YOKOGAWA Yokogawa Corporation of America GUIDE TO MANUALLY TUNE A THREE MODE (PID) CONTROLLER TRIAL AND ERROR METHOD ‘Yokogawa’s universal temperature and profile controllers provide an “auto-tuning” function as, a standard feature, Auto-tuning is a function whereby the controller automatically measures the process characteristics and calculates the best PID parameters for optimum control. Auto-tuning will set optimum PIDs in most applications, however, there are processes where fast loops (also referred to as step response loops where no dead time is detected) suchas some pressure, flow ot processes whose characteristics are not repeatable. Auto-tuning should always be attempted first, if £200 (auto-tuning error) is displayed or if improvement in PIDs selected by auto-tuning are desired, the controller must be tuned manually. The following guide is a trial and error method to manually tune a P.I.D. controller on two distinctly different control loops: fast loops and loops with significant dead time.Definitions: 1) 2) Cycle time - The total length of time for the controller to complete one on/off cycle of the relay or voltage pulse output is the “cycle time” or “duty cycle". The fraction of the cycle time during which the output is ON is proportional the output display value. If output display value is 50% and cycle time is set at 20 seconds, output would be on for 10 seconds, (50% X 20 sec. = 10), and off for 10 seconds. Reducing the cycle time (ON/OFF period) results in faster cycling and finer control, however it also reduces the life of the relay. For relay output cycle time is usually set at 10-30 seconds. Comparison of operation for same control output (50%) ‘cycle time = 10 200 Cycle time = 20 seo Cycle time = 40 S00 <_——~ eee <—~_> es on es Proportional band - The range over which the output is adjusted from 0% to 100% is called the PB. The PB-is expressed in % of the operating span for full output change and is centered around the setpoint when MR (Manual Reset) is set at 50%. A measuring range of 0 ~ 1000 with a PB of 5% would equal a PB of.50 (1000 X 5% = 50) degrees wide and extend 25 degrees above and below the setpoint. * Proportional - control mode uses information about the magnitude of the error.3) Integral, also known as reset, is added to proportional action to overcome the offset or error, from the setpoint. It responds to the error signal of the feedback system just as proportional action does, but this time it responds to both the duration and the magnitude of the error. A large change in the load on a system will cause the controlled variable to experience a large deviation from the setpoint. If the flow of material through a heat exchanger is increased, the temperature of the material will drop before the control system can increase the input of steam to the new load. As the change in the temperature of the controlled variable diminishes, the error signal becomes smaller and the position for the control element gets closer to the point required to maintain a constant value. * Integral - Control mode uses informatiron about the magnitude of eror over a period of time. PROCESS WITH TEMPERATURE OFFSET ////4 Derivative action, also known as rate action, responds to rapid changes in the error signal. It will anticipate the rise or fall of the Process Variable and automatically adjust the proportional band to minimize overshoot or undershoot. Derivative action provides a signal proportional to the rate of change of the error signal. When the controlled variable is steady, the derivative signal is zero. When the value of the controlled variable is changing rapidly, the derivative signal is large. The derivative signal changes the output of the controller. In this way a larger control signal is produced when there is a rapid change in the controlled variable. In turn, the final control element receives a larger input signal. The net result is a faster response to load changes to prevent or limit overshoot/undershoot. ° Derivative - control mode uses information about the rate of error change. *1fD is too large short period oscillations, ‘appear inthe Process Veriable LOOPS WITH SIGNIFICANT DEAD TIME. Defined as a measurable time delay, minutes or hours, before a response in P.V. is observed due to an output change. Most ovens and furnaces fall into this catagory 1” 2 3) R.0.T. (Rule Of Thumb) parameter settings. — 5% P - Proportional Band I - Integral —— D - Derivative Start the process. The process should be run at a setpoint that will allow the P.V. to stabilize with an output being generated.4) 5) 6) PROPORTIONAL BAND (P) With integral and derivative tuned off the P.V. will stabilize with a steady state deviation, or offset from setpoint. If P.V. oscillates, increase the value of P. from 5% to some larger number until P.V. reaches steady state. Note whether or not there are regular cycles at this temperature by observing the measurement on the display. A cycle, or oscillation, may be as long as an hour and will be much easier to detect if a recorder is used to monitor the P.V. If there are no regular cycles in the process, divide the proportional band by two - narrowing the PB leads to tighter control. Allow the process to stabilize and check for oscillations. If oscillations are not detected continue to divide by two until oscillations are obtained. If oscillations are observed, immediately multiply the PB by two. If oscillations are still present continue to multiply PB by two until oscillations stop. ‘The PB is now near its critical setting. Fine tune - increase or decrease the PB setting until process reaches steady state: just prior to ascillations occurring.OSCILLATIONS Primany PRIMARY | PRIMARY SETPOINT SET POINT SET POINT AAA ro ie TIME 5 a 2 s ‘This is close to perfect tuning. Temperature Oscillations INTEGRAL (RESET) Set integral at 5 (five) times the dead/lag time. Dead/lag time is defined as that period between output change (0 ~ 100%) and P.V. change. Assume a P.V. of 200 degrees, the process is in manual control and stabilized. Increase the output by 50% to drive P.V. to new setpoint of 250 degrees. If after 10 (ten) minutes the P.V. begins to climb, we have determined the dead/lag time is 10 (ten) minutes.Integral is set as seconds per repeat, therefore, integral would be set at 3000: 60 sec. X 10 min, = 600 seconds of dead time X 5 = 3000 setting value. Note: Maximum Integral Settings: UT14/15 3600 uT35 6000 uT37 6000 up27 6000 uP25 6000 DERIVATIVE 8) Derivative is usually set at 1/4 of integral, therefore, if integral is set at 3000: derivative would be set at 750 (3000/4) seconds. FAST LOOPS ittle or no dead/lag time. A small or large change in output triggers an immediate change in P.V. When manually tuning a fast loop it is usually found desirable to configure the instrument as a two mode, Pl controller. Derivative, an overshoot/undershoot suppression function, by its nature contributes to instability in a fast control loop. Most pressure and flow loops fall into this catagory.1 2 3) 4) 5) R.O.T. (Rule Of Thumb) parameter settings. P - Proportional Band --—- 100% 1 - Integral — 0% D -Derivative ——- 0% Start the process. The process should be run at a setpoint that will allow the P.V. to stabilize with output being generated. : PROPORTIONAL BAND (P) With integral and derivative turned off the P.V. will stabilize with a steady state deviation, or offset from setpoint. If P.V. oscillates, increase the value of (P) from 100% to some larger number until P.V. reaches steady state. INTEGRAL (1) Set as seconds per repeat - start with an integral of 20 seconds. If P.V. begins to oscillate, make (I) weaker by increasing the value of (I) from 20 seconds to some larger number until P.V. reaches steady state. If the response is sluggish i.e., offset diminishing slowly, strengthen the (I) action by reducing the value of (l) from 20 seconds to some smaller number until P.V. reaches steady state.CONTROL ELEMENTS Control output’s on the Yokogawa UT/UP single loop controllers take several different forms: Time proportional PID relay/voltage pulse, Continuous PID 4~20 mA/1~5 V DC, Position proportional PID and Three position relay output. Time proportional relay/voltage pulse output applies power to the load for a fixed cycle time, e.g., if, when relay output is being used, cycle time is set at 20 seconds and the output displayed is 30% then the N/O relay would be energized (closed) for 6 (six) seconds and de- energized (open) for 14 (eighteen) seconds. Analog outputs provide a continuous signal to the control element, e.g., if control output selected is 4~20 mA and the output displayed is 30% then the continuous signal would be 30% X (16mA span) + 4 mA offset = 8.8 mA D.C. Position Outputs: Position proportional output is used to open and close a motor driven valvé. Position proportional, also referred to as slide wire feedback, couples a potentiometer to the motor shaft to convert its angle of rotation to a resistance value (position signal). The UT/UP uses this position feedback signal, displayed in % (0~ 100%), to monitor and adjust the signal to the valve actuator if the actual valve position does not match the desired valve po: ‘Three Position Control has two relay outputs that provide for on/off control only. A dead band set from 1.0% to 10.0% of the output span is centered around the setpoint. When the deviation is positive and exceeds 1/2 the width of the dead band: output relay #1 is turned on. When the deviation is negative and exceeds 1/2 the width of the center dead band: output Relay #2 is turned on. When deviation is less than 1/2 the center dead band width both outputs are turned off. Three position control is simply on/off control - Proportional band, Integral and Derivative are not used, mostly used in level applications... POWER CONTROLS A device that applies power in response to the controllers output demand is a power controller. There are three common power controls; electromechanical relays, solid state relays (SSR’s) and silicon control rectifiers (SCR’s). The first uses magnetic devices to actuate power switching while the latter two use solid state electronics to effect the switching function. Electromechanical Contactor/Mechanical Relay: An electrical and mechanical device with moving parts. When power is applied to the relay solenoid a contact closure is created through movement of the relays common contact. Because of the moving parts it is susceptible to vibration which eventually leads to mechanical failure. The closure.of the contacts when powered causes burning and pitting - the primary reason for relay failure. Electromechanical contactors provide a positive circuit break whereas solid state devices almost always have a small amount of leakage current flow.If contacts close when the relay is energized they are called “Make” or “Form A” contacts. Ht contacts open when the relay is energized they are called "Break" or "Form B” contacts. IAN UT/UP Controllers and UT15L Limit Controller use "Form C” contacts allowing instrument to be configured for either N.O. or N.C. contact. Unlike the UT/UP controllers, the UTI5L toe catching relay - a relay with contacts that lock in the de-energized position until manually reset - a requirement for F.M. (Factory Mutual) approval. 4. Electromechanical Contactor screw contacts Normally Closed sae ‘Normally Open Contact, =| screw 4 > ‘Common 1 Contact Field Coll UT/UP 15L: Control output relay contact: 250V AC. 3A 120V AC. 5A 24V DC. 3A Alarm output relay contact: 250V AC. 1A 120V AC. 2A 24V DC. 2A ++ all UT/UP controllers have Time Proportional PID (relay output) capabilities for use with mechanical relays. Solid State Relay (SSR): Solid state relays are chosen for their long life and reliability. Unlike mechanical relays they contain no moving parts resulting in higher failure rates. Because SSRs can operate at much faster cycle times than electromechenical relays, the should be employed where ‘extremely tight process control (short cycle times) is required. «+ AILUT/UP controllers have Time Proportional (voltage pulse) output capabilities for use with SSR’s. 10‘Solid Stale Relays Silicon Controlled Rectifier (SCR): Silicon Controlled Rectifiers (SCR’s) provide efficient, reliable and relatively economical means of electric power control. An SCR can be thought of as a solid state switch for passing current. Turn it on and current flows - tur it off, and it stops. Since this device is solid state nothing physically moves, so nothing wears out and the operation is silent. The results finer control with less maintenance than an electromechanical contactor. A contactor (mechanical relay) may cycle three times a minute - an SCR can cycle 60 times per second. Unlike a contactor, the SCR controller modulates small increments of power to the load which helps to eliminate overshoot and undershoot associated with contactor control. Faster cycling time and small modulated increments of power leads to better control of the process. Therefore, the advantages of SCR power controls are: their lack of moving parts, long life and improved controllability. SCRs also typically extend the life of the heating element. SCR Power Control pace "Power Cont uThere are two ways to turn on (or fire) and SCR; id be used where a purely resistive heater load is involved. (A) Zero Firing - These shoul phase with the alternating current. Defined as a load in which the alternating voltage is in (8) Phase Angle Firing - These controllers can be used with any load but must be used for inductive loads - also refereed to as lagging loads. Defined as a load where the alternating current lags behind the alternating voltage of the load. <= = = Phase Difference * AILUT/UP controllers have Continuous PID (4~20mA DC) output capabilities for use with SCR's. 12FINAL CONTROL ELEMENTS The."final control element” is the last part of the loop and the “muscle” of the process control system. Every control loop of any kind has to manipulate a flow of material or energy. Control valves are the most common type of final control element, however, there are other types of devices i.e., mechanisms that regulate (throttle) electric energy such as SCR’s (silicon controlled rectifiers), variable speed drives; proportioning pumps and dampers. Valves The output of the controller sends a corrective electrical signal to the final control element which governs the control of the manipulated variable. In the vast majority of process control applications the final contro! element is a valve: a device that adjusts one or more passages to change the flow rate or path, or both, for one or more fluid streams. Valves are typically driven by motors which are commonly called actuators wi turn drives the stem that positions the valve plug. Control Valves: On/Off valve: Operates in binary fashion, fully opens or fully closes one or more flow paths. Also referred to as an isolation or shutoff valve. Automated or Non-Modulating Throttle Valve: An on/off valve modified by the addition of an actuator and positioner and is operated by a pneumatic cylinder. The distinction between “automated” and “control” valves is usually considered to be the ability of the latter to “modulate,” "throttling" or travel positions during normal control operation. The non-modulating valve is adjusted by hand or by a binary controller to. different positions that remain fixed until the next adjustment. Modulating Throttling Valve: Usually referred to simply as a modulating valve, is operated by an automatic modulating controller that causes the valve to "modulate" or "travel." Like the non-modulating throttle valve it is used to limit flow by adjusting the opening, "throttling" or “choking” the flow. - vi ble-Speed Control: The flow of materials can be modulated by varying the speed of process equipment that uses variable-speed drives, i.e.; conveying solids by means of a variable-speed screw conveyor or conveyor belt: transporting liquids or gases in a pipe or duct by means of a variable-speed pump or compressor. Power drives offering variable speed for process control include: electric motors, pneumatic motors, hydraulic motors, mechanical transmissions and steam turbines. Variable-speed drives can be costly to purchase and maintain. The benefit they provide is to reduce power consumption by using no more power than is needed for pumping at any given time. 13Proportioning Pump: ‘A proportioning pump, also known as a metering PUD, pumps liquids by means of a piston or plunger inside a cylinder. Every back and forth stroke cycle of the pump discharges a fixed Solume of liquid. The length of stroke of the pump can be adjusted by the use of a pneumatic Sr other type of actuator. Each adjustment changes ‘the discharge volume per cycle. Proportioning pumps are usually of low capacity ‘and are frequently used to inject small volumes of a chemical solution into a relatively large stream. Dampers: Industrial fans may be supplied with dampers, louvers or adjustable vanes for manipulating the gas or air flow through the fan. The dampers are placed on the inlet side of the fan and we oe a control valve. They can be actuated automatically a5 part of a control loop or . manually. - 14