03ProcessControlwithLogix.docx

03ProcessControlwithLogix.docx

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03ProcessControlwithLogix

ProcessControlProgramminginLogix

Hands-OnLab

WelcometoProcessControlProgramminginLogixHands-OnLab4

AboutThisHands-OnLab4

LabMaterials4

DocumentConventions5

AboutControlLogixandCompactLogixControllers6

Lab1:

CreatingCascadePIDEControl（40Minutes）7

AboutThisLab7

LaunchingRSLogix5000ProgrammingSoftware8

AddingandConfiguringPIDEinstructionsinaFunctionBlockRoutine9

AddingSimulationBlockstoYourProject15

MonitoringDataUsingNewGlobalObjectsFaceplates22

ExercisingandAutotuningtheCascadePairUsingRSViewSEClient.29

Lab2:

UsingDiscrete3-StateDevice（D3SD）andTotalizer（TOT）FunctionBlockswithaFillTankApplication（30minutes）42

AboutThisLab42

LearningAboutD3SDBlocks43

ReviewingaTypicalD3SDBlockSetup44

ReviewingtheMinimumD3SDBlockConfiguration46

ReviewingOptionalD3SDConfiguration49

LearningAboutTotalizer（TOT）Blocks51

ReviewingaTypicalTOTBlockSetup52

ReviewingtheTOTBlockConfiguration54

ExercisingtheD3SDandTOTFunctionBlockswithRSViewSE56

WelcometoProcessControlProgramminginLogixHands-OnLab

AboutThisHands-OnLab

ThissessionprovidesyouwithanopportunitytoexploretheProcessControlProgramminginControlLogix,FlexLogix,orCompactLogixplatforms,dependingonthestationatwhichyoufindyourselfseated.

Thefollowingsectionsexplainwhatyou’llbedoinginthislabsession,andwhatyouwillneedtodotocompletethehands-onexercises.

WhatYouWillAccomplishInThisLab

Asyoucompletetheexercisesinthishands-onsession,youwill:

▪LearntosolvetypicalprocesscontrolapplicationsusingLogixFunctionBlockDiagrammingeditorandpowerfulbuilt-inprocesscontrolinstructionset.

▪BecomebelieversthatControlLogixoranyoftheLogixprocessorsaremorethanjustdiscretecontrollers.

WhoShouldCompleteThisLab

Thishands-onlabisintendedfor:

UserswhoarefamiliarwithusingaFunctionBlockDiagrammingEditorinaPLCorDCStosolveprocessapplications.

LabMaterials

ForthisHands-Onlab,wehaveprovidedyouwiththefollowingmaterialsthatwillallowyoutocompletethelabsinthisworkbook.

Hardware

Thishands-onlabrequiresoneofthefollowingDemoboxes:

▪ControlLogixDemoBox

Software

Thishands-onlabusesthefollowingsoftware:

▪RSLogix5000programmingsoftware

▪RSLinx

▪RSViewStudioSE

Files

Thishands-onlabrequiresthefollowingprojectfiles:

▪Process_Control_CLX.ACDorProcess_Control_CMPX.ACD

▪Process_Control.apa

DocumentConventions

Throughoutthisworkbook,wehaveusedthefollowingconventionstohelpguideyouthroughthelabmaterials.

Thisstyleorsymbol:

Indicates:

Wordsshowninbolditalics（e.g.,RSLogix5000orOK）

Anyitemorbuttonthatyoumustclickon,oramenunamefromwhichyoumustchooseanoptionorcommand.Thiswillbeanactualnameofanitemthatyouseeonyourscreenorinanexample.

Thetextinthistypeofboxissupplementalinformationregardingthelabmaterials;itisnotinformationthatisrequiredreadinginorderforyoutocompletethelabexercises.Thetextthatfollowsthissymbolmayprovideyouwithhelpfulhintsthatcanmakeiteasierforyoutousethisproduct.

Note:

Ifthemousebuttonisnotspecifiedinthetext,youshouldclickontheleftmousebutton.

AboutControlLogixandCompactLogixControllers

ControlLogix

TheControlLogixplatformprovidesamodularcontrolplatformsuitedforsequential,process,drive,ormotioncontrolapplications-inanycombination.Withthisplatform,youcanmixmultipleprocessors,networks,andI/Owithoutrestrictions.Andasyoursystemgrows,youcanuseeitheraControlNetorEtherNetI/Pnetworktodistributecontroltoadditionalchassisand/orotherLogixplatforms.

AControlLogixsystemcanconsistofanythingfromastand-alonecontrollerandI/Omodulesinasinglechassis,toahighlydistributedsystemconsistingofmultiplechassisandnetworksworkingtogether.ControlLogixcontrollerswillfityourapplicationsifthey:

▪Requireahighperformancecontrolsolution

▪Demandtheintegrationofmultiplecontroldisciplines（e.g.,processcontrolalongwithhighspeedpackagingmachinesintegratingsequentialandmotioncontrol,orwebhandlingapplicationsintegratingsequentialanddrivecontrol）

▪Combinebatchandprocesscontrol,butseekaflexiblechoiceofvisualizationsoftware

▪Requireaplant-widecontrolsolution,fromincomingmaterialstooutboundshipping

▪ExpandanexistinginvestmentinaPLC-5orSLC500controller-basedsystem

CompactLogix

Thecombinationoffeatures,scalability,andthesmallsizeoftheCompactLogixplatformprovideapowerfulalternativeformachine-levelcontrol,materialhandling,dataacquisition,anddistributedcontrol.CompactLogixcombinesthehighperformanceLogixcontrolenginewiththecost-effectiverackless1769I/OplatformandEtherNetandDeviceNetconnectivity.

CompactLogixwillfityourapplicationsif:

▪YouareanexistingLogixcustomerwithlower-end,lower-costcontrolapplications.

▪YouareanewcustomerwhowishestoapplyLogixtechnology,butatalowerinitialinvestment.

▪YouareanexistingPLCand/orSLCcustomerwhowishestoconverttoLogixtechnology.

▪YouperformSCADA/RTUapplicationswithinarangeofindustries（e.g.,petrochemical,wastewater,etc.）

IMPORTANTNOTE!

DuringtheentirelabsessionwewillnotbeconcernedwithwhatLogixcontrollerequipmentisinfrontofyou.AlltheconceptswillapplyacrossallLogixplatforms.

Startingwithver.13orhigherofRSLogix5000,thesoftwarewillrecognizewhattypeofprocessoryouareusingandwillpromptyoutoautomaticallychangeittothecorrectoneduringthedownload.

So,pleasepayspecialattentiontotheRSLogix5000promptsduringthefiledownload.

Lab1:

CreatingCascadePIDEControl（40Minutes）

AboutThisLab

InthislabwewilldiscussaprocesscontrolcapabilitycalledCascadeControl.CascadeControlisanattachmentoftheoutputfromonePIDElooptotheinputofanotherPIDEloop.Thisallowsfordifferentfeedbacktobeintroducedatdifferentlevelsinthecontrolloop.

Hereisanexamplewherethecascadecontrolwouldbeused.Let’ssayweneedtocontroltheproducttemperatureinthemixingtank,whichisheatedbythesteamsuppliedtotheoutsidejacketofthetank.

Cascadecontrolwillallowustotakeadvantageofthefastrespondingjackettemperatureloop（secondaryloop）inanefforttominimizetheoveralltimethattheslowrespondingproducttemperatureloop（primaryloop）is“outoftolerance”.Wewillalsouseacoupleofextrablocks（DeadtimeandLeag-Lag）tosimulatetherespectivesystemresponse.

Inthislabyouwill:

▪OpenanexistingRSLogix5000Projectwithpre-createdFunctionBlockRoutine

▪CreatenewPIDEblocksinCascadeControlusingRSLogix5000

▪OpenanexistingRSViewSEProjectanddesignthescreenusingGlobalObjectsPop-upFaceplates,whichisanewfeaturewithRSViewver.4.0（CPR7）

▪ExerciseandAutotuneCascadedPIDEpairusingRSViewSEClient.

LaunchingRSLogix5000ProgrammingSoftware

Inthissectionofthelab,youwilllaunchtheRSLogix5000software,whichwillallowyoutoprogramaprocessor.

1.Fromthecomputerdesktop,double-clickontheLabFilesfoldertoviewitscontents.

2.Double-clickontheProcessControlfolder.

3.Ifyouareseatedatastudentstationwith:

▪ControlLogix,double-clickonProcess_Control_CLX.acdfiletolaunchRSLogix5000software.

TheRSLogix5000screenappears.

4.ExpandanexistingProgramPIDEandCascadeanddouble-clickonthePIDEcascaderoutine.

Thefirstblockswe’lladdtothediagramaretheEnhancedPIDBlocks（PIDE）toregulatethesimulatedcascadeloop.

AddingandConfiguringPIDEinstructionsinaFunctionBlockRoutine

1.OntheProcesstabonthetoolbar,clickonthe“PIDE”functiontwicetogettwoPIDEfunctionblocksonthesheet.

ThetwoPIDEblocksshouldnowappearonthediagram（PIDE_01andPIDE_02）.

2.MovePIDE_02overbyclickinganddraggingsoyoucanseebothPIDEblocks.

3.Zoomoutifyouneedtobyclickingthe‘ZoomOut’buttononthetoolbar.

4.ConnectthePIDE_01outputCVEUtothePIDE_02setpointSPCascadeasfollows:

Clickonceontheprimary’sCVEUoutputpinandclickagainonthesecondary’sSPCascadetheconnection.Clickanywhereonthewhitearea.Yoursheetshouldlooksimilartotheoneshownbelow:

FYI

Thereareinstanceswhereitisnecessaryforthe‘secondary’（PIDE_02）totellthe‘primary’（PIDE_01）toinitializehisCVEUvaluetothesecondarysetpointsothatabumplesstransferoccurs.Thisisnecessaryforstartupandonareturntocascademodefromanon-cascadesecondarymode.Inordertoprogramtheseloopstoaccommodatethisfunctionalitysomehiddenpinsmustbeexposedforconnection:

CVInitReqandCVInitValueintheprimary,andInitPrimaryandSPinthesecondary（SPisalreadyexposedbydefault）.

5.Exposetheprimary’sparametersbyfirstclickingonthe

buttonforPIDE_01,clickontheParametersTab,scrolldowntofindtheCVInitReqandCVInitValueparameters,andenabletheparameter’svisibilitycheckboxasshownbelow:

6.ClickApplyandOKtoclosethePIDEpropertiesdialog.

7.ExposetheInitPrimaryparameterpinforsecondaryPIDE_02inthesamefashionbycheckingtheparameter’svisibilitycheckboxasyoudidabove.

8.Connecttheinitializationparametersasfollows:

ClickonceonthesecondarysetpointoutputpinPIDE_02.SPandclickagainontheprimaryCVInitValuepinPIDE_01.CVInitValuetomaketheinitializationvalueconnection.ClickonceonthesecondaryInitPrimarypinPIDE_02.InitPrimaryandclickag