Closed Loop Control With Siemens 27-1200
Closed Loop Control With Siemens 27-1200
Closed Loop Control With Siemens 27-1200
PID_Compact
Siemens
SIMATIC S7-1200 / S7-1500 + TIA Portal V17 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/100746401 Support
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Table of contents
Legal information ..................................................................................................... 2
1 Task................................................................................................................. 4
1.1 Overview ........................................................................................... 4
2 Solution........................................................................................................... 5
2.1 Overview ........................................................................................... 5
2.2 Description of the core functionality .................................................... 6
2.3 Hardware and software components .................................................. 7
2.3.1 Validity .............................................................................................. 7
2.3.2 Components used.............................................................................. 8
3 Principle of operation ..................................................................................... 9
3.1 Complete overview ............................................................................ 9
3.2 OB "Main"........................................................................................ 10
3.2.1 FB "Hmi".......................................................................................... 10
3.3 OB "CyclicInterrupt" ......................................................................... 11
3.3.1 FB "PID_Compact" .......................................................................... 12
3.3.2 FB "Simulation"................................................................................ 14
4 Installation and commissioning................................................................... 17
4.1 Hardware adaptation ....................................................................... 17
4.2 Configuration ................................................................................... 20
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1 Task
1.1 Overview
Introduction
For the targeted influencing of certain quantities in a technical system, these
quantities must be controlled. Controllers are also used in a wide variety of
applications in automation technology, for instance speed control.
For the SIMATIC S7-1200/S7-1500, the technology object "PID_Compact"
is provided for proportional actuators.
Figure 1-1
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PID_Compact PT1
Setpoint Control Controlled
Controller
deviation system
Process value
HMI
2 Solution
2.1 Overview
Diagram
The following diagram shows the most important components of the solution:
Figure 2-1
TIA
portal
PC-Station:
HMI-Visualisierung
der Szenarien
Industrial Ethernet
CPU 1211C
The "PID_Compact" technology object reads the measured process value and
compares it with the setpoint (in this example, the setpoint is set via HMI).
From the resulting control deviation, the controller calculates an output value in
order to adjust the setpoint deviation or the disturbance variable if necessary.
The output value of the PID controller consists of three components:
• P component
The P component of the output value is proportional to the control deviation.
• I component
The I component of the output value is the integral component. This increases
as long as there is a control deviation.
• D component
The D component is the differential component and increases as the rate of
change of the control deviation increases.
The "PID_Compact" technology object has the "tuning" commissioning functionality
with which the P, I and D parameters can be calculated automatically depending on
the controlled system. However, you can also specify the control parameters
manually.
The automatic tuning is divided into tuning types:
1. Pretuning and
2. Fine tuning
Both types of tuning are described below.
Monitoring
Alarm view
Configuration
Simulation
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Delimitation
This application example provides an overview of the "PID_Compact" technology
object for commissioning with the SIMATIC S7-1200/S7-1500.
You can use the application example to conveniently operate your control system
via an operator panel and adapt it to your automation task.
The application example was tested by simulating the controlled system.
For real operation, you must adapt the application example to the actuator and
process value sensor you are using:
• Analog control or control via a digital output using the pulse width modulated
signal?
• Required voltage and power for control?
• What are the signal characteristics of the process value sensor used?
Note The application example is not a replacement for the configuration mask of the
PID_Compact Assistant, as it is used to define the start values in the instance
data block, which are decisive for restarting after a power failure.
In addition to the "PID_Compact" control block, STEP 7 (TIA Portal) also provides
the following compact controllers with automatic tuning for the SIMATIC S7-
1200/S7-1500:
• Modulating controller "PID_3Step" for valves or actuators with integrating
behavior (\10\)
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Required knowledge
Basic knowledge of control engineering is required.
Note The version differences of the controller can be found in the chapter "New
features of PID_Compact" in the function manual for PID control (\13\).
Hardware components
Table 2-1
Components Qty. Article number Note
SIMATIC HMI KTP900 1 6AV2123-2JB03-0AX0 Optional (can also be
BASIC simulated in WinCC)
COMPACT SWITCH 1 6GK7277-1AA10-0AA0
MODULE CSM 1277
POWER SUPPLY S7- 1 6EP1332-1SH71
1200 PM1207
CPU 1211C, 1 6ES7211-1AE40-0XB0 Firmware V4.5
DC/DC/DC,
6DI/4DO/2AI
Fan/motor with analog 1 Fan/motor manufacturer - Without integrated
speed control (0 to 10V / speed control
0 to 20mA) electronics
- Optionally with
integrated actual speed
feedback
© Siemens AG 2022 All rights reserved
Software components
Table 2-2
Components Qty. Article number Note
SIMATIC 1 6ES7822-1AA07-0YA5 • Contains WinCC Basic V17
STEP 7 • With update 4
Professional
for S7-1200 and S7-1500
V17
SIMATIC 1 6ES7822-0AA05-0YA5 • Contains WinCC Basic V17
STEP 7 Basic With update 4
V17
3 Principle of operation
3.1 Complete overview
Figure 3-1 shows the chronological sequence of the block calls in the control part
of the TIA Portal project.
Figure 3-1
LSim_PT1
Simulation
Cyclic Scale
interrupt
PID_
Compact
[FB 1130]
The tag transfer between the functions takes place via the data block DB "Tags"
and the instance data block of the controller DB "InstPidCompact".
3.2 OB "Main"
The function block for the HMI transfer is called from the organization block "Main".
3.2.1 FB "Hmi"
Figure 3-2
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Table 3-1
Name Data type Description
Input simulate Bool Enabling simulation
errorSimulation Bool Simulation of a sensor error
tuningMode Int Tuning type selection (1=pre-/2=fine tuning)
errorAckInt Int Acknowledgment tag for HMI bit messages
errorAck Bool HMI request to clear error messages
Output tuningVisible Bool Visibility of the tuning
sutVisible Bool Visibility of the pretuning
tirVisible Bool Visibility of the fine tuning
manualModeVisible Bool Visibility of the switch to manual mode.
setpointLimited Bool Violation of setpoint limit specifications
acknowledgeVisible Bool Visibility of HMI request to clear error
messages
errorSimulationVisible Bool Visibility of the simulation of a sensor error
Tags that the HMI requires for the visibility animation of objects and elements are
defined in the "Hmi" function block.
More detailed descriptions can be found in the network headings.
3.3 OB "CyclicInterrupt"
The actual program (the call of the compact controller "PID_Compact") takes place
in the cyclic interrupt OB, since discrete software controls must be called at a
defined time interval.
100ms was selected as the constant time interval of the sampling time of the OB
"CyclicInterrupt".
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Program Overview
The entire simulated control loop is calculated in the cyclic interrupt OB.
Figure 3-3
Cyclic interrupt
Simulation
QW80
-32768
Q0.0
IW64
The following peripheral connection for controlling a real system is made in the
example project:
Table 3-2
Tag S7-1200 S7-1500
"PID_Compact".Input_PER IW64 IW0
"PID_Compact".Output_PER QW80 QW0
"PID_Compact".Output_PWM Q0.0 Q4.0
Description
In the example project, the compact controller "PID_Compact" accesses the
peripheral signals from Table 3-2. This calculates the manipulated variable from
the control deviation = setpoint - process value as a function of the PID
parameters. The manipulated variable can be output either as an analog or digital
pulse width modulated signal to the peripheral control outputs.
For simulation, the manipulated variable is transferred to the function block
"LSim_PT1" as a floating point number.
The FB "LSim_PT1" simulates a controlled system with PT1 behavior and thus
outputs the simulated process value as a floating point number.
This is converted into an analog value via the FC "Scale".
When the "Error simulation" is activated, the analog process value is overwritten
with the erroneous value (-32768).
In addition, the simulated analog process value is converted via the FC "Scale" into
the corresponding floating point number for the "Input" input of the FB
"PID_Compact".
By deactivating the FB "Simulation" you can switch off the plant simulation and
control a real controlled system (signal evaluation via the control periphery) with
the FB "PID_Compact".
3.3.1 FB "PID_Compact"
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STEP 7 supplies the technology object "PID_Compact" in version 2.3 for the S7-
1200 or version 2.4 for the S7-1500 with the installation.
This function block was specially developed for the control of proportional
actuators.
Figure 3-4
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Table 3-3
Name Data type Description
Input Setpoint Real Setpoint input
Input Real Process value in REAL format
Input_PER Int Analog process value
Disturbance Real Disturbance selection
ManualEnable Bool Activating the "Manual mode" operating mode
ManualValue Real Manual value
errorAck Bool Deletion of error messages / warnings
Reset Bool Resetting, restarting of the controller
ModeActivate Bool Enable "Mode" operating mode
Output ScaledInput Real Scaled process value
Output Real Output value in REAL format
Output_PER Int Analog output value
Output_PWM Bool Pulse width modulated output value
SetpointLimit_H Bool Setpoint is fixed at the upper limit
SetpointLimit_L Bool Setpoint is fixed at the lower limit
InputWarning_H Bool Process value has exceeded upper warning limit
InputWarning_L Bool Process value has undershot lower warning limit
State Int Display of the current operating mode of the PID
controller
(0=Inactive,1=SUT,2=TIR,3=Automatic,4=Manual)
Error Bool At least one error message present
Note A more detailed description of the compact controller can be found in the STEP 7
online help. Select the function block "PID_Compact" in the program call (see
Figure 3-4) and press F1.
3.3.2 FB "Simulation"
Figure 3-5
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Table 3-4
Name Data type Description
Input initialCall Bool First call of the cyclic interrupt
errorSimulation Bool Simulation of a sensor error
Output output Real Simulated process value as REAL format
outputPer Int Simulated analog process value
InOut pidCompact PID_Compact Transfer of the instance data block of the FB
"PID_Compact".
FB "LSim_PT1"
The function block "LSim_PT1" simulates the continuous behavior of a PT1
system. This block comes from the library for controlled system simulation (\7\).
You can also find a detailed description of the FB "LSim_PT1" here. In this
application example, the "LSim_PT1" system simulation module is designed with a
delay time of 3 seconds.
Note Please note that changes of the system parameters are only accepted after
activation of the input "calcParam" (implemented in the example project as
restart of the CPU).
FC "Scale"
The "Scale " function is used for linear conversion according to the following
formula:
𝑜𝑢𝑡𝑝𝑢𝑡𝑅𝑒𝑓2 − 𝑜𝑢𝑡𝑝𝑢𝑡𝑅𝑒𝑓1
𝑜𝑢𝑡𝑝𝑢𝑡 = ∙ (𝑖𝑛𝑝𝑢𝑡 − 𝑖𝑛𝑝𝑢𝑡𝑅𝑒𝑓1) + 𝑜𝑢𝑡𝑝𝑢𝑡𝑅𝑒𝑓1
𝑖𝑛𝑝𝑢𝑡𝑅𝑒𝑓2 − 𝑖𝑛𝑝𝑢𝑡𝑅𝑒𝑓1
Figure 3-6
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Ref2
output
Ref1
input
Figure 3-7
Table 3-5
Name Data type Description
Input input LReal Value to be converted
inputRef1 LReal Input value of reference point 1
inputRef2 LReal Input value of reference point 2
outputRef1 LReal Output value of reference point 1
outputRef2 LReal Output value of reference point 2
Output output LReal Output value
By selecting the data type "LReal", the correct conversion of or into the attached
actual parameters is ensured.
The FC "Scale" converts the process output into an analog value in order to
simulate the behavior of the controller in the event of an error.
The fault occurs in a real system due to the failure of the process value sensor
(e.g. due to wire breakage).
In the simulation, this is achieved by overwriting the analog process value with a
value outside the measuring range (-32768) (see Figure 3-3).
Then FC "Scale" converts the resulting analog value into a floating point value for
the process value selection "Input" of the FB "PID_Compact".
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Input signal
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Output signal
The "PID_Compact" offers the control of the actuator via an analog output or via a
digital pulse width modulated transistor output.
Note Further information on the selection of your peripherals or their wiring can be
found in the hardware catalog in the TIA Portal or:
• in Section A "Technical data" in the S7-1200 manual (\3\)
• in the manual "SIMATIC S7-1500/ET 200MP Manual Collection" (\9\)
• via the TIA selection tool (\11\)
Hardware installation
The following figure shows the hardware structure of the application example with a
SIMATIC S7-1200.
Figure 4-1
L1
N
PE
DC24V+
DC24V-
CPU 1211C
Q0.0 = Output_PWM
0M 0
IP address 192.168.0.241
Subnet mask 255.255.255.0
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Ua1
TIA Portal
Ua2
The following figure shows the hardware structure of the application example with a
SIMATIC S7-1500.
Figure 4-2
L1
N
PE
DC24V+
DC24V-
KTP900 Basic
Ua1
TIA Portal
Ua2
4.2 Configuration
4.2.1 Transferring I/O addresses
Define
• which physical unit is to be used for the
display of setpoint and process value
• whether the controller output is to be
inverted
• whether the controller is to remain
"inactive" after restarting the CPU or
changes to the operating mode stored at
"Mode"
• under "Set mode to:" the operating mode
that is to be activated after a complete
loading into the device.
(The prerequisite for this is that the
"Mode" parameter is not linked -> see
Figure 3-4)
3. Adjust the "Input/Output parameters" submenu
in the basic settings to the sensors/actuators
used:
• Process value as prepared floating point
number "Input" or as analog value
"Input_PER".
• Manipulated variable as floating point
number "Output", as analog value
"Output_PER" or as digital pulse width
modulated signal "Output_PWM".
Note Changes to the start values of a data block are not accepted as actual values
until the next STOP/RUN transition (for non-retentive data types).
You can find a more detailed description in the S7-1200 manual (\3\→ Chapter
10.2.7) and in the function manual on PID control (\13\ → Chapter "Commissioning
PID_Compact V2").
Note The PID parameters are retentively stored in the instance data module of the
"PID_Compact" compact controller.
During a warm start (voltage recovery), the last values passed through are
retained.
The start values are only loaded during a cold start (transfer of the project in the
operating state STOP or overall reset of the memory via MRES).
© Siemens AG 2022 All rights reserved
Table 4-6
No. Action Note
1. • Mark the HMI folder "PID_HMI [KTP900
Basic PN]".
• Click the "Load to device" button to
download the HMI project part into the
KTP900 Basic.
• Follow the wizard to "Load into device".
HMI simulation
If you want to use the PG/PC as an operating device, start the HMI simulation as
© Siemens AG 2022 All rights reserved
follows:
Table 4-7
No. Action Note
1. • Mark the HMI folder "PID_HMI [KTP900
Basic PN]".
• Click the "Start simulation" button.
Figure 5-1
Tuning M onitoring
Alarm view
Configuration
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Simulation Settings
Figure 5-2
e.g. (for the overview screen) or the title in the header line (left):
.
In the middle of the header line you can see which operating mode the controller is
currently in: (for automatic mode)
Figure 5-3
The "Trend view" image shows the time course over 90 seconds.
• of the setpoint (scale left)
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Manual mode
Note Manual mode is activated here via the value setting at the "Mode" parameter in
conjunction with activation via "ModeActivate" (not via "ManualEnable").
Automatic mode
Response to errors
If the process value limits are exceeded (e.g. due to sensor failure), you can
predefine the behavior of the controller.
Check whether, in the case of an error,
or
• Pretuning
• Fine tuning
• Automatic mode
The controller also switches to inactive in manual mode when this behavior is
selected in the event of an error.
In the system simulation mode, the selected behavior in the event of an error can
highlighted in red:
Note These selection fields are highlighted in yellow, since they are non-retentive data
in the instance data block of the "PID_Compact".
You can change them via the operator interface or its simulation to test the
function.
To save these default settings even in the event of a power loss, this value must
be written as start values in the instance data module of the "PID_Compact".
The configuration wizard offers this function (Table 4-4) with subsequent transfer
of the instance data block.
5.1.3 Tuning
In the "Tuning" menu you can set the control parameters automatically or manually.
Figure 5-4
pretuning
• or fine tuning
from the inactive controller state, manual or automatic mode.
Note Manual operation must not be selected via the "ManualEnable" input!
For pretuning, you can choose between the following tuning methods:
• Chien, Hrones, Reswick PID
• Chien, Hrones, Reswick PI
For fine tuning, you can choose between the following tuning methods:
• PID automatic
• PID fast
• PID slow
• Ziegler-Nichols PID
• Ziegler-Nichols PI
• Ziegler-Nichols P
Note The parameter "CancelTuningLevel" ensures tuning even with signal noise at the
setpoint (e.g. when using a potentiometer).
Note If possible, enter a target value in the middle field of the process value range to
avoid aborting the tuning by reaching the limit.
The tuning status and the percentage progress are displayed during tuning.
Use to cancel the tuning and return to the operating mode from which the
tuning was started.
After successful tuning, the determined controller parameters are displayed in the
before tuning.
The saved "BackUp" parameter set can be reloaded into the controller via
.
The current controller parameters ("Retain.CtrlParams") can also be edited
corresponds to the time cycle of the cyclic interrupt organization block in which the
"PID_Compact" is called.
The sampling time of the PID algorithm
corresponds to a multiple of the
sampling time of the controller and depends on the PWM limitation.
After successful tuning, you can calculate the controller parameters using
5.1.4 Monitoring
The monitoring screen shows the online status of the "PID_Compact" compact
controller.
Figure 5-5
© Siemens AG 2022 All rights reserved
You can:
• view all input and output values
• edit the following parameters:
– Setpoint in automatic mode ("Setpoint")
– Feedforward control in automatic mode ("Disturbance")
– On/Off switching of manual operation ("ManualEnable")
– Manual manipulated variable setting in manual mode ("ManualValue")
– Acknowledgment (reset) of the messages "ErrorBits" and "Warning"
("Acknowledge Error")
– Resetting the compact controller ("Reset")
– Changing the operating mode via the selection at the parameter "Mode"
and activation via "ModeActivate".
• Test the process value monitoring configuration
– Editing the upper ("InputUpperWarning") and lower ("InputLowerWarning")
warning limits
– Direct monitoring at the outputs "InputWarning_H" or "InputWarning_L".
Note In this application example, the reset button restarts the blocks "PID_Compact"
and "LSim_PT1". The controller switches to the "Inactive" operating mode. The
messages "ErrorBits" and "Warnings" are reset. The controller then starts in the
operating mode that is applied to the "Mode" parameter.
Note In manual mode (activated via "ManualEnable" = "ON"), the operating mode
cannot be changed via "Mode" and "ModeActivate".
The "Message display" menu displays the current messages at the "ErrorBits"
output and at the "Warning" static parameter of the "PID_Compact" as
hexadecimal error codes, as well as in text form with time stamp and status.
Figure 5-6
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The error messages "ErrorBits" are also displayed globally when they occur.
Figure 5-7
You have the option of acknowledging errors that are no longer pending via .
This deletes all messages that are no longer present at "ErrorBits" and "Warning"
via the "ErrorAck" input.
Within the message display and the other masks, execute this function via
.
The button is only visible for pending messages ("ErrorBits" or "Warning").
Note The complete description of all error messages can be found in the online help of
STEP 7 (TIA Portal). Select the function block "PID_Compact" in the program
call (see Figure 3-4) and press F1.
5.1.6 Configuration
The configuration mask is based on the basic settings of the configuration wizard
(Table 4-4).
Figure 5-8
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Basic settings
• Control type
– Specification of the displayed physical unit (limited to 5 characters; not
identical to the preselection in the configuration wizard)
Note The process value scaling serves for linear conversion of the analog value
"Input_PER" into the scaled process value "ScaledInput".
© Siemens AG 2022 All rights reserved
In simulation mode, however, this conversion is also required when selecting the
process value acquisition via the floating point value "Input" (see Figure 3-3).
Advanced settings
• PWM limits (see Table 4-4, Step 7)
– Editing of minimum switch-on and switch-off time for adaptation to possible
actuator inertia
Setpoint limits
The compact controller "PID_Compact" automatically limits the setpoint to the
"Process value limits".
However, you can also limit the setpoint to a smaller range above the setpoint
limits.
Figure 5-9
Note These input/output fields are highlighted in yellow, since they are non-retentive
data in the instance data block of the "PID_Compact".
You can change them via the operator interface or its simulation to test the
function.
To save these default settings even in the event of a power loss, these values
must be written as start values in the instance data module of the
"PID_Compact".
The configuration wizard offers this function (Table 4-4) with subsequent transfer
of the instance data block.
5.1.7 Simulation
The simulation screen allows you to switch between a real and a simulated control
system.
Figure 5-10
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When the simulation is switched on, the figure shows the block
diagram structure, how the input signals for the controller are calculated:
The output of the PT1 system simulation block supplies the process value.
5.1.8 Settings
Time setting/CPU
The application example has a time synchronization between CPU and HMI.
Via you can edit the date and via the time.
Via you accept these settings and set the CPU system time.
Via you put the CPU into the operating state "RUN".
Via you put the CPU into the operating state "STOP".
In the CPU operating state the header and sidebar flash alternately
orange:
6 Appendix
6.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
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Product information, manuals, downloads, FAQs, application examples and videos
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support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
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Service offer
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• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
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