-animated symbols, if necessary. For example, to display a Process Variable in a diagram or to compare a value with a threshold in the Alarm task.

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2.7-2 Application Comprising More Than 32 PID/20 PIDF Controllers

The number of floating-point type addressable objects available to PL7-MMI 37 is 512.

This maximum number must be shared between all tasks and symbols that use this type of object.

For process control applications, remember:

• The process control (regulation) task uses 14 floating-point objects,

• Each PID controller front panel display (FAV or FAV1 symbols) uses the seven floating-point objects listed below:

PL7-3 Variable (FAV/ FAV1) Symbol (FAV/ FAV1)

PID i,S_PV/ PIDFi,PV_USED Rpvscl i /R1PVi

PID i,S_S/ PIDFi,SP_USED Rspscl i /R1SPi

PID i,S_OUT/ PIDFi,OUT_MAN Rouscli /R1OUTi

PID i,S_PVMAX/ PIDFi,PV_SUP Rpvsupi /R1PVSi

PID i,S_PVMIN/ PIDFi,PV_INF Rpvinf i /R1PVIi

PID i,S_PVHL/ PIDFi,PV_HL

PID i,S_PVLL/ PIDFi,PV_LL

Rpvhl i /R1PVHLi

Rpvll i /R1PVLLi

Description

Process variable value

Set point value

Output value

PV max. value

PV min. value

PV high level alarm

PV low level alarm

E

The basic PL7-PMS configuration therefore comprises 32 PID and 20 PIDF controllers listed in the XTEL-SDBASE data base and using:

14 + (7 x 32) + (7 x 20) = 378 floating-point objects

It is therefore possible to exceed the 32 PID and/or 20 PIDF controller maximum, if the data base objects for the corresponding PID or PIDF OFBs are entered in the

XTEL-SDBASE data base, using the same format as the 32 OFBs already listed there.

Exemple for the PIDF22 OFB

PIDF22 ,LIBELLE

PIDF22,UNIT

PIDF22,PV_USED

PIDF22,SP_USED

PIDF22,OUT_MAN

PIDF22,PV_SUP

PIDF22,PV_INF

PIDF22,PV_HL

PIDF22,PV_LL

PIDF22,SP_RSP

PIDF22,MAN_AUTO

Symbol

R1libl22

R1unit22

R1PV22

R1sp22

R1out22

R1pvs22

R1pvi22

R1pvhl22

R1pvll22

R1spr22

R1ma22

Attention

PL7-PMS can only support up to 68 PID or PIDF controllers (it is restricted by the capacity of the LOOP screen).

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Creating a Man-Machine Interface Application 2

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As PL7-MMI 37 does not perform any checks, the user must ensure that the application does not use more than 512 floating-point type objects. To ensure that this limit is not exceeded, check that not only the objects used by the Process Control task but those used by other PL7-MMI 37 tasks (floating-point variables in the Math and Logic task, floating-point variables used for displaying values via the SCL and ISCL OFBs, etc. The table below shows a list of the number of floating point objects used:

Element

Process Control Task

1 FAV controller

1 FAV1 controller

1 SCLi OFB

1 ISCLi OFB

Number of floating-point variables (Float)

1

1

14

7

7

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Man-Machine Interface Operation F

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Page

Control Screen

1.1

Screen Description 1/1

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Adjust Screens

2.1

Trend Screen Description

2.2

Tune Screen Description

2/1

2/4

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Control Loop Adjustment Methodology 3/1

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Process Control Operator Interface Keyboard 4/1

F

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F / 1

Control Screen 1

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1.1

Screen Description

4

1

2

3

This screen lets the user control the process control application. In this example, it is split into four parts:

1 Data entry field,

2 Alarm banner line display field,

3 Command display field,

4 The process controller front panel dynamic display fields.

Data entry field

This field lets the user check the newly entered value for each selected field: set point or manual output value. <Enter> validates the entries made.

Alarm banner line display field

This field displays the alarm banner line controlled by the Alarms function. The information displayed includes the time the alarm occurred, D if the alarm was generated by a diagnostics OFB, * if the alarm requires acknowledgment, the symbol name assigned to the variable that identifies the alarm, the message assigned to the alarm and the total number of alarms that are active at that time.

F

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F

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Command display field

This field displays all of the commands that can be accessed by the user: command name and its assigned keyboard key:

MENU <F1> Displays the menu screen.

ALARM <S1> Displays the List of Alarms screen.

ALACK <S2> Lets the user acknowledge the oldest as yet unacknowledged alarm displayed in the list of alarms. Once an alarm is acknowledged, the asterisk shown in front of the symbol is deleted and the alarm message takes the appropriate defined acknowledged alarm colors.

MUTE <S3> If an audible alarm is triggered by an alarm, this command lets the operator mute it.

TREND <S4> Displays the TREND adjustment screen. To gain initial access to this screen, the user must first select a process control loop to display the trending curves and corresponding parameters.

L/R <S7>

M/A <S8>

Modifies the type of set point for the selected process controller: Local

(LOC) or Remote (REM) set point.

Modifies the operating mode of the selected process controller:

Manual (MAN) or Automatic (AUT) mode.

SP <S9>

OUT <S10>

- <S11>

+ <S12>

<

<

←

↑

><

><

↓

→

>

<Enter>

>

Activates the "set point value" field for the selected process controller.

This field is then displayed with a frame and its value can be modified if Local (LOC) mode is selected.

Activates the "output value" field for the selected process controller.

This field is then displayed with a frame and its value can be modified if Manual (MAN) mode is selected.

Lets the user change the value of the selected field, by decrementing it: set point or manual mode output value.

Lets the user change the value of the selected field, by incrementing it: set point or manual mode output value.

Let the user select a process controller front panel display.

Let the user define the active field in the selected process controller front panel: set point, output value, type of set point or process controller operating mode.

Validates the entries made. The selected field will then display the newly entered value.

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Control Screen 1

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Process controller front panel dynamic display fields

1

2

3

5

4

6

7

9

(

&

é

8

"

'

1 This field is colored to indicate the process controller selected. Use the horizontal cursor keys to make selections.

2 Name of the control loop controlled by the process controller.

3 Upper limit of the process variable (measurement) scale, expressed in physical units.

4 Lower limit of the process variable (measurement) scale, expressed in physical units.

5 Bargraph showing the process variable (measurement) value.

6 Bargraph showing the set point value.

7 Bargraph showing the output value.

8 Type of physical units.

9 Process variable (measurement) value, expressed in physical units.

& Set point value, expressed in physical units.

é Output value, expressed as a percentage.

"

Type of set point used: Local (LOC) or Remote (REM).

' Process controller operating mode: Manual (MAN) or Automatic (AUT).

( This field is colored to indicate the selected parameter that can then be modified:

• Modification of the value by entering a new value or by pressing keys S11 and S12,

• Modification of the type of set point or of the operating mode of the process controller by pressing keys S7 and S8.

The cursor up and down keys let the user select the various fields accessible for the current process controller: set point value, output value, type of set point, process controller operating mode.

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F

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F

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1 / 4

Adjust Screens 2

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2.1

Trend Screen Description

This screen is the first of the adjust function as it lets the user select the process control loop to adjust. Once the selection is made, it displays the trend of the process variable, set point and output from the process controller.

The first time an adjust view is called-up, the screen is "blank" of useful information as no process control loop has yet been selected. Therefore the user must first select a control loop (via key S5), before attempting to perform any other adjust

operations: e.g. accessing the TUNE screen.

3

1

2

4

5

3

This screen is split into three main fields:

1 Process control loop thresholds and limit values display field,

2 Graphics field,

3 Command display fields.

Like the control screen, this screen also comprises a data entry field 4 and a alarm banner line display 5 .

Control loop parameter display field

1

3

2

F

1

Control loop name,

2 Type of process controller that controls the loop: PID or PIDF,

3

Number of the process controller that controls the loop,

4

Loop parameters:

• PV_HL and PV_LL: process variable higher and lower thresholds,

• SP_MAX and SP_MIN: set point higher and lower thresholds,

• DEV_HL and DEV_LL: higher and lower thresholds for the calculated deviation,

2 / 1

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Graphic field

1 9

3

4

5

2

6

7

8

9

F

& é " ' ( § è

1 Time base that defines the period between two points on a trending curve: 2s, 3s,

4s, 5s, 6s, 8s, 10s, 12s, 15s, 18s, 24s, 30s, 36s, 48s, 60s, 90s, 120s and 180s.

2 Time required to display all of the points of a trending curve: 500 points visible onscreen x Time Base.

3 Trending curves that display the respective changes in the process variable, set point and output values.

4

,

5

and

6

Bargraph that respectively displays the process variable, the set point and the output value.

7 Higher and lower limit of the measurement full scale range expressed in physical units.

8 Measurement value expressed in physical units.

9

Type of physical units.

& Set point value expressed in physical units.

é Type of set point used: Local (LOC) or Remote (REM).

" Output value, expressed as a percentage.

' Process controller operating mode: Manual (MAN) or Automatic (AUT). This field has its colored frame to indicate that it is selected and that its value can therefore be modified.

(

New value entry field, for the selected field: internal set point or output value in manual operating mode. <Enter> confirms the entries made.

§

Error and information message display field.

è Reserved fields, not used for PID and PIDF process controllers.

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Adjust Screens 2

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Command display field

This field displays all of the commands that can be accessed by the user: with the command name and its assigned key:

RETURN <F1> Displays the previous screen.

SAVE <F2> Saves all of the control loop adjustment parameters (refer to Subsection 3.4). This requires that the application be stored in a

backed-up RAM cartridge. No message indicates that the data was not saved if an EPROM cartridge is used.

TIME <F3>

MENU <F4>

Modifies the time base by prompting the user with preset values.

Displays the Menu screen.

A_TUNE <F5> Reserved key, not used by PID and PIDF process controllers.

ALARM <S1> Displays the List of Alarms screen.

ALACK <S2> Lets the user acknowledge the oldest unacknowledged alarm in the list of alarms. When an alarm is acknowledged, the asterisk in front of the symbol is removed and the alarm message takes the preset acknowledgment colors.

MUTE <S3>

<S4>

If an audible warning is sounded when an alarm occurs, this command lets the user mute it.

Not used.

LOOP <S5>

TUNE <S6>

L/R <S7>

M/A <S8>

SP <S9>

OUT <S10>

- <S11>

+ <S12>

<

↑

><

↓

>

Displays a screen that lets the user select the control loop to adjust.

Displays the Tune screen that lets the user set the control loop parameters.

Modifies the type of process controller set point: Local (LOC) or

Remote (REM) set point.

Modifies the process controller operating mode: Manual (MAN) or

Automatic (AUT) mode.

Activates the "set point value" field. This field is highlighted and the user can then change its value.

Activates the "output value" field. This field is highlighted and the user can then change its value.

Lets the user modify the value of the selected field, by decrementing it. This applies to the Local set point or to the manual output.

Lets the user modify the value of the selected field, by incrementing it. This applies to the Local set point or to the manual output.

Lets the user define the active field: set point value, output value, type of set point or process controller operating mode.

F

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2.2

Tune Screen Description

This screen lets the user set the internal parameters of the PID process controller that controls the loop.

Important

The TUNE screen must only be accessible from the TREND screen.

1

7

2

4

3

5

6

F

8 8 8 8 9 9 9

1 RETURN <F1>: This command displays the previous screen: TREND.

2 Process control loop name.

3 Type of process control loop: PID or PIDF.

4 Number of the process controller that controls the loop.

5 Process control loop internal parameter display and modification field. This field displays the following information for each parameter: name, an entry field that lets the user modify the value, current value and the type of physical unit. The following parameters can be accessed by the user:

• KP: PID process controller gain,

• TI: PID process controller integration time,

• TD: PID process controller derivation time,

• OUT_MAX: higher output limit,

• OUT_MIN: lower output limit,

• PV_HL: process variable higher limit,

• PV_LL: process variable lower limit,

• SP_MAX: set point higher limit,

• SP_MIN: set point lower limit,

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Adjust Screens 2

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• DEV_HL: deviation higher threshold,

• DEV_LL: deviation lower threshold,

• DEADBAND: minimum variation of the calculated output causing a variation of the applied output,

• OUTBIAS: compensation for a static error when no integral action is present,

• OUTRATE: limit of output variation between two samples,

• T_CYCLE: cycle time,

• T_FILTER: time constant for the process variable digital filter.

6 Entry field for the new value of the selected parameter.

7 Display field for error and warning messages.

8 Reserved keys, not used for PID or PIDF process controllers.

9

Reserved fields, not used for PID or PIDF process controllers.

To modify a parameter:

<

↑

><

↓

> Move the cursor in the corresponding field,

<xxx> Enter the new value that will be displayed in the data entry field,

<Enter> Validate the data entry made. The new value is displayed in the current value field.

Note

Access to parameter modification is protected by the process control password that must be entered once for the current adjust session (as long as the user does not quit the adjust screens).

F

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Control Loop Adjustment Methodology 3

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Control loop adjustment mainly comprises determining the Kp, Ti and Td parameters required for optimal performance. The three parameters can only be set once the following points have been determined:

• Direction of loop action (DIRECT or REVERSE),

• Filtering applicable to the measurement value.

1 Preliminary adjustments

Sampling period

The T_OFB parameter that sets the sampling period can only be accessed in PL7-3,

OFB Constants mode. The value entered (in ms for the PID OFB and in seconds for the PIDF OFB) is automatically adjusted to the nearest multiple of the period of the task in which the OFB is executed. For example:

• Value entered: 1 sec.

• AUX0 task period: 300 ms

• True task period: 0.9 sec.

Direction of action

The PID or PIDF OFB defaults to REVERSE action (DIR/REV bit set to 1). If the loop should be set for DIRECT action, the user must set the DIR/REV bit to 0 in the OFB

Internal Data. For operational safety reasons, this parameter cannot be modified from an operator dialog terminal. It can only be modified from a programming terminal or from PL7-3 in Data mode or using SYSDIAG.

Measurement filtering

The filter constant must be selected to eliminate the "chaff" around the measurement signal, without introducing any significant delay in addition the normal time factors involved by the process.

For a PID OFB, the value of the filtering constant T_FILTER can be changed from the TUNE screen displayed by the man-machine interface terminal.

For a PIDF OFB, the FC parameter of the SCLF OFB determines the filtering value

(refer to Divider D, Sub-section 6.1).

F

2 Setting parameters Kp, Ti, Td

The default values for these parameters are:

• Kp = 1,

• Ti = 0 (no integral),

• Td = 0.

A number of methods are available for determining the values to give to the parameters. They are usually based on an observation of the response of the process to a change in the output value or in the set value. Section 3 in Divider D describes two methods (one open loop and one closed loop).

The parameters can be modified from the TUNE screen.

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Selecting a loop

• From the TREND screen,

• Press S5 to access the loop selection screen,

• Select a loop using the cursor keys and validate the selection by pressing <Enter>.

This returns the user to the TREND screen.

Predetermining parameters

• Set the process controller to Manual Mode operation for open loop control or

Automatic Mode for closed loop control (depending on the required control method),

• Apply one of the adjustment methods described in Section 9, Divider D and derive the parameter values from the results obtained,

• Press S6 to access the TUNE screen,

• Enter the values of parameters Kp, Ti, Td (when the user attempts to modify the first parameter, the terminal will request a password).

Improving parameter value accuracy

• Press F1 (Return) to return to the TREND screen,

• Set the process controller to Automatic Mode,

• Generate a Set Point increment step and let the measurement value stabilize,

• Make minor changes to the parameter values, if required, as described in Divider

D, Section 9.

• As a rule, the sequence is completed by checking with the application of a Set Point increment step in the Reverse direction. If this yields different settings, an average setting should be selected.

F

3 Additional settings

The TUNE screen also lets the user define:

• High and Low Level alarm values to apply to the Process Variable measurement value in physical units (PV_HL and PV_LL parameters),

• High and Low Level alarm values to apply to the Deviation measurement value in physical units (DEV_HL and DEV_LL parameters),

• High and Low Level values to apply to the Set Point value in physical units

(SP_MAX and SP_MIN parameters),

• High and Low Level alarm values to apply to the percentage value output

(OUT_MAX and OUT_MIN parameters),

• Output bias expressed as a percentage (OUTBIAS parameter),

• Output Deadband expressed as a percentage (DEADBAND parameter),

• An output rate of change limit expressed as a percentage (OUTRATE parameter),

3 / 2

Control Loop Adjustment Methodology 3

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• If a width modulated output is selected, the reference period expressed in seconds

(T_CYCLE parameter).

Note

All of the above parameters have default values that ensure that they cannot operate, except for:

• OUTBIAS : Set for 50%,

• T_CYCLE : Set for 20 seconds.

Adjustment example for a temperature loop

Assuming the PID parameter adjustment procedure supplied the following values:

• Kp = 2.8

• Ti = 15 seconds

• Td = 2 seconds

In addition, the system specifications require:

• Limiting the Set Point to 830

°

,

• Triggering an alarm should the Process Variable exceed the 850

°

threshold,

• Stopping injection of additives during the mixing phase when the deviation (Process

Variable-Set Point) exceeds two degrees.

The adjustment screen corresponding to these values looks like this:

F

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4 Saving the parameters

This operation is ABSOLUTELY NECESSARY.

It transfers the adjustment values entered until now as Internal Data to the Internal

Constants field.

If this operation is not performed first, the PLC may return to the default values read from the OFB after a cold restart. This may cause serious operating problems with the automated system and may be dangerous.

CONSTANTS

DIR_REV$

DATA

DIR_REV

FTX 507

PL7-3

Data Mode

KP$ =

TI$ =

KP =

TI =

SAVE ADJUST

Operator Terminal

TUNE

F

To save the parameters:

• Return to the TREND screen,

• Press F2 (SAVE), the terminal prompts the user to enter the password,

• Once the password is entered, internal data containing adjustment values are transferred to the constants.

If the save fails (PLC stopped, SAVE OFB not configured, etc.), an error message is displayed in the alarm banner line in the TREND screen.

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Process Control Operator Interface Keyboard 4

____________________________________________________________________________

Presentation

The optional process control operator interface keyboard is sealed, flat and can be builtinto any surface. It provides the operator with an easy to use presentation of all of the commands required for process control and adjustment of process control applications: direct access to control loops, set point display, operating mode selection, control view selection, trend and adjustment functions.

1 2 3 4

The keyboard is IBM PS/2 compatible and comprises:

1

Standard function keys: cursor control, tabs, validation, etc.

2 12 application dynamic function keys: F1 to F12,

3

Dedicated function keys for direct access to process control functions: control loop parameters, operating modes, alarm acknowledgment, etc.

4 A numerical keypad for entering adjustment values, process control passwords, etc.

Connection

The process control keyboard can be used as an external keyboard for a monochrome or color TSX CPX 2714/3714 operator console. In this case it should be connected to the 6-pin MINI-DIN connector located on the front or back panel of the console (refer to the appropriate product documentation).

If the operator position comprises a process control keyboard and a monitor, connection to the TSX PCM 37 process controller requires a TSX BMP 010 wiring interface module installed in the PLC rack or in an XGS-R71 (single slot) or an XGS-R74 (4 slot) rack.

If the TSX BMP 010 rack is located in a slot in the TSX PMX 7 process controller it uses the normal rack power supply. Be sure to take into account the power consumption requirements of the keyboard when estimating the power requirements of the PLC installation.

F

TSX BMP 010

TSX PCM 37

TSX VGA ●●●

3 meters max.

TPMX KB1

TSX CMB ●●●

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If the TSX BMP 010 module is installed in an XGS-R7 rack, its front panel must be connected to a mains power source. In this case the PLC rack does not provide the power supply to the keyboard.

TSX PCM 37

XGS-R71

TSX BMP 010

TSX VGA ●●●

40 meters max.

Mains

Dimensions and weight

TPMX KB1

41

408

22

Power requirements

Power consumption in mA

F

+5V 70

Peak

100

Service conditions

Immunity

0 to 55

°

C

-25 to +65

°

C

IP65

ESD CEI 801.2 Level 4

Radiated fields CEI 801.3 Level 3

EMI levels EN 55022 Class A

FCC Class A

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Application Example G

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Page

Controlled Installation Description

1.1

Process Presentation

1.2

Process Control Loops

1.3

Alarms

1.4

Reaction to a Power Break/Return

1/1

1/3

1/4

1/4

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Application Analysis

2.1

Selecting Analog I/O Modules

2.2

Distributing Processing

2.3

Handling Process Control

2.3-1 Principle

2.3-2 Diagram

2.3-3 Reaction to an Invalid Measurement Value

2.3-4 Reaction to PLC Stoppage

2.3-5 Reaction to Power Return

2/1

2/1

2/2

2/2

2/2

2/3

2/3

2/4

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PLC Application

3.1

Hardware Configuration

3.2

PL7-3 Application Configuration

3.2-1 For a V4 Level PLC

3.2-2 For a V5 Level PLC

3.3

Programming

3.3-1 Application Using PID OFBs (V4 Level PLC)

3.3-2 Application Using PIDF OFBs (V5 Level PLC)

3/1

3/3

3/3

3/5

3/7

3/9

3/19

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Man-Machine Interface Application

4.1

Application Description

4.2

Diagram Screen Layout

4.3

Control Screen Layout

4.4

Alarms

4/1

4/3

4/5

4/6 G

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G / 1

Controlled Installation Description 1

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1.1

Process Presentation

The process to control corresponds to the diagram below:

It is a batch process application where sequential control and process control programming is closely linked.

The manufacturing process uses a basic product into which two additives are injected at constant flow. During the mixing phase, the temperature must be maintained at a constant recipe value (injecting additive 1 will increase the temperature of the solution).

The temperature is controlled by a jacket in which hot water is circulated (obtained by mixing cold water with steam). This type of process requires using cascade process control to ensure temperature control of the solution and jacket temperature.

Description of the normal production cycle

The cycle comprises five phases:

• Filling,

• Preparing,

• Mixing,

• Emptying,

• Rinsing.

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__________________________________________________________________________________________ a) Filling phase

The basic product is injected into the tank until it reaches a preset level. In parallel with this operation, a dose of each additive is prepared. During this phase, the jacket temperature is maintained at 60

°

C.

b) Preparation phase

Once the TEMP_SOLU/TEMP_ENV loop is established, the temperature-solution set point is progressively brought up to the value set in the recipe, in steps of 0.03

°

C every second.

c) Mixing phase

Once the temperature of the solution reaches the level set in the recipe, the additives are injected in a constant flow.

The temperature-solution loop reacts to compensate for the increase in temperature caused by injecting additive 1.

During this phase, if the TEMP_SOLU deviation (difference between SP and PV) exceeds 2 degrees, injection of additives is stopped. It is restarted once the deviation is again less than 1

°

C.

The mixing phase continues until the complete doses of additives have been used up. This takes a few minutes.

d) Draining phase

The TEMP_SOLU/TEMP_ENV cascaded loops are disconnected with the

TEMP_ENV loop continuing its control function using the last set point provided by the TEMP_SOLU loop. The contents of the tank are emptied into the waiting drums.

e) Rinsing phase

The tank is filled with a rinsing product. Rinsing lasts a few moments before the contents of the tank is drained via the purge valve.

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Controlled Installation Description 1

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1.2

Process Control Loops

Four loops are required for process control:

• Two loops DEB-ADD1 and DEB-ADD2 to control the flow of additives:

- The measurement sensors provide a quadratic output signal in the 4 - 20 mA range,

- The valves are controlled by a 4 - 20 mA signal.

• A temperature-envelope control loop, with:

- Temperature measurement taken from a Pt100 probe,

- Steam as the adjustable variable,

- This loop always remains in service.

• A temperature-solution control loop that acts in cascade on the previous loop:

- The measurement value is also taken from a Pt100 probe,

- The cascade is looped back during some phases of the production cycle.

Control loop status in normal operation

Filling

DEB-ADD1

Not active

DEB-ADD2

Not active

TEMP_ENV

SP = 60

°

C

TEMP_SOLU

Cascade open

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Preparation Not active Not active Cascade loop

SP TEMP_SOLU 80

°

C

Mixing Active controlled Active by PLC Operator

No operator action action allowed

Cascade loop

SP TEMP_SOLU = 80

°

C

Draining Not active Not active

Rinsing Not active Not active

SP set to the last value supplied by the

SP 60

°

C

Open cascade loop

Cascade open

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1.3

Alarms

An alarm message that identifies the source of the error is displayed by the manmachine interface terminal if:

• Tank level exceeds 90 %,

• The temperature-solution level exceeds 85

°

C,

• One of the measurement values is invalid.

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1.4

Reaction to a Power Break/Return

The way the system reacts depends on the duration of the power break.

Power break < 10 seconds

Hot restart: the cycle restarts where it left off and the control loops are reactivated in the same state as when they stopped.

Power break > 10 seconds

It is up to the operator to restart the system. The control loops are set to Manual (MAN) mode and the outputs to 0.

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Application Analysis 2

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2.1

Selecting Analog I/O Modules

A TSX AEM 411 module is used to acquire flow measurement information:

• Input range: 4 - 20 mA,

• Standard range display (0-10 000) after square root extraction.

A TSX AEM 413 module is used to acquire temperature measurement information from the Pt100 probes.

A TSX ASR 402 module is used to control the valves.

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2.2

Distributing Processing

The multitasking processing supported by PMX process controller PLCs is especially suited to this type of application as it means that a task can be dedicated to control loop processing. This makes it easy to separate sequential processing from the process controls while supporting extensive interaction.

A solution based on process control loop Optional Function Blocks (OFBs), an integral part of the PL7-3 programming language, is used in this example for the type of process described here.

The following assignments are used:

MAST Task

• PRELIMINARY processing: Power return sensing,

• CHART: Sequential processing,

• POST processing: Additional processing.

AUX0 Task: Dedicated to process control

• Checks the validity of the measurement values,

• Initializes the process control loops on power return,

• Scans process control loops,

• Controls the TSX AEM and TSX ASR analog modules.

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2.3

Handling Process Control

2.3-1 Principle

A PID OFB (V4 level PLC) or a PIDF OFB (V5 level PLC) is assigned to each process control loop:

• PID0/PIDF0 is assigned to: DEB-ADD1, • PID2/PIDF2 is assigned to: TEMP_ENV,

• PID1/PIDF1 is assigned to: DEB-ADD2, • PID3/PIDF3 is assigned to: TEMP_SOLU.

The process time constants are adequate, allowing the use of the default sampling period of 300ms. The process control loops are controlled by task AUX0. The TSX AEM and TSX ASR modules are assigned to this task. The period of the AUX0 task can be set to 100ms. The time period corresponds to the time required by a TSX AEM module to acquire measurements for a channel.

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2.3-2 Diagram

TSX AEM 411

Ch0

DEB-ADD1 Loop

PV

RSP

PID0*

OUTPUT

TSX ASR 402

Ch0

Ch1 PV

RSP

PID1*

OUTPUT

Ch1

DEB-ADD2 Loop

TSX AEM 413

Ch0

TEMP-ENV Loop

PV

RSP

PID2*

OUTPUT

Ch2

G

Ch3

Ch1 PV

RSP

PID3*

OUTPUT

(Ch3 not used)

TEMP-SOLU Loop

(*) or PIDF for V5 level PLCs

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Application Analysis 2

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Assignments of the other TSX AEM module channels

AEM 413

Tank Level

—

Channel 3

—

—

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2.3-3 Reaction to an Invalid Measurement Value

Reminder

The PID/PIDF OFB updates the output regardless of the measurement status.

If the user requires a specific reaction to an invalid measurement value, it is up to the user to program it explicitly.

The following processing is implemented in the example:

• If the measurement value is valid, process controller status (AUTO/MAN) is unchanged,

• If the measurement value is invalid, the process controller is forced to Manual mode

(MAN) and the output retains its last value,

• When the measurement value becomes valid again, the process controller returns to its normal operating mode (AUTO or MAN).

Note

Remember, the PID/PIDF OFB must be systematically sampled by each cycle of the task in which it is programmed. This means that it is illegal to use a command line such as:

! IF "measurement valid"

THEN EXEC PID

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2.3-4 Reaction to PLC Stoppage

If the PLC is stopped, the outputs retain the last value provided by the PID/PIDF OFBs.

This feature is implemented by the TSX ASR 402 output modules.

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2.3-5 Reaction to Power Return

The required reaction is described below:

• If the duration of the power break is less than 10 seconds: the control loops are reset to the same state as before the power break occurred.

• If the duration of the power break is greater than 10 seconds: the control loops are forced to Manual mode, output at 0. Any return to Automatic mode and restarting the cascade loop between TEMP-SOLU and TEMP-ENV are left up to the user.

The processing corresponding to these requirement will differ depending on whether the application is run on a V4 level PLC using PID OFBs or on a V5 level PLC using PIDF

OFBs.

a) Using PID OFBs (V4 level PLCs)

On power return the PID OFBs are set to Manual mode by the system, output at 0. Therefore:

• In the case of a power break exceeding 10 seconds, no specific processing is required as the operating state selected by the system is the desired one.

• In the case of a power break of less than 10 seconds, it is up to the application to set the OFBs to the desired state. The following processing applies:

- On power return and until the TSX AEM modules are operational (self-tests complete and measurement values valid), the process controllers remain in

Manual mode with output values equal to the last ones calculated before the power break,

- As soon as the TSX AEM modules are able to supply a valid measurement, they switch to Automatic mode using the set point retained prior to the power break.

Note

This type of processing assumes that the output from each process controller is always retained in memory and continually updated.

b) Using PIDF OFBs (V5 level PLCs)

On power return, the OFBs restart in the same state as prior to the power break:

• In the case of a power break exceeding 10 seconds, it is up to the application to force the process controllers to Manual mode and set the output values to 0.

• In the case of a power break of less than 10 seconds, it is not necessary to change the state of the process controllers.

However, given the that duration of the TSX AEM module self-test sequence is greater than that of the PLC processor, it is necessary to wait until the measurement values are valid before allowing the process controllers to operate normally. The following processing sequence is proposed: on power return and until the TSX AEM modules are operational (self-tests complete and measurement values valid), the process controllers use a measurement value equal to the last one provided prior to the power break. In this way, outputs will only change due to the integral action, therefore with only a slight change in amplitude.

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PLC Application 3

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3.1

Hardware Configuration

TSX AEM 413

TSX AEM 411

T PMX 87 420 or

T PMX 87 425

TSX ASR 402

TSX PCM 37

TSX BMP 010

TSX VGA 19

Sensors

Actuators Man-Machine Interface

TSX AEM 411 module configuration

The minimum scan period is selected: 400ms.

Channels 0 and 1 are configured the same:

• Input range: 4 - 20 mA,

• Specific processing: square root extraction,

• Type of output: standard 0 - 10000 output range.

T PMX KB1

Note

The measurement value in 0-10000 format is directly compatible with the PID OFBs. When a PIDF

OFB is used, it must be converted into floating point mode using an SCLF OFB.

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TSX AEM 413 module configuration

The minimum scan period is selected: 400ms.

The measurement values must be expressed in 0 - 10000 format. This means using user defined units with higher and lower (min/max) values (expressed in tenths of degrees

C) corresponding to values of 0 and 10000.

In the example temperatures that vary between 0 and 100

°

C are used:

TEMP-ENV

0

TEMP-SOLU

0

Limit corresponding to 10000

(in 1/10th of a degree) 1 000 1 000

The corresponding configuration screen is shown below:

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TSX ASR 402 module configuration

Using register word OW3,1

To use standard measurement values (0 - 10000 format), the module must be configured for operation with a percentage of Full Scale Range. The following program line is required:

! H'00F0'

→

OW3,1

Note

The output from the PID OFBs is an integer value that must also be expressed in 0 - 10000 format.

This is selected by setting the OUTRANGE bit to 1 in the OFB internal constants.

The output from the PIDF OFBs is a floating point value between 0 and 100.

This output must be converted to an integer value using the ISCLF OFB so that it can be sent to a TSX ASR module in 0 - 10000 format.

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PLC Application 3

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3.2

PL7-3 Application Configuration

3.2-1 For a V4 Level PLC: This can only be performed via PL7-3

Application

Periodic tasks

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Inputs/Outputs

OFBs

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PLC Application 3

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3.2-2 For a V5 Level PLC: Configuration is split between XTEL-CONF and PL7-3

Application: PL7-3

Periodic tasks: X-TEL

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Inputs/Outputs: X-TEL

OFBs: PL7-3

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PLC Application 3

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3.3

Programming

Introduction

The complete programming information for the sequential part of the application will not be detailed here as it exceeds the context of the example.

In the rest of the example, only the specific programming required for processing the process control application will be detailed, covering:

• Measurement value acquisition and validity checks,

• Scanning process control loops,

• Interaction between sequential and process control programming (start-up, cascade loop set and reset, set value slopes, etc.),

• Process control loop processing on power return,

• Process control loop processing on PLC stoppage,

• Formatting of data required for the man-machine interface (alarms, scaling, etc.).

To ensure better comprehension, a simplified Grafcet chart of the installation is provided so that the user can see the interactions between sequential and process control programming in the production cycle.

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G

G

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Simplified Grafcet chart

IN

0

TEMP LOOP_ENV IN AUTO

SP = 60 °C

M0

START

M1

CYCLE

M2

STOP

OUT

IN

CASCADE LOOP TEMP_SOLU/

TEMP. ENV

IN 0

RISE TEMP_SOLU

→

80 °C

M11

FILL 1

M12

PREPARATION OUT

M13

MIX

M14

DRAIN

IN

0

START LOOPS

ADDITIVE FLOW

MONITOR TEMP_SOLUTION

M15

RINCE

Start cycle

1

STOP LOOPS

ADDITIVE FLOW

OUT

IN

END CASCADE LOOP

MAINTAIN TEMP_ENV LOOP

AT LAST SP

OUT

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PLC Application 3

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3.3-1 Application Using PID OFBs (V4 Level PLC)

PL7-3 variable assignment

DEB-ADD1 DEB-ADD2 TEMP_ENV TEMP_SOLU

PID0 PID1 PID2 PID3

Words

Save output

External SP

W100

W105

W106

W110

W115

W116

W120

W125

W126

Bits

Save power return

Save status AUT/MAN

Measurement status

Save type of SP

(INT/EXT)

B100

B101

B102

B103

B110

B111

B112

B113

B120

B121

B122

B123

B0 : Power return or cold restart indicator.

B6 : Save SY6.

W137 : Solution temperature recipe.

W138

W139

Higher and lower (Min/Max) limits used for temperature rises.

W130

W135

W136

B130

B131

B132

B133

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Task AUX0

< CONTROL AEM AND ASR MODULES

!

< LOAD TSX AEM 411 MODULE CONFIGURATION

!

IF IW1,1,D + SY0

THEN EXEC AEMLD0(0;0=>)

< LOAD TSX AEM 413 MODULE CONFIGURATION

!

IF IW2,1,D + SY0

THEN EXEC AEMLD1(1;0=>)

< TSX ASR 402 MODULE CONFIGURATION

!

H'00F0'->OW3,1;SET OW3,0,C;SET OW3,0,E

< PROGRAM LOOP DEB-ADD1

!L100

:

< POWER RETURN PROCESSING

!

IF B100•NOT IW1,0,C

!

THEN W100->PID0,OUT_MAN;RESET B102;JUMP L102

IF B100•IW1,0,C

THEN RESET B100;B101->PID0,MAN_AUTO

< TEST MEASUREMENT STATUS

!L101

!

:IW1,0,C•NOT IW1,1,8•NOT I1,S->B102

IF NOT B102

!

THEN RESET PID0,MAN_AUTO;JUMP L102

IF RE(B102)

THEN B101->PID0,MAN_AUTO

< PROCESS LOOP

!L102

:EXEC PID0(IW1,3;=>;;OW3,3;)

< STORE OUTPUT VALUE AND STATUS

!

IF B102

THEN PID0,OUT_MAN->W100;PID0,MAN_AUTO->B101;

PID1,SP_RSP->B103

PID0

IW1,3

W105

PV

RSP

ERROR

STATUS0

OUTPUT

PW_OUT

W106

OW3,3

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PLC Application 3

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< PROGRAM LOOP DEB-ADD2

!L110

:

< PROCESSING FOR POWER RETURN

!

IF B110•NOT IW1,0,C

!

THEN W110->PID1,OUT_MAN;RESET B112;JUMP L112

IF B110•IW1,0,C

THEN RESET B110;B111->PID1,MAN_AUTO

< TEST MEASUREMENT STATUS

!L111

!

!

:IW1,0,C•NOT IW1,1,9•NOT I1,S->B112

IF NOT B112

THEN RESET PID1,MAN_AUTO;JUMP L112

IF RE(B112)

THEN B111->PID1,MAN_AUTO

< PROCESS LOOP

!L112

:EXEC PID1(IW1,4;W115=>;W116;OW3,4;)

< STORE PROCESS CONTROLLER OUTPUT AND STATUS

!

IF B112

THEN PID1,OUT_MAN->W110:PID1,MAN_AUTO->B111;PID1,SP_RSP->B113

PID1

IW1,4

W115

PV

RSP

ERROR

STATUS0

OUTPUT

PW_OUT

W116

OW3,4

< PROGRAM LOOP TEMP-SOLU

!L120

:

< PROCESSING FOR POWER RETURN

!

IF B130•NOT IW2,0,C

!

THEN W130->PID3,OUT_MAN;RESET B132;JUMP L122

IF B130•IW2,0,C

THEN RESET B130;B131->PID3,MAN_AUTO

< TEST MEASUREMENT STATUS

!L121

!

:IW2,0,C•NOT IW2,1,9•NOT I2,S->B132

IF NOT B132

THEN RESET PID3,MAN_AUTO;JUMP L122

!IF RE(B132)

THEN B131->PID3,MAN_AUTO

< PROCESS LOOP

!L122

:EXEC PID3(IW2,4;W135=>;W136;W125;)

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< STORE PROCESS CONTROL OUTPUT AND STATUS

!

IF B132

THEN PID3,OUT_MAN->W130;PID3,MAN_AUTO->B131;PID3,SP_RSP->B133

PID3

IW2,4

W135

PV

RSP

ERROR

STATUS0

OUTPUT

PW_OUT

W136

W125

< PROGRAM LOOP TEMP-ENV

!L130

:

< PROCESSING FOR POWER RETURN

!

IF B120•NOT IW2,0,C

!

THEN W120->PID2,OUT_MAN;RESET B122;JUMP L132

IF B120•IW2,0,C

THEN RESET B120;B121->PID2,MAN_AUTO

< TEST MEASUREMENT STATUS

!L131

!

:IW2,0,C•NOT IW2,1,8•NOT I2,S->B122

IF NOT B122

THEN RESET PID2,MAN_AUTO;JUMP L132

!IF RE(B122)

THEN B121->PID2,MAN_AUTO

< PROCESS CASCADE

!

IF XM12+XM13+XM14

THEN PID3,OUTPUT->W125

< PROCESS LOOP

!L132

:EXEC PID2(IW2,3;W125=>;W126;OW3,5;)

< STORE PROCESS CONTROLLER OUTPUT AND STATUS

!

IF B122

THEN PID2,OUT_MAN->W120;PID2,MAN_AUTO->B121;PID2,SP_RSP->B123

PID2

IW2,3

W125

PV

RSP

ERROR

STATUS0

OUTPUT

PW_OUT

W126

OW3,5

G

The TEMP_SOLU and TEMP_ENV loops form a process control loop cascade where

TEMP_SOLU is the master or external loop and TEMP_ENV is the slave or internal loop.

When the cascade loop is complete, the output from the loop, TEMP_SOLU is applied as set point for the TEMP_ENV loop.

The order in which the two loops are run is therefore important. The TEMP_SOLU loop

(instruction EXEC PID3) must always be executed before the TEMP_ENV loop

(instruction EXEC PID2).

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PLC Application 3

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The two screens shown below as examples, show the values of the constants in the

PID3 OFB:

Constant PV_HL$ defines the measurement high level alarm (value 8500 corresponds to 85

°

C).

If the temperature-solution measurement exceeds this value, bit 2 of the Status word is set to 1.

This is the information used by the Alarms task to trigger display of the message

TEMP_SOLU EXCEEDED. Constant DEV_HL$ defines a maximum deviation (PV -

SP). If the measurement (PV) exceeds the Set Point by +2

°

C, a bit in the PID OFB Status word is set to 1 (this bit is reset to zero once the deviation is again less than 1

°

C, allowing for hysteresis of 1%).

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The alarm information (bit 4 of the Status word) is used in the additive injection step to stop injecting additive 1 when the temperature-solution measurement exceeds the preset value by more than 2

°

C.

Note

There are two ways to initialize the internal constants of the PID OFB:

• From PL7-3 in Program mode (the CONTENT key that is accessible once the name and number of the OFB is entered. This key lets the user access the constants screen): This approach is necessary for the first five internal constants,

• For the other internal constants, from a Dialog/Adjustment terminal, using the SAVE function key that is accessible from the TREND screen.

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PLC Application 3

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PRL Processing

< CALCULATE POWER BREAK DURATION

!

IF SY1

THEN CALL SR0;RESET B0,RESET B1

ELSE JUMP L10

!

IF B1

THEN SET SY0;0->B100[4]->B110[4]->B120[4]->B130[4];

0->W100->W110->W120->W130

ELSE SET B100;SET B110;SET B120;SET B130

< SET TASK AUX0

!L10

:IF NOT CTRL4,R

THEN START CTRL4

< ACTIVATE AEM MODULE DIAGNOSTICS OFB

!

IF NOT B0

THEN EXEC AEMDG0(;0=>;);EXEC AEMDG1(;1=>;);SET B0

AEMDG0

INIT

AEM

ERROR

Remark

SR0 is a subroutine that calculates the duration of the power break using informations stored in words SW50 to SW57. On return from the subroutine, bit B1 is at:

• 1 if the power break exceeded 10 seconds,

• 0 if not.

The programming required for subroutine SR0 is not described here.

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CHART Processing

X11,0

X12,IN

ACTION ON ACTIVATION

< SET LOOP TEMP-ENV TO AUTO, REMOTE SET POINT

!

SET PID2,MAN_AUTO;SET PID2,SP_RSP;6000->W125

< ALIGN OUTPUT LOOP TEMP-SOLU READY FOR SMOOTH TRANSITION

TO CASCADE LOOP OPERATION

!

RESET PID3,MAN_AUTO;6000->PID3,OUT_MAN

CASCADE LOOP TEMP-SOLU/TEMP-ENV

ACTION ON ACTIVATION

< ALIGN REMOTE SET POINT ON LOCAL SET POINT AND LOOP BACK

!

SET PID3,MAN_AUTO;PID3,SP->W135;SET PID3,SP_RSP

X12,0

ACTION ON ACTIVATION

< READ RECIPE

!

EXEC ISCL2(=>;;W137)

ISCL2

ERROR

STATUS

OUTPUT

ISCL2, VAL_MAX$

ISCL2, VAL_MIN$

ISCL2, OUT_MAX$

ISCL2, OUT_MIN$

= 100

= 0

= 10000

= 0

W137

G

CONTINUOUS ACTION

< CHECK PROCESS CONTROLLER STATUS

!

IF PID3,MAN_AUTO•PID3,SP_RSP

THEN W137-3->W138;W138+3->W139

ELSE PID3,SP->W135;JUMP L10

< SET POINT RAMP

!

IF SY6•NOT B6•[W135<=W138]

THEN W135+3->W135;JUMP L10

!

IF SY6•NOT B6•[W135>=W139]

THEN W135-3->W135

!L10

:SY6->B6

TRANSITION X12,0->X12,1

!

[W135>W138]•[W135<W139]•NOT W136,3•NOT W136,4

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PLC Application 3

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X13,I

X13,0

START ADDITIVE INJECTION LOOPS

ACTION ON ACTIVATION

< ACCEPT RECIPES

!

EXEC ISCL0(=>W105);EXEC ISCL1(=>;;W115)

< START LOOPS (AUTO, REMOTE SP)

!

SET PID0,MAN_AUTO;SET PID0,SP_RSP;

SET PID1,MAN_AUTO;SET PID1,SP_RSP

MONITOR REACTION

CONTINUOUS ACTION

!

IF W137,4

THEN RESET PID0,MAN_AUTO;0->PID0,OUT_MAN

ELSE SET PID0,MAN_AUTO

X13,1 STOP ADDITIVE INJECTION LOOPS

ACTION ON ACTIVATION

!

RESET PID0,MAN_AUTO;RESET PID0,SP_RSP;

RESET PID1,MAN_AUTO;RESET PID1,SP_RSP

X15,I

END CASCADE LOOP AND MAINTAIN LOOP TEMP-ENV AT THE LAST SP VALUE

ACTION ON ACTIVATION

< END CASCADE TEMP-SOLU / TEMP-ENV

!

RESET PID2,SP_RSP

< SET LOOP TEMP-SOLU TO MANUAL MODE

!

RESET PID3,MAN_AUTO

Note

During the reaction phase X13,0 the status of the process controller DEB_ADD1 (OFB PID0) is continually monitored by the PLC. This means that it is impossible to modify its state from a manmachine interface terminal.

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POST Processing

< SCALE TANK LEVEL

!

EXEC SCL0(IW1,5=>;)

IW1,5

SCL0

VALUE ERROR

STATUS

SCLO, VAL_MAX$

SCLO, VAL_MIN$

= 10000

= 0

SCLO, OUT_MAX$ = 100

SCLO, OUT_MIN$ = 0

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PLC Application 3

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3.3-2 Application Using PIDF OFBs (V5 Level PLCs)

This application differs from one using PID OFBs in the points listed below:

• PIDF OFBs use floating point format variables, with the following consequences:

- Measurements from TSX AEM modules must be converted from integer format into floating point notation using SCLF OFBs.

- Outputs intended for TSX ASR modules must be converted from floating point notation into integer format using ISCLF OFBs.

- The PL7-3 variables corresponding to PIDF OFB input parameters (e.g. PIDF, RSP) or exchanged with PIDF OFB internal data must either be expressed in floating point notation (using DWs) or be be subject to I

→

F / F

→

I conversion using SCLF and

ISCLF OFBs (in the example, they are expresses in floating point notation using

DW).

• On power return, the PIDF OFBs restart in the same state as prior to the power break,

• Cascade handling is ensured by the OFBs.

PL7-3 variable assignment

OFB

DEB-ADD1 DEB-ADD2 TEMP_ENV TEMP_SOLU

PIDF0

SCLF0

ISCLF0

PIDF1

SCLF1

ISCLF1

PIDF2

SCLF2

ISCLF2

PIDF3

SCLF3

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Words

Remote Set Point

Image state 0 PIDF OFB

DW104

W106

DW114

W116

DW124

W126

DW134

W136

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Bits

Save power return B100 B110 B120 B130

Measurement state B102 B112 B122 B132

B0

B6

: Power return or cold restart indicator.

: Save SY6.

DW138 : Solution temperature recipe.

DW140 :

Higher and lower (Min/Max) limits used for temperature rises.

DW142 :

DW150 : Tank level (after I

→

F conversion by SCLF3).

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Task AUX0

<CONTROL AEM AND ASR MODULES

!

<LOAD TSX AEM 411 MODULE CONFIGURATION

! IF IW1,2,D+NOT B1

THEN EXEC AEMLD0(0;0=>)

OFB: I/O PARAMETERS

0

0

AEM : word

APPLI : word

AEMLD0

<LOAD TSX AEM 413 MODULE CONFIGURATION

! IF IW2,2,D+NOT B1

THEN EXEC AEMLD1(1;0=>);SET B1

OFB: I/O PARAMETERS

1

0

AEM : word

APPLI : word

AEMLD1

<TSX ASR 402 MODULE CONFIGURATION

! H’F0'->OW3,1;SET OW3,0,C;SET OW3,0,E

<PROGRAM LOOP DEB_ADD1

!L100 :

<POWER RETURN PROCESSING

! IF NOT AEMLD0,READY

THEN JUMP L103

<TEST MEASUREMENT STATUS

!L101 :AEMLD0,READY.NOT IW1,1,8.NOT I1,S->B102

! IF NOT B102

THEN RESET PIDF0,MAN_AUTO;JUMP L102

! IF RE(B102)

THEN B101->PIDF0,MAN_AUTO

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PLC Application 3

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<PROGRAM LOOP

!L102 :EXEC SCLF0(IW3,3=>;;)

OFB: I/O PARAMETERS

IW3,3 INP : word

SCLF0

ERROR : bit

STATUS : word

OUTP : dwor

!L103 :EXEC PIDF0(SCLF0,OUTP;DW104;=>;W106;;)

OFB: I/O PARAMETERS

SCLF0,OUTP

DW104

PV : dwor

RSP : dwor

FF : dwor

PIDF0

ERROR : bit

STATUS : word

OUTP : dwor

PW_O : bit

! EXEC ISCLF0(PIDF0,OUTP=>;;OW3,3)

OFB: I/O PARAMETERS

PIDF0,OUTP INP : dwor

ISCLF0

ERROR : bit

STATUS : word

OUTP : word

W106

OW3,3

<STORE STATUS

! IF B102

THEN PIDF0,MAN_AUTO->B101;PIDF0,SP_RSP->B103

<PROGRAM LOOP DEB_ADD2

!L110 :

<PROCESSING FOR POWER RETURN

! IF NOT AEMLD0,READY

THEN JUMP L113

<TEST MEASUREMENT STATUS

!L111 :AEMLD0,READY.NOT IW1,1,9.NOT I1,S->B112

! IF NOT B112

THEN RESET PIDF1,MAN_AUTO;JUMP L112

! IF RE(B112)

THEN B111->PIDF1,MAN_AUTO

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<PROCESS LOOP

!L112 :EXEC SCLF1(IW1,4=>;;)

OFB: I/O PARAMETERS

IW1,4 INP : word

SCLF1

ERROR : bit

STATUS : word

OUTP : dwor

!L113 :EXEC PIDF1(SCLF1,OUTP;DW114;=>;W116;;)

OFB: I/O PARAMETERS

SCLF1,OUTP

DW114

PV : dwor

RSP : dwor

FF : dwor

PIDF1

ERROR : bit

STATUS : word

OUTP : dwor

PW_O : bit

! EXEC ISCLF1(PIDF1,OUTP=>;;OW3,4)

OFB: I/O PARAMETERS

PIDF1,OUTP INP : dwor

ISCLF1

ERROR : bit

STATUS : word

OUTP : word

W116

OW3,4

<STORE STATUS

! IF B112

THEN PIDF1,MAN_AUTO->B111;PIDF1,SP_RSP->B113

<PROCESS LOOP TEMP_SOLU

!L120 :

<PROCESSING FOR POWER RETURN

! IF NOT AEMLD1,READY

THEN JUMP L123

<TEST MEASUREMENT STATUS

!L121 :AEMLD1,READY.NOT IW2,1,9.NOT I2,S->B132

! IF NOT B132

THEN RESET PIDF3,MAN_AUTO;JUMP L122

! IF RE(B132)

THEN B131->PIDF3,MAN_AUTO

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PLC Application 3

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<PROCESS LOOP

!L122 :EXEC SCLF3(IW2,4=>;;)

OFB: I/O PARAMETERS

IW2,4 INP : word

SCLF3

ERROR : bit

STATUS : word

OUTP : dwor

!L123 :EXEC PIDF3(SCLF3,OUTP;DW134;=>;W136;;)

OFB: I/O PARAMETERS

SCLF3,OUTP

DW134

PV : dwor

RSP : dwor S

FF : dwor

PIDF3

ERROR : bit

TATUS : word

OUTP : dwor

PW_O : bit

<STORE STATE

! IF B132

THEN PIDF3,MAN_AUTO->B131;PIDF3,SP_RSP->B133

<PROGRAM LOOP TEMP_ENV

!L130 :

<PROCESSING FOR POWER RETURN

! IF NOT AEMLD1,READY

THEN JUMP L133

<TEST MEASUREMENT STATUS

!L131 :AEMLD1,READY.NOT IW2,1,8.NOT I2,S->B122

! IF NOT B122

THEN RESET PIDF2,MAN_AUTO;JUMP L132

! IF RE(B122)

THEN B121->PIDF2,MAN_AUT

<CASCADE LOOP

! IF XM12+XM13+XM14

THEN PIDF3,OUTP->DW124

W136

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<PROCESS LOOP

!L132 :EXEC SCLF2(IW2,3=>;;)

OFB: I/O PARAMETERS

IW2,3 INP : word

SCLF2

ERROR : bit

STATUS : word

OUTP : dwor

!L133 :EXEC PIDF2(SCLF2,OUTP;DW124;=>;W126;;)

OFB: I/O PARAMETERS

SCLF2,OUTP

DW124

PV : dwor

RSP : dwor

FF : dwor

PIDF2

ERROR : bit

STATUS : word

OUTP : dwor

PW_O : bit

! EXEC ISCLF2(PIDF2,OUTP=>;;OW3,5)

OFB: I/O PARAMETERS

PIDF2,OUTP INP : dwor

ISCLF2

ERROR : bit

STATUS : word

OUTP : word

W126

OW3,5

<AUTOMATIC CASCADE HANDLING

! PIDF2,SP_RSP->PIDF3,LINKED;PIDF2,SP_NORM->PIDF3,BUMPLESS;

SET PIDF2,COMMAND,D

<STORE STATE

! IF B122

THEN PIDF2,MAN_AUTO->B121;PIDF2,SP_RSP->B123

G

The TEMP_SOLU and TEMP_ENV loops form a process control loop cascade where

TEMP_SOLU is the master or external loop and TEMP_ENV is the slave or internal loop.

When the cascade loop is complete, the output from the loop, TEMP_SOLU is applied as set point for the TEMP_ENV loop.

The order in which the two loops are run is therefore important. The TEMP_SOLU loop

(EXEC PIDF3 instruction) must always be executed before the TEMP_ENV loop (EXEC

PIDF2 instruction).

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PLC Application 3

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The two screens shown below as examples, show the values of the constants in the

PIDF3 OFB:

The PV_HL$ constant defines the measurement high level alarm (85

°

c).

If the temperature-solution measurement exceeds this value, bit 3 of the OFB STATUS word is set to 1.

This is the information used by the ALARMS task to trigger display of the message

TEMP_SOLU EXCEEDED. Constant DEV_HL$ defines a maximum deviation (PV -

SP). If the measurement (PV) exceeds the Set Point by +2

°

C, a bit in the PIDF OFB

STATUS word is set to 1 (this bit is reset to zero once the deviation is again less than

1

°

C, allowing for hysteresis of 1%).

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The alarm information (bit 5 of the STATUS word) is used in the additive injection step to stop injecting additive 1 when the temperature-solution measurement exceeds the preset value by more than 2

°

C.

Note

There are two ways to initialize the internal constants of the PIDF OFB:

• From PL7-3 in Program mode (the CONTENT key that is accessible once the name and number of the OFB is entered. This key lets the user access the constants screen): This approach is necessary for the first five internal constants,

• For the other internal constants, from a Dialog/Adjustment terminal, using the SAVE function key that is accessible from the TREND screen.

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PLC Application 3

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PRL Processing

<CALCULATE POWER BREAK DURATION

! IF SY1

THEN CALL SR0;RESET B0;RESET B1

ELSE JUMP L10

! IF B1

THEN SET SY0;0->B100[4]->B110[4]->B120[4]->B130[4];

RESET PIDF0,MAN_AUTO;RESET PIDF1,MAN_AUTO;

RESET PIDF2,MAN_AUTO;RESET PIDF3,MAN_AUTO;

0>PIDF0,OUT_MAN->PIDF1,OUT_MAN->PIDF2,OUT_MAN->PIDF3,OUT_MAN

<ENABLE TASK AUX0

!L10 :IF NOT CTRL4,R

THEN START CTRL4

<ENABLE AEM MODULE DIAGNOSTICS OFBS

! IF NOT B0

THEN EXEC AEMDG0(;0=>);EXEC AEMDG1(;1=>);SET B0

OFB: I/O PARAMETERS

0

INIT : bit

AEM : word

AEMDG0

ERROR : bit

OFB: I/O PARAMETERS

1

INIT : bit

AEM : word

AEMDG1

ERROR : bit

Remark

SR0 is a subroutine that calculates the duration of the power break using information stored in words SW50 to SW57. On return from the subroutine, bit B1 is at:

• 1 if the power break exceeded 10 seconds,

• 0 if not.

The programming required for subroutine SR0 is not described here.

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CHART Processing

X11,0

X12,IN

X12,0

SET LOOP TEMP_ENV TO AUTO, SET POINT AT 60 DEGREES C

ACTION ON ACTIVATION

<SET LOOP TEMP_ENV TO AUTO, REMOTE SET-POINT

! SET PIDF2,MAN_AUTO;SET PIDF2,SP_RSP;60.->DW124

CASCADE LOOP TEMP_SOLU/TEMP_ENV

ACTION ON ACTIVATION

<ALIGN REMOTE SET POINT WITH INTERNAL SET POINT AND LOOP

! SET PIDF3,MAN_AUTO;PIDF3,SP->DW134;SET PIDF3,SP_RSP

BRING SET POINT TEMP_SOLU TO RECIPE VALUE IN STEPS OF 0.03 DEGREES C

RECIPE VALUE AVAILABLE IN DW138

CONTINUOUS ACTION

<CHECK PROCESS CONTROLLER STATUS

! IF PIDF3,MAN_AUTO.PIDF3,SP_RSP

THEN 0.03->DW144;SUBF(DW138;DW144)->DW140;

ADDF(DW138;DW144)->DW142

ELSE PIDF3,SP->DW134;JUMP L10

<SET POINT RAMP

! IF SY6.NOT B6.NOT SUPF[DW134;DW140]

THEN ADDF(DW134;DW144)->DW134

! IF SY6.NOT B6.NOT INFF[DW134;DW142]

THEN SUBF(DW134;DW144)->DW134

!L10 :SY6->B6

TRANSITION X12,0->X12,1

!

SUPF(DW134;DW140).INFF(DW134;DW142).NOT W136,4.NOT W136,5

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PLC Application 3

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X13,I

START ADDITIVE INJECTION LOOPS

ACTION ON ACTIVATION

<START LOOPS (AUTO,REMOTE SET POINT)

! SET PIDF0,MAN_AUTO;SET PIDF0,SP_RSP;

SET PIDF1,MAN_AUTO;SET PIDF1,SP_RSP

X13,0

MONITOR REACTION

CONTINUOUS REACTION

<STOP INJECTING ADDITIVE 1 IF TEMP_SOLU > SP + 2 DEGREES

! IF W136,4

THEN RESET PIDF0,MAN_AUTO;0->PIDF0,OUT_MAN

ELSE SET PIDF0,MAN_AUTO

X13,1

X15,I

STOP ADDITIVE INJECTION LOOPS

ACTION ON ACTIVATION

! RESET PIDF0,MAN_AUTO;RESET PIDF0,SP_RSP;

RESET PIDF1,MAN_AUTO;RESET PIDF1,SP_RSP

END CASCADE LOOP AND MAINTAIN LOOP TEMP_ENV AT THE LAST SP VALUE

ACTION ON ACTIVATION

<END CASCADE LOOP TEMP_SOLU/TEMP_ENV

! RESET PIDF2,SP_RSP

Note

During the reaction phase X13,0 the status of the process controller DEB_ADD1 (OFB PIDF0) is continually monitored by the PLC. This means that it is impossible to modify its state from a manmachine interface terminal.

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POST Processing

<I->F CONVERSION OF TANK LEVEL

! EXEC SCLF4(IW1,5=>;;DW150)

OFB: I/O PARAMETERS

IW1,5 INP : word

SCLF4

ERROR : bit

STATUS : word

OUTP : dwor DW150

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Man-Machine Interface Application 4

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4.1

Application Description

The man-machine interface application is created using the PL7-M37 program and the

REGUL (process control) option. It is executed by a TSX PCM 37 module.

Programming this application comprises:

• Defining the contents of the screens,

• Defining screen sequences,

• Defining the commands available to the operator in each screen,

• Defining alarms.

For this example, the following are used:

• A process diagram screen with the four process control loops shown by a small front panel (PFAV) symbol,

• A control screen mainly comprising the four process controller front panel (FAV) symbols that let the operator monitor or access any of the loops,

• An alarm screen,

• A TREND screen (tendencies),

• A TUNE screen (adjustment).

Only the first two screens DIAGRAM and CONTROL must be created, the other three screens are ready made.

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The sequence of screens is shown below:

ALARMS

DIAGRAM

F1

CONTROL

F1

F1

S1

From any screen

TREND

F7

Return to first screen

S4

S6

TUNE

F1

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The links between:

CONTROL

TREND

CONTROL

TREND

TREND

TUNE

ALARM

screens are predefined.

The links between:

DIAGRAM

DIAGRAM

CONTROL

ALARMS screens are defined by the user.

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Man-Machine Interface Application 4

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4.2

Diagram Screen Layout

This screen comprises:

• A diagram of the process (drawings and animations are user defined),

• The pre-animated ready made front panel (PFAV) displays used in the diagram represent the four process control loops,

• An alarm banner line,

• Function keys assigned to process control:

- F3 : START INSTALLATION,

- F4 : STOP INSTALLATION,

- F5 : START CYCLE,

- F6 : STOP CYCLE,

- F7 : SELECT AUTOMATIC MODE or CYCLE/CYCLE.

• Function keys for access to other screens:

- F1 : Control screen,

- S1 : Alarms screen.

• Text entry lines for the recipe values,

• Numerical output display for tank level.

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Animations other than pre-animated symbols

Function Action Value

F7

To Control screen

To Alarm screen

Start installation

Stop installation

Start cycle

Stop cycle

Select Auto/Cycle

SET

FOR

ON

ON

ON

ON

TGL

Assigned

Variable

DISPLAY

DISPLAY

START

STOPGEN

STARTCYC

STOPCYC

AUTOCYC

CONTROL

ALOG

—

—

—

—

—

PL7

Variable

—

—

B83

B84

B81

B82

B80

Text input lines

Location

Over the

PL7 Variable

Variable Min. Value Max. Value V4 PLC V5 PLC

REC-ADD1 0 40 ISCL0, VALUE DW104

ISCL1, VALUE DW114 Over the REC-ADD2

Over the

TEMP-SOLU display

REC-TEMP

0

0

60

83 ISCL2, VALUE DW134

Numerical output display

Location

Over the tank

Variable

TANKLEV

PL7 Variable

V4 PLC

SCL0, OUTPUT

V5 PLC

DW150

Alarm banner: Assigned variable: ALBANNER.

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Man-Machine Interface Application 4

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4.3

Control Screen Layout

This screen comprises:

• 4 pre-animated ready made FAV screens that support user dialog with the process control loops in the PLC,

• 1 input selector that lets the user select the active front panel,

• 1 pre-animated ready made TOUCHES symbol that supports:

- A link to the ALARMS screen with keys (S1, S2, S3),

- Access to the TREND screen (key S4),

- Control of the selected loop (keys S7 to S12).

• 1 alarm banner line,

• 1 function key (F1) to return the user to the DIAGRAM (SYNOP) screen.

The user can also add a function key to return to the Run Manager.

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4.4

Alarms

The Alarms task requires that the user define:

• A group of alarms assigned to the tank,

• Within this group, each event that generates an alarm message.

In the selected example, the group of alarms is called Tank.

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There are six events that generate alarms:

• Tank level > 90 %,

• Solution temperature > 85

°

C,

• Loop 0 measurement invalid,

• Loop 1 measurement invalid,

• Loop 2 measurement invalid,

• Loop 3 measurement invalid.

The tank level alarm is obtained by comparing the level value scaled by OFB SCL0 to the value 90.

The solution temperature alarm is obtained by using information from the PID3/PIDF3

OFB (bits 2/3 of Status word 0).

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Man-Machine Interface Application 4

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The invalid measurement alarms are obtained from information produced by the AUX0 task (bits B102, B112, B122, B132).

The correspondence between the symbols used in the PL7-M37 program and the PL7-3 variables is ensured by XTEL-SDBASE.

In V5 level applications, the variable SCL0, OUTPUT is replaced by DW150.

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