Industrial Control & Automation

Programmable Logic Control – Siemens TIA Portal

Hardware components used in Programmable Automation
Siemens SIMATIC S7 Family
Performance Grades of SIMATIC PLCs

ET-200SP
Siemens SIMATIC S7-1200 PLC
SIMATIC S7-1200: Installation & Mounting Positions
SIMATIC S7-1200 Modules
Siemens SIMATIC S7-1200 PLC
Siemens SIMATIC S7-1200 PLC – CPU1212C
TIA Portal V16.0/V17.0 Software Package
TIA Portal Basic & Professional
Portal View & Project View
Project View
Menu Bar & Toolbar
Project Tree: 1st level
Project Tree: 2nd level
Connection to PLC
Manual PC Ethernet Settings

192.168.0.100
Online Access
Memory Concept & Memory Reset
Add New Device: Hardware Configuration
Inserting / Deleting H.W. Modules
Compiling and Downloading
Downloading to CPU

4
 Addresses & Tags

%IB1

%I1.5 %Q0.2

%M25.4 %M26.4

{Size}
Register Size, Data Type & Address
Process Image (Input / Output Tables)
PLC Tags
PLC Tags
Symbolic & Absolute Addressing
Watch Tables
Define Tag while programming
Program Structure
Types of Program Blocks (Functions/ Subroutines)
Cyclic Program Execution
Network / Rung / Segment
Program Editing
Block Call
Compile, Save & Download
Monitor program while running
Physical & Logical status
Normally Open & Normally Closed Signals
Data Types
 Elementary Data Types

U- Unsigned
S-Short
D-Double
L-Long
Data Blocks
Binary Logic Operations: AND, OR
Binary Logic Operations: XOR
Binary Logic Operations: ASSIGNEMENT, SET, RESET, NOT
Binary Logic Operations: FLIP FLOP

FBD

LAD
Binary Logic Operations: Edge Trigger
Binary Logic Operations: RLO Edge Evaluation
Binary Logic Operations: SET/ RESET Bit Field (Range of Bits)
Binary Logic Operations: JUMP/ LABEL
Digital Operations: DATA Types
Digital Operations: TON – Timer On-Delay
Digital Operations: Counters
Digital Operations: Comparison

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Digital Operations: MOVE
Digital Operations: MOVE Block
Digital Operations: IN_RANGE/ OUT_RANGE
Digital Operations: Date & Time of Day
 Exercises
Exercise No: 1.a
Objective: Associate Input(s) to Output(s)
Language Elements: Contacts & Coils

Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED
 Exercises
Exercise No: 1.a: Single Output
Start_PB: I0.0 Green_LED: Q0.0
-----| |----------------------------------------------------------( )

Exercise No: 1.b: Multiple Outputs … Lamp Test on Control Panel

Start_PB: I0.0 Green_LED: Q0.0

-----| |----------------------------------------------------------( )
Red_LED: Q0.1
----------------------------( )
Blue_LED: Q0.2
----------------------------( )
 Exercises
Exercise No: 2.a
Objective: Latch, Self Hold or Sealing Circuit
Language Elements: Contacts & Coils

Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED
 Exercises
Exercise No: 2.a: Latch
Start_PB: I0.0 Green_LED: Q0.0
-----| |------------------------------------------------------------( )
Green_LED: Q0.0
-----| |--------------------
Exercise No: 2.b: Unlatch using physically NO Stop PB
Start_PB: I0.0 Stop_PB: I0.1 Green_LED: Q0.0
-----| |--------------------------| / |-----------------------------( )
Green_LED: Q0.0
-----| |--------------------
Exercise No: 2.c: Unlatch using physically NC Stop PB
Start_PB: I0.0 Stop_PB: I0.1 Green_LED: Q0.0
-----| |--------------------------| |-----------------------------( )
Green_LED: Q0.0
-----| |--------------------
 Exercises
Exercise No: 3.a
Objective: On Delay Timer
Language Elements: Contacts, Coils & Box (Block)

Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED

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 Exercises
Exercise No: 3.a: Delayed Start: TON without latch
T1

Start_PB: I0.0 Green_LED: Q0.0

-----| |----------------- ------------------------ -------------------( )

Exercise No: 3.b: Delayed Start: TON with latch using Memory bit

Start_PB: I0.0 Stop_PB: I0.1 M0.0

-----| |--------------------------| |-----------------------------( )
M0.0
-----| |-------------------- T1

M0.0 Green_LED: Q0.0

-----| |----------------- ------------------------ -------------------( )
 Exercises

Exercise No: 3.c: Run Load for Certain Time: TON with latch using Memory bit

Start_PB: I0.0 M0.0 Green_LED: Q0.0

-----| |--------------------------| / |--------------------------------( )
Green_LED: Q0.0
-----| |--------------------
T1

Green_LED: Q0.0 M0.0

-----| |----------------- ------------------------ -------------------( )
 Exercises

Exercise No: 3.d: Run Load for Certain Time: TON with latch using Memory
bit (reduced circuit)

Start_PB: I0.0 M0.0 Green_LED: Q0.0

-----| |--------------------------| / |--------------------------------( )
Green_LED: Q0.0
T1
-----| |--------------------
M0.0
--( )
 Exercises
Exercise No: 4.a
Objective: Time Sequencer of (n) loads ..e.g. 3 loads
Language Elements: Contacts, Coils & Box (Block)

Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED
 Exercises
Exercise No: 4.a: Time Sequencer using separate timer for each load
Start_PB: I0.0 M0.0 Green_LED: Q0.0
-----| |--------------------------| / |--------------------------------( )
T1
M0.0
Green_LED: Q0.0
------( )
-----| |--------------------
M0.0 M0.1 Red_LED: Q0.1
-----| |--------------------------| / |--------------------------------( )
T2
M0.1
Red_LED: Q0.1
------( )
-----| |--------------------
M0.1 M0.2 Blue_LED: Q0.2
-----| |--------------------------| / |--------------------------------( )
T3
M0.2
Blue_LED: Q0.2
------( )
-----| |--------------------
 Exercises
Exercise No: 4.b: Time Sequencer using one timer for all load
Start_PB: I0.0 M0.1 M0.0
-----| |--------------------------| / |--------------------------------( )
T1
M0.1
M0.0
------( )
-----| |--------------------

T1 T1 Q0.0
-----| > |-----------------------| < |--------------------------------( )
0 3
T1 T1 Q0.1
-----| > |-----------------------| < |--------------------------------( )
3 5

T1 T1 Q0.2
-----| > |-----------------------| < |--------------------------------( )
5 9
 Exercises
Exercise No: 5
Objective: Traffic Light Control
Language Elements: Contacts, Coils
& Box (Block)
Equipment:
PLC: S7-1200, CPU 1212C AC/DC/RLY
Inputs: I0.0: NO Green Push Button
I0.1: NC Red Push Button
I0.2: Selector Switch
Outputs: Q0.0: Green LED
Q0.1: Red LED
Q0.2: Blue LED
Exercises No. 5a: Traffic Light: Time Sequencer using one timer
Start_PB: I0.0 M0.1 M0.0
-----| |-----------------| / |-------------------------( )
T1
M0.0 M0.1
-----| |---- ------( )

T1 T1 RED: Q0.0
-----| > |--------------| < |-------------------------( )
0 2
T1 T1 AMBER: Q0.1
-----| > |--------------| < |-------------------------( )
2 3
-----| > |--------------| < |----
6 7
T1 T1 GREEN: Q0.2
-----| > |--------------| < |-------------------------( )
3 6
Exercises No. 5b: Traffic Light: Flashing Signal
 Exercises No. 5b: Traffic Light: Flashing Signal
Start Signal M0.1 M0.0
-----| |-----------------| / |-------------------------( )
T1
M0.0 M0.1
-----| |---- ------( )
T1 T1 RED: Q0.0
-----| > |--------------| < |-------------------------( )
0 2
T1 T1 AMBER: Q0.1
-----| > |--------------| < |-------------------------( )
2 3
-----| > |--------------| < |----
9 10
T1 T1 GREEN: Q0.2
-----| > |--------------| < |------------------------( )
3 6 Flasher
-----| > |--------------| < |----| |------
9
Ladder Logic Elements
Transforming a Circuit Diagram into Ladder Logic Diagram
Transforming a Circuit Diagram into Ladder Logic Diagram
 Exercise No. 6 : Car Park
Car Exit
Counter Actuator
Q0.1
Exit
Exit Sensor 2
Sensor 1 I0.3
I0.2

Exit

Car Park
Full
Indicator
Lamp
Entrance
Q0.2
Sensor 2
I0.1
Entrance

Entrance Entrance
Sensor 1 Actuator
I0.0 Q0.0
Exercise No. 7 : Mixing Tank
(1) Process Diagram
Exercise No. 7 : Mixing Tank
(2) Sequence Of Operation
 Exercise No. 7 : Mixing Tank
(3) Tag List, Symbol Table, Variable Table
Exercise No. 7 : Mixing Tank
(4) PLC Program
Exercise No. 7 : Mixing Tank
Exercise No. 7 : Mixing Tank
 Exercise No. 7 : Mixing Tank

(5) Download Program to PLC

(6) Switch PLC to RUN mode
(7) Monitor the Program while it is running
(8) Monitor the Tags in the watch table
(9) Modify program and repeat above steps
Exercise No. 7 : Mixing Tank
Analog Value Processing in PLC

➢ A/D Convertor
➢ D/A Convertor

➢ Resolution
➢ Conversion rate

1
0 - 10VDC
4 - 20mA

2 0 - 27648
Common Ranges of Analog Signals
Analog Sensor Connection to CPU Integrated Analog Inputs
 Analog Values

Process Sensor/ Analog Input CPU HMI Operator

Transmitter
Physical Electrical Converted Physical Display/
Quantity Analog Digital Scaling Quantity Control
Quantity Quantity
-Temperature
-Pressure 0-10VDC 0-27648 Scaled Engineering Display/
-Level 4-20mA Value Units Control
-Flow
-Speed
Analog Values
Analog Value Scaling
Analog Value Scaling

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 Analog Value Processing
Analog Input Handling:

Analog Output Handling:

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 Analog Value Processing

➢ Use Conversion Operations

➢ Norm_X
➢ Scale_X
 Exercise No.1 : Analog Signal Processing
Objective: Analog Input Reading & Scaling to 50m
Language Elements: Conversion Operations
Equipment: -PLC: S7-1200, CPU 1212C AC/DC/RLY
-Input: IW64: Potentiometer
230VAC
To 24VDC
0 – 10VDC
24VDC To
Power 10VDC
Supply
HMI Selection
HMI Selection

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HMI: Wizard
HMI: Manual Configuration of IP
HMI: Manual Networking to PLC

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HMI: Manual Connection to PLC
HMI Root Screen
HMI Objects
 HMI Major Functions

• Display processes with a straight forward screen structures

• Communicate with processes

• Output alarms
• Archive process values and alarms
• Document process values and alarms as reports
• Manage process and machine parameters in recipes
• User management & administration
 Exercise : HMI

1. Use the HMI Buttons to Start/ Stop a load with events.

2. Use the HMI I/O field to display a reading from the PLC.
3. Use the HMI I/O field to enter a setpoint to the PLC.
4. Use the HMI Bar to display an analog value reading.
5. Animation .. Color change
6. Create Several Screens and navigations.
7. Work with Template to create a header.
8. Display Trend.
9. Work with Alarms and Messages.
10. Users & Passwords
 Design of the KTP700 Basic for PROFINET

① Connection for power supply

② USB interface for USB
mass storage device or USB mouse
③ PROFINET interface
④ Recesses for a mounting clip
⑤ Display/touch screen
⑥ Mounting gasket
⑦ Function keys
⑧ Rating plate
⑨ Connection for functional ground
⑩ Guide for labeling strip
Settings on Touch Panel KTP700 Basic/Start Center

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Setting the transfer properties and assigning the IP address

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WinCC user interface
Planning the screen structure
Program Structure
Types of Program Blocks (Functions/ Subroutines)
Reusable Functions: Tag Types
Exercise No.1: Reusable Function for Analog Scaling
Exercise No.2: Reusable Function for Alarms
Reusable Functions: Parameter Assignable Block
Reusable Functions: Declaration of Formal Parameters
Reusable Functions: Editing Parameter Assignable Block

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Reusable Functions: Calling Parameter Assignable Block
Reusable Functions: Using FB and Multiple Instances DB

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Reusable Functions: Block Interface for FB

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VSD
 VSD

1. VSD: Variable Speed Drive

2. VFD: Variable Frequency Drive

3. VVVF: Variable Voltage Variable Frequency Drive
4. ASD: Adjustable Speed Drive

5. VSI/CSI: Voltage/Current Source Inverter

6. Rectifier/ Convertor / Inverter/ PMW
5. Frequency Converter
 VSD: Functions & Applications
Variable frequency drives are used in diverse industrial applications:
for example:
• Pumping, ventilating and compressing
• Positioning, processing, moving and machining
These functions are used in many industry sectors:
• Food & beverage industry
• Automotive industry
• Heating, ventilating and air conditioning (HVAC)
• Water and wastewater industry
• Paper industry
• Oil & gas
• Chemical industry
• Logistics
• Wind turbines, hydroelectric power
and photovoltaic systems
• Marine
 VSD: Types
Types of Industrial Motor Drive Systems:

• Low Voltage Converters: from 0.12 kW up to 6840 kW

• Medium Voltage Converters: from 150 kW up to 85 MW
• Servo Converters: from 0.1 kW up to 6840 kW
• DC Converters: from 6.3 kW up to 30 MW

_
 VFD: Definition

What is a frequency converter or variable frequency drive?

Frequency converters or also named variable frequency drives are electronic
devices that convert a (more or less) fixed frequency and voltage into a
variable frequency and voltage. This device allows electric motors to be
operated with a variable speed.

What are frequency converters / variable frequency drives used

for?
Today, frequency converters are used practically everywhere to operate
single-phase and three-phase electric motors with a variable speed. And not
just in industrial environments, but in everyday life. Starting from very low
power ratings to control washing machine drums up to medium power ratings
for pumps used in municipal water supplies.

_
VFD: Electrical Drive Chain
VFD: Building Blocks
VFD: Electrical Signal Manipulation

_
VFD: Power Circuit
 VFD: Power Circuit

Contactor

ELCB/
RCCB
 VFD: Additional External Components

A line reactor supports With a line filter, The sine-wave filter at the inverter
the overvoltage the inverter can output limits the voltage rate-of-rise
protection, smooths the achieve a and the peak voltages at the motor
harmonics in the line higher radio winding. The maximum permissible
supply and buffers interference length of motor feeder cables is
commutation dips. class. increased to 300 m.
 VFD: Principle of Operation
Principle of Operation of Variable Frequency
Drive (VFD):

Speed of an induction motor is

proportional to the frequency
of the supply ( N = 120 f/p ) and by varying
the frequency we can obtain the variable
speed.
But, when the frequency is decreased, the
torque increases and thereby motor draw a
heavy current. This in turn increases the flux
in the motor. Also the magnetic field may
reach to the saturation level, if the voltage of
the supply is not reduced.
Therefore, both the voltage and frequency
have to be changed in a constant ratio in order
to maintain the flux within the working range.
Since the torque is proportional to the
magnetic flux, the torque remains constant
throughout the operating range of v/f.
The figure shows the torque and speed variation of an induction motor for voltage and frequency control.
Voltage and Frequency are changed at a constant ratio up to the base speed.
Thus the flux and thereby torque remain almost constant up to the base speed.
This region is called as a constant torque region.
Since the supply voltage can be changed up to the rated value only and hence the speed at rated voltage is the base
speed. If the frequency increased, beyond the base speed, the magnetic flux in the motor decreases and thereby torque
begins falling off. This is called flux weakening or constant power region .
This type of control is called constant v/f control method used in variable frequency drives (VFDs).
It is the most popular type of control in industries .
 VFD: Speed vs. Frequency relation

VFD

N = Speed; Ns: Stator Speed (Electro-Magnetic),

Nr: Rotor Speed (Mechanical)
F = Frequency
P = Number of pole
 VFD: Components

Operator
Panel Power
Module

Control
Module
VFD: Motor Name Plate
 VFD: Drive Control Sources

1. Operator Panel

2. Terminals

3. Communication
 VFD: Drive Control Sources: Operator Panel

LCD DISPLAY

INCREASE

DECREASE

STOP

START

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VFD: Drive Control Sources: Terminals: Push Button/Switch & Pot.
VFD: Drive Control Sources: Terminals: PLC & HMI
HMI
VFD: Drive Connection to PLC through I/O’s
 VFD: Parametrizing & Commissioning
Commissioning and Parameters Programming in VFD
• Commissioning is needed for the proper functioning of VFD.

• Necessary (Quick Commissioning Parameters) from Motor Nameplate:

• Motor Power Rating
• Motor rated Voltage,
• Motor rated Current,
• Motor rated Speed,
• Motor rated Frequency,
• Motor Power Factor.

• Advanced commissioning: Give the details of all the digital and analog inputs
and outputs:
• Digital inputs: Start command and Speed Selection command
• Digital Outputs: Status of Drive Running and Drive in Fault etc.
• Analog Inputs: Speed setpoint Input 1 and/or Speed Input 2
• Analog Outputs: Current and Frequency of Motor
 VFD: PLC Program

NETWORK 1: Checking whether the VFD is ready to start. This signal will come when all
the conditions are healthy as well as safety and power feedbacks are active.

NETWORK 2: When start button is pressed, VFD Drive_DO bit will be set, if
Ready_to_Start and No Error will be there.

NETWORK 3: When stop button is pressed it will reset the Drive_DO bit.
 VFD: PLC Program
NETWORK 4: This logic is required for safety: as soon as Drive_DO bit is set and if for any reason the
VFD will not operate, then after predefined wait time, it will reset the Drive_DO bit and generate Error.

NETWORK 5: If the VFD is taking more current and gives overload error, then it will reset Drive_DO bit
and generate Error.

NETWORK 6: if you select speed input as a remote then it will activate Speed Selection bit resulting
Speed_DO present.

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 VFD: HMI Program
Normal State: Running State:

Error State:
VFD: Drive Connection to PLC through Communication
VFD: PLC Control of Multiple Drives
 VFD: Practical Exercise

Model: AS2 - 15 Model: AS2 - 15

In: Single Phase 220VAC, 50/60Hz Digital Inputs: 6
Out: Three Phase 220VAC, 1.5KW/2Hp Digital Output: 1
Rated Output Current: 8Amp Analog Inputs: 2
Analog Output: 1
VFD: Terminal Wiring Diagram
VFD: Power Connections
VFD: Control Connections: Analog Inputs

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VFD: Control Connections: Digital Inputs/Outputs

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VFD: Hardware Settings
VFD: Operator Panel
VFD: Example: Change Acceleration Time
VFD: Example: Change Maximum Frequency Limit
VFD: Example: Keypad/Display Control of Drive
Example 01: - Use the Up/Down Arrows to adjust speed
- Use the FWD/REV buttons to run the motor
- Use the STOP button to stop the motor

Parameters:
CD 10 = 0
CD 12 = 0
VFD: Example: Analog Pot. Control of Drive
Example 02 - Use the FWD/REV buttons to run the motor
- Use the STOP button to stop the motor

Parameters:
CD 10 = 1
CD 12 = 0
VFD: Example: Terminal Control of Drive
03 :
VFD: Example: PLC Control of Drive
04 :

AQ0 DQ0.0 DQ0.1

S7-1200 PLC
 Encoder
Rotary Encoder Linear Encoder Tacho Generator
Digital device that produces electrical pulses Analog device that
based on mechanical rotational motion produces a voltage
proportional to speed.

Resolver
Encoder Function
Encoder Definition
 Encoder Types
• Incremental Encoder
– Provides identical electronic pulses at each division of
shaft rotation.
– Used for position or speed/velocity measurements.

• Absolute Encoder
– Provides a unique electronic piece of information at
each division of shaft position.
– Used for position measurement.

• Resolver
– Provides sine wave and cosine wave to provide both
velocity and position feedback.

• Tacho generator
– Provides analog voltage proportional to speed.
_
Encoder Classification
Encoder Types
Linear Encoder
Incremental Encoder
Absolute Encoder
 Encoder Technologies

Sensing Technologies:

❑ Magnetic (Magneto-resistive)
 Tough and simple
 Heavy Duty enough for Mills
 No Optics (no glass breakage)
 Limited to 2048 PPR

❑ Optical
 Higher Resolution (up to 10,000 PPR)
 Better signal quality
 Shafted and Hollow shaft designs
 Rotary Encoder
Incremental Encoder Absolute Encoder
 Incremental Encoder

❑ Incremental encoders are usually supplied with two channels

(A & B) that are offset by 90 degrees.
❑ If complements are included (A, B ), the signal is
“quadrature”, providing speed of rotation AND direction of
rotation.

A
A

B
Encoder
B
 Incremental Encoder

❑ Signal A leads B in one direction, B leads A in the reverse

direction
❑ Complement pulses, A and B are used to provide electrical
noise immunity for the signal as it travels through the cable.

A
A

B
Encoder
B
 Incremental Encoder

A marker pulse (reference, index or Z pulse) is a once per

revolution pulse that occurs at precisely the same
mechanical point in a 360º revolution of the encoder shaft.

Marker
Z

Although a “Marker” pulse is standard on some encoders, it is

additional feature (charge) on many encoders. Ask for one, if
you need one.
Incremental Encoder
Incremental Encoder Output
Incremental Encoder Signals
Incremental Encoder Interface
Absolute Encoder
Absolute Encoder
Absolute Encoder
Absolute Encoder
Absolute Encoder
Incremental vs. Absolute Encoder
 PLC & Encoder -> HSC
For S7-1200 PLC V4.x why to use HSC:

Hardware consideration:
The default digital input filter setting is: 6.4 ms,
which limits the maximum counting rate to: 78 Hz.

You can change the filter settings to count higher or lower frequencies
depending on the design of your system.

Software Consideration:
In normal scan cycle PLC updates digital inputs once per cycle based on
a variable program speed; which is usually greater than 1 ms.

➢ The basic counter instructions are limited to counting events that

occur at a rate slower than the scan cycle of the S7-1200 CPU.
➢ The High-speed counter (HSC) function provides the ability to count
pulses occurring at a higher rate than the PLC scan cycle.
PLC & Encoder -> Max. Frequency
 PLC & Encoder –> Configuring the HSC
1. Configure HSC in
device configuration;
CPU properties

2. Configure Digital
Input Filters
PLC & Encoder -> Programming the HSC

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 PLC & Encoder -> Programming the HSC

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 PLC & Encoder -> Programming the HSC

High
Speed Data Default
Counter Type Address
(HSC)
HSC 1 DInt ID 1000
HSC 2 DInt ID 1004
HSC 3 DInt ID 1008
HSC 4 DInt ID 1012
HSC 5 DInt ID 1016
HSC 6 DInt ID 1020
 PID Control

➢ . A Proportional – Integral – Derivative controller

➢ . PID controller
➢ . Three-Term controller

is a feedback control
loop mechanism that is widely used
in industrial control systems and a
variety of other applications requiring
continuously modulated control.
An everyday example is the cruise control of a car

Today the PID concept is used universally in applications

requiring accurate and optimized automatic control.
 PID Control: Historical Development

Early PID theory was developed by

observing the actions of helmsmen in Pneumatic PID (three-term)
keeping a vessel on course in the face of controller. The magnitudes of
varying influences such as wind and sea the three terms (P, I and D) are
state. adjusted by the dials at the top.
Electronic Industrial PID Controllers (Process Controllers)
Software (PLC) based Industrial PID Controllers
 PID Control

The PID control combines Proportional, Integral and Derivative actions to

create a control signal, where each action has a strong characteristic that
helps to control the output:
❖ The Proportional action makes the system respond to the present
error and enables immediate action in the face of variations or
disturbances;
❖ The Integral action eliminates errors such as jumps or steps in a
permanent and long term regime;
❖ The Derivative action anticipates the behavior of the process.
From Manual Control to Automatic PID Control
 PID Control:

In theory, a controller can be used to control any process that has:

1. a measurable output (PV),

2. a known ideal value for that output (SP),
3. and an input to the process (MV) that will affect the relevant PV.

Controllers are used in industry to regulate:

temperature, pressure, force, feed rate, flow rate, level chemical
composition (component concentrations), weight, position, speed,

and practically every other variable for which a measurement exists.

PID Control: Principle
 PID Control: Principle

Block diagram of a PID controller.

r (t ) is the desired process value or setpoint (SP),
e (t ) is the calculated error value,
y (t ) is the measured/actual process value (PV),
u (t ) is the calculated control variable (CV) or manipulated variable (MV).
 PID Control: Mathematical

Another form:
 PID Control
How Does PID Works?

A PID controller continuously calculates an error value = e(t);

which is the difference between adesired setpoint SP= r(t) and a
measured process variable PV = y(t): r(t) – y(t) , and applies a
correction based on proportional, integral, and derivative terms.

The controller attempts to minimize the error over time by

adjustment of a control variable u(t), such that the control
element is adjusted to a new value determined by a weighted
sum of the control terms.
 PID Control: P Term
❑ Term P is proportional to the current value of the SP−PV; error e(t):

Kp . e(t) Kp : Proportional Gain

• The control output will be proportional to error value.

• Using proportional control alone will result in an error between the
setpoint and the actual process value called (Steady State error) because
it requires a non-zero error to generate the proportional response.
• If there is no error, or small error there is no corrective response (Dead
Band).
• Tuning theory and industrial practice indicate that the proportional term
should contribute the bulk of the output change.
PID Control: I Term
 PID Control: D Term
❑ Term D is a best estimate of the future trend of the SP − PV error,
based on its current rate of change:

• It is sometimes called "anticipatory (predictive) control", as it is

effectively seeking to reduce the effect of the SP − PV error by
exerting a control influence generated by the rate of error change.

• The more rapid the change, the greater the controlling or damping
effect.

• Derivative action is seldom used in practice because of its

variable impact on system stability in real-world applications.
 PID Control: Effect of Kp

Oscillation: Unstable

Overshoot: Fast response

Damped: Slow response,

less responsive or less
sensitive controller

Response of PV to step change of SP vs time, for three values of Kp (Ki and Kd held constant)
 PID Control: Effect of Ki

Eliminates
the
Faster residual
Response steady-
state error

Response of PV to step change of SP vs time, for three values of Ki (Kp and Kd held constant)
 PID Control: Effect of Kd

Improves
settling
time and
stability

Response of PV to step change of SP vs time, for three values of Kd (Kp and Ki held constant)
 PID Control:

Setpoint
------

Actual Value
------
 PID Control:

Effects of increasing a parameter independently

Steady-state
Parameter Rise time Overshoot Settling time Stability
error

Kp Decrease Increase Small change Decrease Degrade

Ki Decrease Increase Increase Eliminate Degrade

No effect in Improve
Kd Minor change Decrease Decrease
theory if Kd small
 PID Control:
Selective use of control terms:

Although a PID controller has three control terms, some

applications need only one or two terms to provide
appropriate control.

This is achieved by setting the unused parameters to zero

and is called a PI, PD, P or I controller in the absence of
the other control actions.

PI controllers are fairly common in applications where

derivative action would be sensitive to measurement
noise, but the integral term is often needed for the system
to reach its target value.
 PID Control: Tuning

Control Loop tuning

❑ Tuning a control loop is the adjustment of its control

parameters (proportional band/gain, integral gain/reset,
derivative gain/rate) to the optimum values for the desired
control response.
• Stability (no unbounded oscillation) is a basic requirement
• Zero Steady State Error
• Fast Response to changes and disturbances
❑ PID tuning is a difficult problem, even though there are
only three parameters.
❑ There are several methods for tuning a PID loop.
 PID Control: Tuning Methods
Choosing a tuning method
Method Advantages Disadvantages

Manual tuning No mathematics required; online. Requires experienced personnel.

Process upset, some trial-and-

Ziegler–Nichols Proven method; online.
error, very aggressive tuning.
Process upset, some trial-and-
Tyreus Luyben Proven method; online.
error, very aggressive tuning.
Consistent tuning; online or offline - can employ
computer-automated control system design
(CAutoD) techniques; may include valve and
Software tools sensor analysis; allows simulation before Some cost or training involved.
downloading; can support non-steady-state
(NSS) tuning.
Some mathematics; offline; only
Cohen–Coon Good process models.
good for first-order processes.
Can be used for auto tuning; amplitude is
The process itself is inherently
Åström-Hägglund minimum so this method has lowest process
oscillatory.
upset
PID Control: Manual Tuning
PID Control: Ziegler-Nichols Method
 PID Control: S7-1200 PLC & Auto Tuning Method (1)
1. Call PID_Compact controller in a cyclic
interrupt by adding new Organization block
2. Select cyclic interrupt OB35
3. Set Cycle Time to 50 ms
4. From Technology Instructions
Drag & Drop the PID_Compact
5. Assign a name for the
instance data block
and apply it with OK.
6. Expand the view of the
block by clicking the
up arrow.
Interconnect this block as
shown in figure:
setpoint, actual value,
manipulated variable
and Reset input for
deactivating the controller
 PID Control: S7-1200 PLC & Auto Tuning Method (2)
7. Open the configuration mask of the controller and set the parameters
 PID Control: S7-1200 PLC & Auto Tuning Method (3)
8. Save, compile & download the project to the PLC
9. Activate the monitoring function
10. Start the PID commissioning & tuning by clicking the icon
 PID Control: S7-1200 PLC & Auto Tuning Method (4)
11. Press Start for measurement & after that Start for Pre-tuning
 PID Control: S7-1200 PLC & Auto Tuning Method (5)
12. After successful tuning parameters obtained can be saved to project
 PID Control: Exercise: Training Kit

PID Simulation Kit

The lamp (Q0.0) is to be used to control the temperature.
The controller is be started up using the Auto-tune functionality.
PID Control: Exercise: Create TAGs

Create Tags as in Table

 PID Control: Exercise: Set PID Block Parameters as in Figure

• Select controller type "Temperature“

• Select "°C" as the unit
• Set the setpoint as constant e.g. "60“ or use Tag.
• Select "Input_PER" as the input and "temperature_sensor" (IW64) as the tag.
• Select "Output_PWM" as the output and "heating (bulb)" (O0.0) as the tag.
PID Control: Exercise
PID Control: Exercise
 PID Control: Exercise: Prepare data to show on HMI

Parameterize the "Setpoint" input with the tag "Setpoint" (MD100)

Parameterize the "ScaledInput" output with the tag "Scaled_Input" (MD104).
 PID Control: Exercise: HMI – I/O Field

Displaying actual value and setpoint on the HMI as I/O Fields

 PID Control: Exercise: HMI - Trend

Displaying actual value and setpoint on the HMI as TREND

 Introduction to SCADA System
SCADA stands for:
Supervisory Control And Data Acquisition.
❖ A SCADA system is an automation system which is used to gather
data from sensors and instruments located locally or at remote sites
and to transmit and display this data at a central site for control or
monitoring purposes.
❖ The collected data is usually viewed on one or more SCADA Host
computers located at the central or master site.
❖ A layer of equipment between the remote sensors/ instruments and the
central computer is used to digitize then packetize the sensor signals
so that they can be digitally transmitted via an industrial
communications protocol over long distances to the central site;
such devices include: RTU, PLC, IEDs, and Smart devices.

❖ These devices employ standard industrial data communication

protocols such as: Modbus, IEC, and DNP3.0.
 Introduction to SCADA System: Major Components

There are Four essential composing parts of a SCADA system:

➢ Master System/ Central System/ Supervisory System: Human

Machine Interface (HMI)

➢ Communication Infrastructures

➢ Remote Terminal Units (RTUs) or Programmable Logic

Controllers (PLCs)

➢ Field Devices: Sensors/ Instruments and Actuators

Introduction to SCADA System: Typical SCADA HMI
Introduction to SCADA System: Architecture: Local/ Wired
Introduction to SCADA System: Architecture: Remote/ Wireless
 Introduction to SCADA System: Major Functions

Major Functions of SCADA:

A SCADA system performs four major functions:

➢ Data acquisition
➢ Networked data communication
➢ Data presentation
➢ Control
Introduction to SCADA System: SCADA vs. HMI

HMI

• Small Scale
• Close to Process
• Usually stand alone
• Usually no Data Base
connectivity

SCADA HMI
 SIMATIC WinCC (TIA Portal) Runtime Software
What is WinCC RT advanced?

SIMATIC WinCC Runtime Advanced

(TIA Portal)
- PC-based HMI solution for
- single-user systems
- directly at the machine.
- The range of functions of WinCC
Runtime Advanced includes:
- Visualizing (graphics)
- Alarming (messaging)
- Trending (graphs & curves)
- Archiving (logging & history)
- Recipes
- Reporting
- Administration
- It can be expanded to suit requirements and costs by using optional packages.
 SIMATIC WinCC Advanced: Practical
1.Create a new project in the TIA
Portal.
2.In the Project View you double-
click "Add new device" and select
the S7 controller. Click the "OK"
button to add the controller.
3.Through the Hardware Catalog
you add more components to the
Device View (like power supply, IO
modules).
4.Click the PROFINET interface of
the S7 controller and assign a
unique IP address and the
associated subnet mask under
"Properties > General > Ethernet
Addresses".

5.Double-click "Add new device"

and select WinCC Runtime
Advanced from the PC System
sub folder.
 SIMATIC WinCC Advanced: Practical
6. In the Device View in the Hardware
Catalog you select the "IE General"
communication module and double-click to
add this to the PC station.
 SIMATIC WinCC Advanced: Practical
7. Click the "IE General" interface
just added. Under "Properties >
General > PROFINET interface [X1]
> Ethernet addresses" you enter the
IP address and subnet mask of the
Runtime station.

8. Switch to the Network View and

enable "Connections" to create an
HMI connection. Connect the
interfaces of the S7 controller and
the Runtime station by drag-and-
drop.
 SIMATIC WinCC Advanced: Practical
9. Click the HMI connection.
Under "Properties > General >
Access point" you enter the name
you are using in the PG/PC
interface of the Runtime station.
In this example we use the preset
name "S7ONLINE".

10. Open the PG/PC interface

on the Runtime station through
"Start > Control panel > Set
PG/PC interface".

11. Complete the configuration similar to

normal HMI and download the project to the
S7 controller and the PC Runtime station.