SIMATIC based technology Loop control with SIMATIC

Product Brief April 2002

Summary
The tasks to be handled by programmable controllers (PLC) are becoming increasingly complex. In many cases, solutions for closed-loop control tasks already belong to the standard repertoire of a PLC. Closed-loop control is required in many different fields of application: General mechanical engineering Industrial plant construction Industrial furnaces cooling and heating unit construction Food processing industry Rubber and plastics machines Wood and paper industry Chemical and process industry Glass and ceramics industry The most frequent applications are PID controls for analog variables such as temperature, pressure and flow. SIMATIC provides many functions for solving such closed-loop control tasks: Integrated functions are available in the programming software or in the CPU for simple closed-loop control tasks. Appropriateoption packages based on the STEP 7 programming software are available for solving medium and complex control tasks. Highly complex closed-loop control tasks with backup facilities are most appropriately solved using special function groups. Control with SIMATIC offers many advantages: SIMATIC offers a system-wide product range for control tasks of any complexity The software solutions can be implemented with all SIMATIC S7-200, S7-300, S7-400 and C7 controllers as well as with PC-based control (WinAC) The hardware solutions can be used in the SIMATIC S7-300/S7-400 and C7 controllers and distributed with the ET 200 Each solution can be implemented system-wide via all controllers with similar functions All functions are parameterized in the same way using a simple screen form interface

Contents of the Product Brief Closed-loop control with SIMATIC

Selection guide for controllers Controller types Control structures Integrated functions PID Control in STEP 7, STEP 7 (Micro/Win), CFC, CPU 313C/314C: Integrated, simple PID control algorithm for universal applications with SIMATIC S7 PID Temperature Control: Integrated, simple PID control algorithm designed specifically for temperature control Modular PID Control: Range of function blocks for modular closed-loop control for S7-300/S7-400 Standard PID Control: PID controller with off-the-shelf control structures for SIMATIC S7-300/S7-400 Function modules

Page 3 Page 4 Page 5 Page 12

STEP 7 option package (PID control)

Page 9

Page 10

FM 355 C/S, FM 455 C/S: Page 6 Controller module with backup facility for universal applications with online self-tuning for SIMATIC S7-300, C7, ET 200M

Application modules STEP 7 option package (PID self-tuner) Pulse width modulation Technical specifications 2

FM 355-2 C/S: Controller module with backup facility for temperature control and integrated online self-tuning for SIMATIC S7-300, C7, ET 200M Complex closed-loop control with the FM 458 application module in SIMATIC S7-400 PID Self-Tuner: Function block for online self-optimization of PID controllers for SIMATIC S7-300/S7-400, FM 355/FM 455 ET 200S function modules: 2 Pulse module for intelligent control of actuators Summary of closed-loop control functions/modules

Page 8

Product Brief FM 458 (can be ordered using the fax form on the back page) Page 13

Page 11 Page 14 2

Selection guide for control products

Task

Can be used in all types of temperature, volumetric flow, level, and pressure control

Requirements Instances Products Formats Controllers Functions

Basic SW PID Control

Intermediate SW Standard PID Control

Advanced SW Modular PID Control HW module FM 355C, FM 355S, FM 455C, FM 455S

Suitable for flexible use in SIMATIC S7-300, S7-400, C7, ET 200 Continuous closed-loop controllers, step controllers, pulse controllers

Closed-loop control basic functions

Wide range of closed-loop control functions

Extensive range of closed-loop control functions Backup facility: continuation of closed-loop control in the event of a stop or CPU failure

User-friendly online self-optimization for all controllers with PID self-tuner Blocks FB 41 FB 42 FB 43, etc. FB 1 FB 2 FC 1 27 standard function blocks C controllers: FM 355C/455C S controllers: FM 355S/455S Pulse controllers: FM 355S/455S Preset; closed-loop control structures and processing functions can be adapted through parameter assignment

Closed-loop control structures

Preset; closed-loop control structures and Freely configurable: processing functions can be adapted the function blocks through parameter assignment can be combined and interconnected as required Tabular parameter overview

Configuration tools

Graphic configuration with user-friendly parameter assignment screen forms Changes applied and recorded immediately in online operation

Task

Designed specifically for temperature control Basic SW PID temperature control Suitable for flexible use in SIMATIC S7-300, S7-400, ET 200M, C7 Intermediate to advanced HW module FM 355-2 SIMATIC S7-300, C7, ET 200M

Requirements Instances Products Formats

Controllers Functions

Continuous closed-loop controllers, step controllers, pulse controllers --

Specialist temperature algorithms Integrated online self-optimization Self-optimization as initial/follow-up optimization at operating point Backup facility Ideal support for thermocouples

Blocks Closed-loop control structures

FB 58, FB 59

Function blocks for integration into the user program

Closed-loop Preset; control basic closed-loop control structures and processing functions can be adapted via functions parameter assignment Initial optimiz. and adaptation to operating point Graphic configuration with user-friendly parameter assignment screen forms Changes effective and recorded immediately in online operation 3

Configuration tools

Tabular parameter overview

Controller types

We would like to start with a summary of the most important controller types and structures that can be implemented with SIMATIC S7/C7.
a)

Controller types

Continuous controller: Response of manipulated variable 50% 25%

The choice of controller depends on the final control element to be controlled. All closed-loop control products offer the following controller types:
Continuous controllers

In continuous controllers (see Fig. 1a), the manipulated variable Y can assume any value within the control range. The output value is an analog value. Such controllers are required if the final control element requires a continuous signal (e.g. a voltage constantly applied to a valve).
Pulse controllers

b)

Pulse controller with one digital 1 output (2-position control): Response of pulse/space signal: A short period T, i.e. many positioning pulses per unit of time, result in an almost continuous response of the manipulated 0 variable

25%

25%

37%

50%

50%

In pulse controllers (see Fig. 1b), the continuous output signal is converted into a mark/space signal. The control response is determined by the ratio between the pulse length and the intermediate spaces. In the case of a temperature control with electrical heating elements, for example, a specific mark/space ratio is output for each constant temperature value. The pulse controller may have a two-position or three-position response (e.g. HEATING - OFF - COOLING).
Step controllers

Fig. 1

Response of a continuous controller (a) and a pulse controller (b)

Step controller: (3-position response)

AUF

A step controller (see Fig. 2) has 3 switching states, e.g. COUNTERCLOCKWISE - STOP CLOCKWISE. Step controllers are used if a control element with latching is to be controlled. These final control elements must always have an integrated-action response. They can be implemented with or without a position feedback. Step controllers are used, for example, for electric motors as the actuator, for valves, dampers, slides etc. The motor only receives a corresponding pulse when either the actual value deviates from the setpoint (without position feedback) or when the position feedback deviates from the calculated manipulated variable.

ZU t 1. Digital output (DO): Positioning pulse for Open valve 1

1. DA 0 t 2. Digital output (DO): Positioning pulse for Close valve 1

2. DA 0 t

Fig 2:

Response of a step controller for a valve

Control structures

Fixed setpoint control

This is the simplest control structure where a fixed setpoint is defined on the controller. This setpoint is only rarely changed depending on the process. A fixed setpoint controller is frequently used as a single-loop controller, and also as a master controller in a cascade, ratio or blending control.
Follow-up control

Liquid PID 1 Master controller PID 2 Follow-up controller Manipul. variable

Heat exchanger

In contrast to a fixed setpoint control, the setpoint is changed online here. The special task of the follow-up controller is to bring the controlled variable into line with the continuously modified setpoint quickly and precisely. A follow-up controller is frequently used as a subordinate controller in a cascade structure.
Cascade control

Flow Temperature

If the control results are unsatisfactory when using single-loop control, the control response can be improved by using additional variables from the process. A cascade control structure comprising a master controller and a follow-up controller, is illustrated in the upper figure. The measured intermediate variable is adjusted to a defined setpoint by the follow-up controller. This setpoint is defined by the master controller and its result. Examples Heater with control of steam flow and temperature Position control with subordinate speed and current controls.
Ratio control

Temperature/flow cascade control

PID 1 Master controller

PID 2 Follow-up controller

Manipul. variable

x Flow of gas

Ratio factor

Air Gas

In some processes, the ratio between two or more controlled variables is more important than their absolute values. Such tasks require a ratio control. The subordinate control loop in the lower figure shows the design of a ratio control where the ratio of air and gas is held constant.

Flow of air

Temperature control with classical ratio cascade control

A combination of a cascade structure and a subordinate ratio structure results in a ratio cascade control as shown in the lower figure using an example of a temperature control (master controller) with a ratio control for air and gas (follow-up controller).

Blending control

In blending control, the components to be mixed must be held at a defined percentage similar to the ratio control. The total quantity required must also be controlled.

FM 355 and FM 455 universal closed-loop control modules

The FM 355 closed-loop control modules for SIMATIC S7-300, C7 and ET 200M (on S7-300/S7-400 master) and FM 455 for S7-400 can also be used in PCS 7 and offer the same functionality. The only difference is the number of channels: the FM 355 has 4 channels, the FM 455 has 16. Both modules have a special selfoptimization function with which the controllers can be optimized. The backup functions enable fault-free operation if the CPU fails or goes to Stop. Two versions of the modules are available for driving different final control elements: FM 355 C/FM 455 C as a continuous controller for driving analog final control elements. FM 355 S/FM 455 S as a step or pulse controller for driving motorized final control elements (integrating control elements or binary-driven final control elements e.g. electrical heating strips and cartridges).
Application

The FM 355 (right) and FM 455 (left) closed-loop control modules

The closed-loop control modules are suitable for universal use, e.g. for temperature, pressure, volumetric flow or level control in numerous applications in machine and system production. The backup function in particular makes the modules particularly suitable for I&C applications in the chemical, glass and ceramics industries. They can also be used to control continuous processes and batch processes.
Scope of delivery

The parameter assignment software supplied with the modules contains extensive online help for the input screen forms as well as a function block that provides the module data to the STEP 7 program in the CPU channelby-channel. A comprehensive manual and Getting Started tutorial are also provided.
Functions Controller optimization

Operating modes

In addition to automatic and backup modes, the modules also work in the following modes: Manual mode Follow-up mode Safety mode
Firmware update

The closed-loop control modules contain several ready-to-use control structures: Fixed setpoint control Cascade control Ratio control 3-component control Up to 4 controllers can be interconnected to form one control structure (this limit also applies to FM 455).

The module has two individual algorithms with various optimization options: Fuzzy controller with integrated online self-optimization for temperature ranges. Optimization possible for setpoint step changes of 12% and upwards. PID controller can be optimized via the parameter software (PG/PC required).
Backup mode

In order to update the firmware fast and effortlessly, simply download the current version from the Internet. Use the parameter assignment software to transfer the new firmware into the module.
Test functions

Extensive test functions and simulation options are available to offer assistance during the startup process.

This function ensures that the controller continues to operate even if the CPU fails or goes to Stop. It is possible to set a safety setpoint or a safety manipulated variable for backup mode.

FM 355 and FM 455 universal closed-loop control modules

Design

Both modules are double-width. Sensors and actuators can be connected directly to the module.
Inputs

The 4 or 16 analog inputs can be used for analog-value acquisition or for disturbance variable feedforward. An additional input is used for temperature compensation in thermocouple mode. The resolution is 12 or 14 bits including the sign. The sampling time comprises: 12-bit resolution: 20 ms * no. of channels + 20 ms for temperature compensation 14-bit resolution: 100 ms * no. of channels + 100 ms for temperature compensation On the FM 455, sampling takes place in two groups in parallel. A maximum of 8 analog inputs is permitted per group.
Connectable sensors
Parameter assignment screen form for FM 355 S

The associated characteristics are stored on the module for the connectable sensors and are activated through parameter assignment. If a sensor characteristic is not already present, it is possible to enter any characteristic by defining interpolation points.

Comprehensive operating and monitoring functions facilitate testing and therefore reduce the duration of the startup phase.

FM 355-2 temperature controller module

The FM 355-2 temperature controller module is a function module based on the FM 355 and designed specifically for controlling temperature ranges. Like the FM 355, the FM 355-2 has 4 channels and is available as the FM 355-2 C and FM 355-2 S. Both versions of the module have an integrated online self-optimization facility and a backup facility.
Application

The module is designed to control temperature ranges. Controllers with heating or active cooling functions can be implemented and optimized. In principle, other ranges with similar requirements can also be controlled.
Scope of delivery
Controller optimization on temperature controller module FM 355-2

See FM 355 (page 6). A screen form is supplied with the module to facilitate control of the major controller functions. The user can integrate this easily into an OP27 project.
Functions Control algorithm

The module operates with a PID algorithm.

Controller optimization

The controllers response to setpoint changes can be changed and overshoots avoided by adjusting the attenuation of the proportional component in the event of setpoint changes. The control output limits can be modified online.
Backup mode

Increased accuracy

The accuracy of the FM 355-2 is greater than that of the FM 355. This is particularly beneficial when using thermocouples.
Connectable encoders

The FM 355-2 has an integrated online self-optimization function, which can be used for controller optimization during operation without the need for a PG/PC. Self-optimization can be started either when the ambient temperature is reached, via a control output jump (initial optimization) or when the controller reaches its operating point (follow-up optimization). A quasi-stationary state is required to start optimization, i.e. actual value drift can be tolerated. The control parameters are available as soon as the turning point of the step response is reached. Startup time is reduced considerably as a final state is not required. The controller has a control zone to accelerate the approach to the operating point.

In the event of a CPU stop or failure, the module can continue to control operation in backup mode (see FM 355). However, input through the operator panel is not possible in the event of a CPU failure.
Resolution

As the FM 355 but with the addition of the Type E thermocouple. However, the p80 mV input is not available. Temperature compensation when using thermocouples: Through external Pt100 Internal temperature detector Parameterized value
Test functions

The analog inputs have a resolution of 14 bits.

Sampling time

Extensive test functions and simulation options are available to offer assistance during the startup process.

The sampling time is 100 ms for each analog input used. If the compensation input is used, it must be taken into account along with the sampling time.

Modular PID Control

Modular PID Control is a collection of standard function blocks, which can be combined to create any type of control structure for SIMATIC S7/C7. The blocks can be connected using STEP 7, SCL, and CFC. The following controller types are available: Continuous PID controller Pulse controller Step controller
Application

Modular PID Control is suitable both for applications requiring extensive control structures and for applications in which memory must be saved and individual controllers from the standard module stock are sufficient for application requirements. It is often worth purchasing the product even if the only blocks used are computational blocks such as dead band, polygon, scaling or time scheduler. The main applications are in processing plants.
Scope of delivery

Modular PID Control with the CFC graphic editor

The scope of delivery includes the following ready-to-use examples: Fixed setpoint controller with various outputs Single-loop ratio controller Multiple-loop ratio controller Blending controller Cascade controller Controller with precontrol Controller with feedforward control function Range selection controller Multiple variable controller Sampling times down to 5 ms are possible in conjunction with the SM 334 analog module.

A software program, which considerably simplifies the commissioning of the PID controller, can be supplied for Modular PID Control with SIMATIC S7/C7. This software contains a control loop display with bargraphs and a curve recorder for displaying signal characteristics (see left figure on page 11). Modular PID Control is available as a function block library for SIMATIC S7-300/S7-400 and C7.
Functions

Design of closed-loop control structures with CFC

The following technical functions have the same characteristics as in Standard PID Control: User-friendly parameter assignment Test functions Controller optimizing Transient response without overshoots Control algorithm for step controller Combination with the PID Self-Tuner is also recommended here for online selfoptimization of controlled systems for temperature.

For the first time, CFC V5.0 (Continuous Function Chart) and later supports the configuration and user-friendly interconnection of any type of control structure. The 27 blocks of Modular PID Control are complement one another perfectly and can thus be combined both quickly and easily using the CFC graphic editor (see figure above). Complex control structures can therefore be designed and tested reliably and clearly within a short time. In particular when combined with CFC, Modular PID Control is a universal modular concept for solving a wide range of closed-loop control tasks.

Standard PID Control

Standard PID Control is a preconfigured controller structure, which can be adapted to the control process simply by activating or deactivating functions.
Application

Standard PID Control is suitable for closed-loop control tasks of low or medium complexity: for temperature, pressure, flow and level controls. Standard PID Control is particularly suitable for applications previously automated with compact controllers.
Scope of delivery

The scope of delivery of the function blocks includes the following ready-touse examples: Step controller with loop simulation Continuous controller with loop simulation Multiple loop ratio controller Blending controller Cascade controller Siemens offers parameter assignment software for Standard PID Control that permits the functions of the standard function block to be easily utilized.
Functions Test functions

The clear controller structure of Standard PID Control

User-friendly parameter assignment

Controller optimization

A comprehensive range of test functions facilitates startup and diagnostics. As in the case of the controller modules FM 355/455 and Modular PID Control, a control loop display with bar graph and curve recorder are available for plotting the signal curves (see left figure on page 11). The windowing techniques of Windows allow the control structure, the parameters entered, and their effect on the result to be displayed simultaneously. The curves plotted with the curve recorder can be saved to file for subsequent editing e.g. in MS Excel.

Parameter assignment with the uniform, clearly arranged Windows user interface that supports intuitive working methods is particularly simple and is common to all function packages that rely on STEP 7. The clear controller structure allows functions to be selected or deselected simply using software switches (see figure above). The user interface for parameter assignment means that changes to parameters can also be made with the CPU in the RUN status. In addition, changes to parameters are now also possible while the curve recorder or the loop display are active. Cursor positioned in input fields: Display of parameter name and address in instance block. The current value is additionally displayed in online mode. Cursor positioned on measuring points: Display of name and address in the instance block. The current value is additionally displayed in online mode. The multi-instance data block (DB) benefits from user-friendly support from the control structure image, loop image, curve recorder and controller optimization.

For Standard PID Control, controller optimization is integrated in the parameter assignment software. Using this self-tuning function, controllers can be optimized very quickly even without precise knowledge of the controlled system. To initiate the function, the process is activated with a step change in manipulated variable or a modification in the setpoint. During the transient response, the process values are automatically recorded and displayed. The program calculates a mathematical module of the controlled system from the values, and determines the optimum control parameters for PI and PID controllers. At each input step, the relevant information is displayed on the screen. This simplifies start-up and produces rapid results.
Transient response without overshoots

In the case of self-optimization, two different transient responses are available for selection: transient response of the control loop with overshoots of up to 10 %, or transient response without overshoots. This means that self-optimization can also be used when overshooting has to be avoided at all costs.

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10

Standard PID Control

2 Pulse module

Optimization of Standard PID Control with PID Self-Tuner

2 Pulse module

Functions (continued) Pulse controller

2 Pulse module Step controller

The pulse controller is now combined with the continuous controller in one block including the conversion into a pulse/space signal (pulse generator). This simplifies the parameter assignment and startup of the pulse controller. It is also possible to set the sampling time of the controller separately from the period duration of the pulse generator, so that the period duration can be longer than the sampling time. The advantage of a shorter sampling time is the faster reaction of the controller to faults and operator input commands. On the other hand, a longer period reduces wear on the final control element by reducing the pulse generator frequency. Oscillations in actual values are suppressed in that the effective period is automatically shortened. A further advantage is the lower CPU loading since the pulse generator can be scanned at longer intervals. The example of a pulse controller with 3-position output (HEATING - OFF COOLING) facilitates startup of the temperature control.

A control algorithm ensures that step controllers switch up to 50 % less often than conventional step controllers for the same control precision. This reduces wear on the final control elements and lengthens their service life considerably.
Extended manual/automatic switchover

The 2 Pulse module is a 2-channel, 15 mm wide ET 200S technology module for controlling actuators and valves. In connection with the SIMATIC software control packages, e.g. Standard PID Control, it can output pulse-width-modulated control outputs, relieving the load on the CPU.
Areas of application

The following functions can be parameterized for the manual/ automatic switchover: Bumpless manual/automatic switchover Manual/automatic switchover with bumps and corresponding jump in the manipulated variable for fast compensation of the deviation Tracking of manual value in automatic mode

The 2 Pulse module can for example be used to control solid-state contactors or to switch cartridge type heaters.
Operating modes

The 2 Pulse module operates in the following modes: Pulse output: A single pulse is output on the 24 V digital output. PWM (Pulse Width Modulation): - A pulse-width-modulated signal sequence is output on the 24 V digital output (this operating mode is particularly suitable for control engineering); or - A signal present on the 24 V digital input is output on the 24 V digital output with an ON/OFF delay Pulse train: A number of pulses set by the user is output on the 24 V digital output.

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PID Control

PID temperature control

Areas of application

PID Control provides a simple PID algorithm with which simple closedloop control tasks can be directly solved. It is particularly suitable for simple control tasks.
PID Control for SIMATIC

- S7-200 is a component STEP 7MicroWin programming software. - S7-300/S7-400 is integrated in STEP 7, STEP 7-Mini CFC V1.1 and later as well as in the operating system of the CPU 313C/314C. The number of controllers which can be implemented with the S7-300/S7-400 depends on the available memory space and the resulting total runtime. PID Control uses standard function blocks loaded into the CPU to solve the closedloop control task.
Scope of delivery

Control parameters on the S7-300/400 using the example of PID Control

SIMATIC S7-200 Controller block for implementing a continuous closed-loop controller, step controller or pulse controller SIMATIC S7-300 One function block each for the continuous closed-loop controller, step controller or pulse generator module

PID Temperature Control Application Functions

Functions Controller parameter assignment

PID Control for S7-200: Simple programming thanks to a special operations wizard PID Control for S7-300/S7-400: User-friendly thanks to tabular overview (see figure).

In addition to the universal PID Control function blocks, STEP 7 Version 5.1 SP3 and later offers two new controller blocks designed specifically for controlling simple temperature ranges. When developing the blocks, particular importance was placed on ease of handling For example, the function block interfaces were simplified considerably for the purpose of userfriendliness The controller blocks can be used in heating or cooling applications. In principle, other ranges with similar requirements can also be controlled.
Scope of delivery

The blocks are supplied integrated into STEP 7 together with parameter assignment software, a sample project and an electronic manual.

In addition to the PID Control functions described, the FB 58 TCONT_CP blocks also have functions for temperature control via an integrated online selfoptimization facility. This means that a PG/PC is not required for optimization. The blocks also have an integrated pulse generator module for implementing pulse controllers. In contrast to the solution with PID Control, the user does not have to interconnect any controller blocks. Programming is replaced by parameterization. The FB 59 TCONT_S controller block is used to create step controllers. The new parameterization software can be started directly from the SIMATIC Manager by double-clicking on the associated instance data block. In addition to the familiar PID Control functions, the parameterization software also has a self-optimization wizard and a special installation screen form.

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Integrated controller

PID self-tuner

PID-self-tuner

PID parameters Manipulated variable

Setpoint

Actual value Process

PID controller

SIMATIC S7-300 CPU 314C

PID self-tuner optimizes a PID controller

The operating systems of the new 313C and 314C compact CPUs contain integrated closed-loop control blocks. The following blocks are supplied as system function blocks (SFBs): Continuous controller Step controller Pulse generator module The advantage: No user memory is used for the controller blocks. Both the analog and digital I/O integrated in the CPU can be used to implement the controller. Appropriate modules from the extensive SIMATIC range can also be used. Special outputs for pulse width modulation are also available. These are suitable for the direct control of valves, actuators and switching devices.
Functions

Application

Same functional scope as PID Control.

Parameter assignment

The PID Control Parameterization tool supplied with STEP 7 is used for parameter assignment.

By adding a function block, the PID SelfTuner software package converts the PID controller into a self-optimizing PID or PI controller, enabling users to set PID controllers online and adapt them during operation. The controller can be adapted to the process quickly and easily in online mode using easy-to-understand functions and systematically constructed examples. PID Self-Tuner is ideal for optimizing temperature, level, and volumetric flow controllers. The process must satisfy the following conditions: Stable asymptotic transient response Reasonable delay times (delay time < 0.3 * recovery time) Sufficient linearity in the selected working range Sufficient quality of measured signals Moderate process gains. PID Self-Tuner is versatile: it can be combined with all controller products and used on both the SIMATIC S7-300/ S7-400 and C7 hardware platforms.
Functions

Online adaptation of the PID controller for follow-up optimization at the operating point Optimization of processes with heating and active cooling Manual mode Optimization for control zone response Test functions Function blocks - FB TUN_EC for optimizing continuous PID controllers - FB TUN_ES for optimizing step controllers with and without position feedback Sample project Electronic manual

Scope of delivery

Initial online tuning of PID controllers 13

Technical specifications
Control functions/modules Delivery form PID Control in S7-200 Software, Component of STEP 7-MicroWin PID Control in STEP 7, CFC, CPU 313C/314C Software, Component of STEP 7, CFC, CPU 313C/314C

PID Temperature Control Software, Component of STEP 7 from V5.1 SP3 PID temperature controller in STEP 7 for simple heating or cooling controllers with integrated selfoptimization Standard PID Control SW optional packages: function blocks (FB), parameterization software, manual
PID controller with off-theshelf control structure and for control tasks of simple to medium complexity, incl. 5 examples

Application

PID controller in S7-200 for PID controller in STEP 7 simple closed-loop control for simple closed-loop tasks: up to 8 independent control tasks control loops

Properties Number of channels Installation width Backup capability Startup (test, diagnostics) 8 channels per CPU See I/Os See I/Os Determined by CPU and I/Os ---

Determined by CPU and I/Os ----In conjunction with PID Self-Tuner

With parameterization software Yes, for continuous and In conjunction with pulse controllers PID Self-Tuner (integrated optimization)

Online self-optimization of controller with -controlled systems for temperature

Online self-optimization of controller with -systems other than for temperature

In conjunction with PID Self-Tuner also for fill level and flow control

Controllers for ranges with similar characteristics can be optimized

With param. software

Elementary closed-loop control functions PID algorithm Output of continuous PID controller Output of pulse controller Output of PID step controller Pulse generator Integrator Differentiator Physical scaling Dead band Conversion of analog input value Conversion of analog output value Limit monitor Limiter Yes Yes Yes -Yes Yes Yes (FB 41, SFB 41) Yes (FB 41, SFB 41, FB 43 and SFB 43) Yes (FB 42, SFB 42) Yes (FB 43, SFB 43) Yes Yes (FB 58) Yes (FB 58) Yes (FB 59) Component of FB 58 Yes Yes (FB 1) Yes (FB 1) Yes (FB 2) Yes (component of FB 1)

Component of PID algorithm Component of PID algorithm Yes (in the actual value and man. var. branches) -Yes Yes Yes (in the actual value
and man. var. branches)

Component of PID algorithm Component of PID algorithm Yes (in act. value branch) Yes (in setpoint, actual value and man. var. branches) Yes Yes Yes Yes (in the system dev.) Yes (in act. value branch) Yes (in man. var. branch)

Yes (in the system dev.) Yes (in act. value branch) Yes (in man. var. branch) -Yes (in man. var. branch)

Yes (in act. value branch and in the system dev.) Yes (in setpoint and actual value branches) Yes -Yes (in setpoint and man. var. branches) Yes Yes (FC 1)

--

System deviation monitoring

--

---

Controller call distributor (for even -distribution of CPU program runtime load) Supplementary functions Setpoint generator Time scheduler Ramp generator 1st order delay element 2nd order delay element ------

------

------

Yes (in setpoint branch) Yes (in setpoint branch)

Yes (in setpoint and man. var. branches) Yes (as filter in actual value branch) --

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Modular PID Control SW optional packages: function blocks (FB), parameterization software, manual Modular FB building blocks for complex closed-loop control tasks with maximum flexibility and minimum memory requirements and shortest runtime, with 12 examples PID Self-Tuner Software, Optional package: function blocks incl. manual FB for online selfoptimization of PID temperature controllers, can be combined with Standard and Modular PID Control, FM 355/455 and any PID algorithm, with 3 examples FM 355-2 C FM 355-2 S FM 355-2 C, FM 355-2 S, incl. parameterization software, manual, and Getting Started FM 355 C FM 355 S FM 355 C, FM 355 S, incl. parameterization software, manual, and Getting Started FM 455 C FM 455 S FM 455 C, FM 455 S, incl. parameterization software, manual, and Getting Started Module with off-the-shelf control structures and back-up capabilities when the CPU is at Stop or in the event of a CPU failure, integrated online self-optimization of controlled systems for temperature, tailored onboard I/Os. Specifically for FM 355-2C/S: specialist for temperature control, increased accuracy, improved control response. Specifically for FM 455C/S: self-optimization to speed up commissioning of control structures.

See I/Os Determined by CPU and I/Os -With parameterization SW In conjunction with PID Self-Tuner

See I/Os

4 Double width (80 mm)

4 Double width (80 mm) Yes

8/16 Double width: 2 slots (50 mm) Yes

-Irrelevant In conjunction with PID controllers

Yes With param. software Yes, PID controller with integrated online selfoptimization. Initial optimization and adaptation, heating and cooling. Ranges with similar characteristics can be optimized

Yes, self-optimizing fuzzy controller

With parameterization software or with PID SelfTuner

--

Only with parameterization or in conjunction with PID Self-Tuner

Yes (FB 19) Yes (FB 13) Yes (FB 13 and FB 20) Yes (FB 14) Yes (FB 20) Yes (FB 8) Yes (FB 6) Yes (FB 16) Yes (FB 5) Yes (FB 2) Yes (FB 3) Yes (FB 11) Yes (FB 12)

--------------

Yes Yes (FM 355-2 C) Yes (FM 355-2 S) Yes (FM 355-2 S) Yes (FM 355-2 S) Component of PID algorithm Component of PID algorithm Yes (in act. value branch) Yes Yes Yes

Yes Yes (FM 355 C) Yes (FM 355 S) Yes (FM 355 S) Yes (FM 355 S)

Yes Yes (FM 455 C) Yes (FM 455 S) Yes (FM 455 S) Yes (FM 455 S)

Yes Yes Yes

Yes Yes Yes

Yes (in act. value branch and in the system dev.) Yes (in setpoint and manipulated value branches)

Yes (FB 7) Yes (FC 1)

---

Yes Not required

Yes

Yes

Yes (FB 25) Yes (FB 21) Yes (FB 22) Yes (FB 9) Yes (FB 10)

------

--Yes (in setpoint branch)

---

---

Yes (as filter in actual value branch) ----

15

Technical specifications
Control functions/modules Supplementary functions (continued)
Adaptive dead band

PID Control in STEP 7, CFC, CPU 313C/314C PID Temperature Control Standard PID Control ----------------

PID Control in S7-200

------

Dead time Non-linear static characteristic Linear scaling Linearization

Override control Parameter control Range selection (split range) Analog-value switch Setpoint branch Setpoint generator Time scheduler Scaling Limiter Limitation of modification rate FC call (nested) Actual-value branch Format conversion Scaling Smoothing Square-root function Monitoring of modification rate Limit monitor FC call(nested) Closed-loop controller Continuous PID controller PID pulse controller PID step controller Temperature controller Position feedback Connectable encoders Thermocouples Resistance-type thermometer Voltage Current Inputs/outputs Analog inputs per controller channel Digital inputs per controller channel Analog outputs per controller channel Digital outputs per controller channel Connection method

-----

-----

-----

-----

-------

-------

-------

Yes YesYes Yes Yes Yes

Yes Yes Yes --Yes --

Yes Yes ------

Yes Yes ------

Yes YesYes Yes Yes Yes Yes

Yes Yes Yes (programmable) Yes (programmable) --

Yes Yes Yes Poss. (with PID SelfTuner) --

Yes Yes Yes Yes --

Yes Yes Yes Yes (with PID Self-Tuner) Yes

-----

-----

-----

-----

------

------

------

------

16


Modular PID Control PID Self-Tuner FM 355-2 C FM 355-2 S FM 355 C FM 355 S FM 455 C FM 455 S Yes (FB 1) Yes (FB 4) Yes (FB 15) Yes (FB 23) -------Yes -Linearization of thermocouples B, E, J, K, R, S, and Pt100; root function; free polygon-based function --Yes ---Yes ---Yes --

Linearization of thermocouples B, J, K, R, S, and Pt100; root function; free polygon-based interpolation

Yes (FB 17) Yes (FB 18) Yes (FB 24) Yes (FB 26)

-----

--Yes --

--Yes --

Yes (FB 25) Yes (FB 21) Yes (FB 16 and FB 23) Yes (FB 12) Yes (FB 22) Yes

-------

--Yes Yes ---

--Yes Yes ---

--Yes Yes ---

Yes (FB 2) Yes (FB 16 and FB 23) Yes (FB 9) -Yes (FB 22) Yes (FB 11) --

--------

-Yes Yes Yes -Yes --

-Yes Yes Yes -Yes --

-Yes Yes Yes -Yes --

Yes (FB 19 and FB 13) Yes (FB 19, FB 13, FB 21) Yes (FB 19 and FB 14) Yes (with PID Self-Tuner) Yes (FB 19 and FB 14)

------

Yes, temperature controller Yes, temperature controller Yes, temperature controller Yes Yes

Yes Yes Yes Yes (fuzzy) Yes

Yes Yes Yes Yes (fuzzy) Yes

-----

-----

Type B, E, J, K, R, S Pt100 0 ... 10 mV 0 ... 20 mA, 4 ... 20 mA

Type B, J, K, R, S Pt100

Type B, J, K, R, S Pt100

p80 mV, 0 ... 10 mV

0 ... 20 mA, 4 ... 20 mA

p80 mV, 0 ... 10 mV

0 ... 20 mA, 4 ... 20 mA

------

------

1 2 1 (only FM 355-2 C) 2 (only FM 355-2 S) Standard front connector

1 2 1 (only FM 355 C) 2 (only FM 355 S)

1 1 1 (only FM 455 C) 2 (only FM 455 S)

17

Technical specifications
Control functions/modules Manipulated variable branch Manual/automatic switchover Manual-value generator Scaling Format conversion Limiter Limiting of modification rate FC call (nested) Pulse generator Closed-loop control structures Fixed setpoint control Follow-up control Cascade control Ratio control Blending control 3-component control Split range System environment Central use Distributed use PC-based Control System integration Hot swapping of modules Supported by -STEP 7-MicroWin -STEP 7 from V3.0 CPU 313C/314C from STEP 7 V5.1 SP3 CFC V1.1 Yes Part of STEP 7 Yes (PID Control is integrated into CFC) Via function blocks Yes, via memory card or micro memory card S7-200 (CPU 214) -Yes, as DP-, MPI slave Yes -Yes (programmable) ----Yes -Limited Limited ---Yes -Yes Yes ----Yes -Yes Yes Yes --Yes PID Control in S7-200 PID Control in STEP 7, CFC, CPU 313C/314C

PID Temperature Control Standard PID Control Yes -Yes Yes Yes --Yes Yes Yes Yes Yes Yes Yes Yes Yes

Yes -Limited Limited ----

Yes Yes Yes Yes Limited -Limited

S7-300, CPU 313C/314C, S7-400, C7-6xx Yes -Yes --

S7-300, S7-400, C7-6xx Yes --

-STEP 7 from V5.1 SP3

-STEP 7 from V2.1

Function blocks Parameterization software Integration with CFC Types of access Module replacement without prog. device Authorization/licensing Authorization Runtime license for FB/FC/C library License for parameterization software Order No. group

-Part of STEP 7-MicroWin -Via user program Yes, via memory module

Yes

Yes Yes

Can be integrated

-Via FB/FC

Yes, via memory card

-Irrelevant Irrelevant 6ES7810-2BC01-....

--

--

Yes, for param. software Required for each CPU Required for each PC/PG

6ES7810-4....-....

6ES7810-4....-....

6ES7830-2AA..-....

18


Modular PID Control PID Self-Tuner FM 355-2 C FM 355-2 S FM 355 C FM 355 S FM 455 C FM 455 S Yes (FB 13 and FB 14) Yes (FB 25) Yes (FB 16 and FB 23) Yes (FB 3) Yes (FB 12) Yes (FB 21) -Yes (FB 20) --------Yes Yes Yes Yes Yes --Yes (only FM 355-2 S) Yes Yes Yes Yes Yes --Yes (only FM 355 S) Yes Yes Yes Yes Yes --Yes (only FM 455 S)

Yes (examples 1 and 2) -Yes (example 7) Yes (examples 4 and 5) Yes (example 6) -Yes (example 10)

--------

Yes Yes Yes Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes

S7-300 (from CPU 313), S7-400, C7-6xx Yes -Yes --

S7-300, ET 200M on S7-Master, C7-6xx -In ET 200M on S7-Master --

S7-400 ---

-STEP 7 from V3.1

--

Yes, with active backplane bus STEP 7 from V5.1 SP4 STEP 7 from V2.1

-STEP 7 from V3.1

Yes Yes Yes, with CFC from V5.0 via FB/FC (Function Call) Yes, via memory card

Yes -Yes

Yes, for data exchange with user program Yes Yes Via function block Yes Yes Yes Yes Yes Yes Yes

Yes, for param. software Required for each CPU Required for each PC/PG 6ES78..-.....-....

--

-Covered by FM 355-2

-Covered by FM 355 Covered by FM 355 6ES7355-.....-....

-Covered by FM 455 Covered by FM 455 6ES7455-.....-....

Irrelevant 6ES7860-4AA..-....

Covered by FM 355-2 6ES7355-2....-....

19

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Siemens Aktiengesellschaft Automation and Drives Industrial Automation Systems P.O. Box 4848, D-90327 Nuremberg

www.siemens.com/simatic-technology Order No. 6ZB5310-0ET02-0BA7 Produced in the Federal Republic of Germany 26100/201356 SB 04021.

Siemens AG 2002 Subject to change without prior notice.

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