YOKOGAWA AUSTRALIA Section 6.

Regulatory Control


SECTION 6

CS3000
REGULATORY CONTROL




CONTENTS


6 Regulatory Control________________________________________________2
6.1 Types of the Regulatory Control Blocks _______________________________ 2
6.2 I/O Data Handled by the Regulatory Control Blocks ____________________ 4
6.2.1 Data Value ____________________________________________________________4
6.2.2 Data Status____________________________________________________________4
6.2.3 Input Data ____________________________________________________________5
6.2.4 Output Data ___________________________________________________________7
6.3 I/O Connections___________________________________________________ 9
6.3.1 Summary of wiring rules _________________________________________________9
6.3.2 Explanation of I/O Connections __________________________________________10
6.3.3 Area Connections _____________________________________________________12
6.4 Function Block Processing _________________________________________ 14
6.4.1 Input Processing ______________________________________________________14
6.4.2 Output Processing _____________________________________________________15
6.4.3 Alarm Processing______________________________________________________16
6.4.4 Block Modes and Statuses _______________________________________________17
6.5 PID Controller Block and Functions_________________________________ 18
6.5.1 Summary of PID Functions: _____________________________________________19
6.5.2 Tuning Parameters for the PID Block ______________________________________20
6.5.3 Input/Output Compensation______________________________________________21


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6 Regulatory Control


6.1 Types of the Regulatory Control Blocks

The regulatory control blocks vary by the types of data handled and control
computation processing functions provided. The blocks are classified into these
blocks below.

Input indicator blocks
Controller blocks
Manual loader blocks
Signal setter blocks
Signal limiter blocks
Signal selector blocks
Signal distributor blocks
Pulse count input connection block
Alarm block


Input Indicator Blocks

Block Code Name
PVI Input Indication Block Input Indicators
PVI-DV Input Indication Block with deviation alarm

Controller Blocks

Block Code Name
PID PID controller block
PI-HLD Sampling PI controller block
PID-BSW PID controller block with batch switch
ONOFF 2-position ON/OFF controller block
ONOFF-G 3-position ON/OFF controller block
PID-TP Time-proportioning ON/OFF controller block
PD-MR PD controller block with manual reset
PI-BLEND Blending PI controller block
Controllers
PID-STC Self-tuning PID controller block

Manual Loader Blocks

Block Code Name
MLD Manual loader block
MLD-PVI Manual loader block with input indicator
MLD-SW Manual loader block with Auto/Man switch
MC-2 2-position motor control block
Manual Loader
MC-3 3-position motor control block

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Signal Setter Blocks

Block type Code Name
RATIO Ratio set block
PG-L13 13-zone program set block
BSETU-2 Batch set block for flow measurement
Signal Setter
BSETU-3 Batch set block for weight measurement

Signal Limiter Block

Block type Code Name
Signal Limiters VELLIM Velocity limiter block

Signal Selector Blocks

Block type Code Name
AS-H/M/L Autoselector blocks
SS-H/M/L Signal selector blocks Signal Selectors
SS-DUAL Dual signal block

Signal Distributor Blocks

Block type Code Name
FOUT Cascade control signal distribution block
FFSUM Feedforward control signal addition block
XCPL Noninteracting control output addition block
Signal Distributors
SPLIT Split control signal distribution block

Pulse Count Input Connection Block

Block type Code Name
Pulse Count Input
Connection Block
PTC Pulse count input connection block

Alarm Block

Block type Code Name
Alarm ALM-R Representative alarm block


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6.2 I/O Data Handled by the Regulatory Control Blocks

As a rule, the data transmitted via I/O terminals handled by the regulatory control
blocks is the engineering unit data. Each data item consists of data value and data
status.


6.2.1 Data Value

The data value is a numeric data that is transmitted in or out of a function
block. The data values handled by the blocks include process variable (PV),
cascade setpoint value (CSV) and manipulated output value (MV).

The data values handled by the regulatory control blocks are numeric data in
engineering unit. However, the data sent to analog output modules and the
data received from input modules are percentage data between 0 % and 100 %,
except those used for temperature measurement.

The data value read into a function block via an input terminal is called input
data, while the value written out of a function block via an output terminal is
called output data.


6.2.2 Data Status

The data status is a piece of status information that indicates the value and
quality of I/O data. The data status is conveyed as I/O data from one function
block to another via I/O connection along with a data value.

The data status is used to test the existence of exceptional events, such as
process failures and computation errors occurred in the control computation
processing performed by the function blocks.

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6.2.3 Input Data


The input data is numeric data that the function blocks read from input terminals.
The types of input data are shown below:

Process variable (PV)
Setpoint value (SV), cascade setpoint value (CSV), remote setpoint
value (RSV)
Input signal values (RV1, RV2, RV3)
Reset limit values (RLV1, RLV2)
Input or Output Compensated value (VN)
Tracking switch (TSW)


Process Variable (PV)

The engineering unit and scale range of raw input signals (RAW) input to an
IN terminal agree with the engineering unit and scale range of data at the
connected destination of the IN terminal. A raw input signal turns into a
process variable (PV) after input processing. Use the function block detail
definition builder to set the engineering unit and scale range. However, the
process variable (PV) of Motor control blocks (MC-2, MC-3) must be an
integer value between 0 and 2.


Setpoint Value (SV), Cascade Setpoint Value (CSV), Remote Setpoint Value (RSV)

The engineering unit and scale range of the setpoint value (SV), cascade
setpoint value (CSV) and remote setpoint value (RSV) agree with the
engineering unit and scale range of the process variable (PV) except in the
function blocks shown below:


Input Signal Values (RV1, RV2, RV3)

The input signal values (RV1, RV2, RV3) are input data handled by the Signal
selector blocks. Use the function block detail definition builder to set the
engineering unit and scale range of input signal values. The input signal values
(RV1, RV2, RV3) are regarded as having the same engineering unit and scale
range as those of the selected signal value (PV).

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Reset Limit Values (RLV1, RLV2)

The reset limit values (RLV1, RLV2) are input data that are handled by a
controller block when the reset limit function is used. The reset limit values
(RLV1, RLV2) are regarded as having the same engineering unit and scale
range as those of the manipulated output value (MV).


Input or Output Compensated Value (VN)

The engineering unit and scale range are not defined for input compensated
values (VN) received from the BIN terminal, as the numeric data of input
compensated values (VN) taken in from outside are used directly for input or
output compensation computation.


Tracking Switch (TSW)

The data handled by the tracking switch (TSW) for the TSI terminal must be
an integer value of 0 or 1. 1 and 0 indicate ON and OFF, respectively.


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6.2.4 Output Data

The output data is a numeric data value that is written out of a function block via
an output terminal. The types of output data are shown below:

Manipulated output value (MV)
Auxiliary output values (PV, DPV, MV, DMV)
Process variable (PV)


Manipulated Output Value (MV)

Use the function block detail definition builder to set the display form
for the manipulated output value (MV).


MV Display Style:

Select Automatic Determination or User Define. The
default is Automatic Determination.

When Automatic Determination is selected, the engineering
unit and scale range of the manipulated output value (MV)
change according to the connected destination of the OUT
terminal.

When the connection destination is an input terminal of another
function block than SET terminal, self determination must be
selected. When User Define is selected, set the engineering
unit and scale range for the manipulated output value (MV).

For the MV displayed on an instrument faceplate, set whether
to display the engineering unit data as is or to convert the data
into a percentage-unit value first. Use the function block detail
definition builder to set the instrument faceplate display.


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Auxiliary Output Values (PV, DPV, MV, DMV)

The auxiliary output values include PV, DPV, MV and DMV, the
types vary with the function block. The engineering unit and scale
range of the auxiliary output values change in accordance with the
connected destination of the SUB terminal.


Process Variable (PV)

The process variable (PV) can be output directly from the input indicator
blocks. The engineering unit and scale information of the process variable
(PV) vary with the connected destination of the OUT terminal.

If the connected destination is a process I/O module, the
scale range and engineering unit of the output value are
fixed to 0 to 100 and %, respectively.
If the connected destination is another function block, the
scale range and engineering unit of the output value agree
with those of the process variable.
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6.3 I/O Connections

6.3.1 Summary of wiring rules


1. GENERAL WIRING RULE
A data item must connect to a data terminal

Never connect data item to data item or data terminal to data terminal

Examples:

PV IN
OUT RV






PID

ADD
IN Out
PV RV
PVI





2. CASCADE RULE
Always connect the OUT terminal to a SET terminal

Note, the OUT terminal must contain the MV. For example, connecting the OUT of
an SS-H (contains PV) will not work. Use the AS-H instead, as it contains the MV in
its OUT terminal.




PID
Set
P
Out IN

PID PVI





3. SWITCH RULE
The above two rules hold across a switch for the source and destination modules
on either side of it.


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6.3.2 Explanation of I/O Connections

All blocks have terminals that allow the reading or writing of data to another function
block. Each contains data items that other modules read from or write to using
terminals.

For example, when a PVI is connected as an input to a PID, the IN terminal is reading
the PV of the PVI block, as shown below:



PVI - FI100 PID - FIC100


PV

PV
IN




In other words for PID tag FIC100, IN = FI100.PV

And this value is then assigned to the PV of the PID block.

This is called a Data Reference Connection.

Similarly it is possible to write to a data item in a block from the terminal of a
previous block as shown below:



PID - FIC100 ADD - FQ100


MV

RV
Out




In other words, for PID tag FIC100, OUT = FQ100.RV

The MV is assigned through the OUT terminal to the RV of the ADD block.

This is called a Data Setup Connection.

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Cascade Connections

This is a special connection type where the data flow is two way, that is, data is being
read and written between two function blocks through the one connection.

The main application for this is a cascade control loop. This is where the output of a
(primary) controller inputs to the setpoint of another (secondary) controller, as shown
in the following diagram:

MV -> CSV
MODE
SV -> MV


Here, the output (MV) of the primary controller is written to the setpoint (CSV) of the
secondary controller.

However, the block mode (CAS, AUT, MAN) of the secondary controller is written
back to the primary controller. If the secondary controller is not in CAS, then it is not
reading the output of the primary controller and it goes into IMAN. While the
primary controller is in IMAN, it's output tracks the setpoint of the secondary
controller.


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6.3.3 Area Connections

It is possible to connect function blocks that are on different control drawings, or even
in different FCSs. This is done using LINK blocks called:

AREAIN - link between blocks within the same FCS
AREAOUT - link between blocks in different FCSs


To connect blocks between two control drawings in an FCS, use the AREAIN block
as follows:














FI100

PVI
IN
AREAIN Link block
Control Drawing 2 Control Drawing 1
FI100.PV
FIC200

PID

To write to a block in another control drawing, also use the AREAIN. Note that
AREAIN does not mean input. It means within the same FCS.













FQ100

ADD
OUT
AREAIN Link block
Control Drawing 1 Control Drawing 2
FQ100.RV
FIC200

PID

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Cascade connections can be connected in the same way. However, there must be a
link block in each control drawing, as follows:


OUT
AREAIN Link block
Control Drawing 1
FIC200.SET
FIC100

PID













SET
AREAIN Link block
Control Drawing 2
FIC100.OUT
FIC200

PID













Inter FCS Connections

Connections between function blocks in different FCS is carried out in exactly the
same way as described above. However, use the AREAOUT link block instead of the
AREAIN.

When AREAOUT Links blocks are used, an ADL (Area Data Link) block is
automatically set up in the FCS. This manages the transfer of data between the two
FCSs. The scan rate for the data, and other parameters, are setup in the FCS
properties.


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6.4 Function Block Processing

6.4.1 Input Processing

Function blocks are provided with various types of input processing methods to
convert the input signals for the control calculation and arithmetic calculation.


Input Processing

Input processing is a general term used for processing for the input signal read
from the connection destination of an input terminal, executed by the function
block before the calculation processing. There are various forms of input
processing corresponding to the function block type and the input signal
format.


Input Processing Common to All Regulatory Control Blocks

The Regulatory Control Blocks have the input signals processed as shown in
the figure below. After the processing, the signal becomes process variable
(PV).



Figure - Block Chart of Input Processing Common to All Regulatory Control Blocks

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6.4.2 Output Processing

Output processing is a term defining the functions carried out on an output signal
before it is loaded to the final output item (eg, MV). There are various forms of output
processing corresponding to the function block type and the output signal format.
Some forms of output processing are common to Regulatory Control Blocks and
Calculation Blocks, while others are specific to certain particular blocks.

Output Processing Common to Regulatory Control Block

In a Regulatory Control Block, the value obtained from control computation
undergoes output processing, then outputs as the manipulated output variable
(MV), as depicted in the figure below.



Figure - Block Chart of Output Processing Common to Regulatory Control Block

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6.4.3 Alarm Processing

This is a function that detects any abnormality in the process from values such as
process variables (PV) and manipulated output values (MV). In order to detect
anomalies in the process, the alarm detection function performs the following alarm
checks:

Alarm Type Status ID
Input open alarm check IOP, IOP-
Input error alarm check PERR
Input high-high and low-low limit alarm check HH, LL
Input high and low limit alarm check HI, LO
Input velocity alarm check VEL-, VEL+
Deviation alarm check DV-, DV+
Output open alarm check OOP
Output failure alarm check CERR
Output high and low limit alarm check MHI, MLO
Connection failure alarm check CND


Alarm definition is configured in the detailed specification for the function block in
the control drawing. The actual alarm levels are configured through the operator
display.




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6.4.4 Block Modes and Statuses


Every module has a block mode. This defines the status of it's function processing.
These are listed below:



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6.5 PID Controller Block and Functions

The PID controller block (PID) provides the most general control function to perform
proportional-integral-derivative control based on the deviation of the process variable
(PV) from the setpoint value (SV).



Figure - Function Block Diagram of PID Controller Block (PID)

Reference: IM 33S1B30-01, Section D1.4 & 5.

The above referenced sections provide detailed information about the functions of the
PID controller block. Below is a summary of the main features of the block.


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6.5.1 Summary of PID Functions:




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6.5.2 Tuning Parameters for the PID Block 6.5.2 Tuning Parameters for the PID Block

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6.5.3 Input/Output Compensation

The input/output compensation uses the VN input data item as an adder to the PV
or MV of the controller.

As an adder to the PV (input compensation) it can be used for predictive
control.
As an adder to the MV (output compensation) it can be used for
feedforward.

Schematically the function works as follows:
BIN
input compensation output compensation
VN
+
+
CB CB
x
x
CK CK
PID
Calculation
PV
MV
+
+


To select input or output compensation, go to the EDIT DETAIL of the function
block and select the CONTROL CALCULATION tab.



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Example Feedforward application

One of the most common applications for output compensation is feedforward.
This is where a signal is added to the output of a controller. A typical example
is a boiler application.

The boiler level controller calculates a flow demand based on the boiler level.
The problem with this is that sudden changes in demand for steam means that
the boiler level can drop a long way before the level controller can correct it.
To provide closer control, the change in steam flow is added to the output of
the steam controller.

That is, if the steam flow increases by 10%, then increase the feed water flow
by 10% (or some factor of it). This can be tuned by setting the CK
(compensation gain) in the tuning panel.




Put the DPV into the SUB
SUB
FI100
PVI
Set to Output Compensation
VN
Boiler
Level
IN OUT
LIC100
PID
SET
Feed Water
Flow
IN OUT
FIC100
PID