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GE VersaMax PLC User Manual
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14
PID
Built-in
Function
Block
This
chapter
describes
the
PID
(Proportional
plus
Integral
plus
Derivative)
built-in
function
block,
which
is
used
for
closed-loop
process
control.
•
Operands
of
the
PID
Function
•
Reference
Array
for
the
PID
Function
•
PID
Algorithm
Selection
and
Gain
Calculations
•
Determining
the
Process
Characteristics
•
Setting
and
T
uning
Loop
Gains
•
Example
PID
Built-in
Function
Block
GFK-1503E
User
Manual
273
For
public
disclosure
272
274
Table of Contents
Default Chapter
7
Table of Contents
7
1 Introduction
17
The Versamax Family of Products
17
CPU Modules for Versamax Plcs
18
Basic CPU Features
18
Available Versamax Cpus
18
EZ Program Store
20
Power Supplies
20
Available Power Supplies and Carrier
21
I/O Modules
21
Available I/O Modules
22
Carriers
25
Available Carriers and Terminal Strips
26
Expansion Modules
27
Versamax Modules for Expansion Racks
27
Available Expansion Modules
28
Communications Modules
29
Available Versamax PLC Communications Modules
29
Profibus-DP Network Slave Module
29
Devicenet Network Control Module
30
Asi Network Master Module
30
Serial Communications Module
30
2 CPU Module Datasheets: CPU001, CPU002, CPU005
31
Features
32
Module Specifications
32
Versamax General Product Specifications
33
Serial Ports
34
Serial Port Baud Rates
35
Mode Switch
35
CPU Leds
36
Configurable Memory
37
3 CPU Module Datasheet: CPUE05
39
Features
40
Module Specifications
41
Versamax General Product Specifications
42
Serial Ports
43
Cable Lengths
44
Serial Port Baud Rates
44
Ethernet LAN Port
45
Mode Switch
45
CPU Leds
46
Ethernet Restart Pushbutton
47
Ethernet Leds
47
Configurable Memory
48
Ethernet Interface Overview
49
SRTP Server
49
Ethernet Global Data
49
Station Manager Functionality
49
4 Installation
51
Mounting Instructions
52
Removing the CPU from the DIN Rail
52
Panel-Mounting
52
Installing an Expansion Transmitter Module
54
Removing an Expansion Transmitter Module
54
Installing an Expansion Receiver Module
55
Removing an Expansion Receiver Module
55
Expansion Rack Power Sources
55
Connecting the Expansion Cable: RS-485 Differential
56
Differential Inter-Rack Connection (IC200CBL601, 602, 615)
56
Building a Custom Expansion Cable
56
Connecting the Expansion Cable: Single-Ended
57
Single-Ended Inter-Rack Connection (IC200CBL600)
57
Power Sources for Single-Ended Expansion Rack Systems
57
Installing Power Supply Modules
58
Removing the Power Supply
58
Installing Additional Modules
59
Activating or Replacing the Backup Battery
60
Lithium Battery Replacement
60
Serial Port Connections
61
Providing Power to an External Device from Port 2
61
Cable Lengths and Baud Rates
61
Port 1: RS-232
61
Port 2: RS-485
61
Point-To-Point Connection with Handshaking
65
Multidrop Serial Connections
65
Ethernet Connection for CPUE05
67
Network Connection
67
CE Mark Installation Requirements
68
5 Configuration
69
Using Autoconfiguration or Programmer Configuration
70
Autoconfiguration
70
Software Configuration
70
Configuring Racks and Slots
71
Software Configuration
72
Configuring CPU and Expansion Parameters
72
Configurable Memory for CPU Module IC200CPU001, CPU002, CPU005
74
Configurable Memory for CPU Module IC200CPUE05
75
Configuring Serial Port Parameters
76
RTU and Serial I/O Delays
77
Configuration Required to Use Winloader
78
Note for RTU Communications
78
Storing a Configuration from a Programmer
78
Autoconfiguration
79
Autoconfiguration Assigns Reference Addresses
79
Autoconfiguration Diagnostics
79
Diagnostic Message Summary
80
6 Ethernet Configuration
81
Ethernet Configuration Overview
82
Autoconfiguration
82
Configuring the Ethernet Interface
83
Configuring Ethernet Global Data
85
Before You Configure EGD Exchanges
85
Configuring a Global Data Exchange for a Producer
86
Configuring a Global Data Exchange for a Consumer
87
Selective Consumption
88
Configuring Advanced User Parameters
89
Format of the Advanced User Parameters File
89
Example Advanced User Parameter File
89
Advanced User Parameter Definitions
89
7 CPU Operation
93
Parts of the CPU Sweep
94
Standard CPU Sweep Operation
97
The Sweep Windows
97
The Watchdog Timer
97
Constant Sweep Time Operation
97
CPU Stop Modes
98
Flash Memory
99
Controlling the Execution of a Program
99
Calling a Subroutine Block
99
Creating a Temporary End of Logic
99
Executing Rungs of Logic Without Logical Power Flow
99
Jumping to Another Part of the Program
99
Run/Stop Mode Switch Operation
100
Configurable Run/Stop Mode Operation
100
Configurable Memory Protection
100
Summary of CPU Switch Run/Stop Operation
100
Privilege Levels and Passwords
101
Protection Level Request from Programmer
102
The OEM Protection Feature
102
8 Elements of an Application Program
103
Structure of an Application Program
103
Subroutines
104
Declaring a Subroutine
104
Calling a Subroutine
105
Program Languages
105
Sequential Function Chart
105
Ladder Diagram
106
The Instruction Set
107
Contacts
107
Coils
107
Timers and Counters
108
Math Functions
108
Relational Functions
109
Bit Operation Functions
109
Data Move Functions
109
Conversion Functions
110
Table Functions
110
Control Functions
111
9 Program Data
113
Data Memory References
114
Word Memory References
114
Bit Memory References
115
Transition Bits and Override Bits
115
Retentiveness of Data
116
System Status References
117
Using the System Status References
117
S References
117
SA, %SB, and %SC References
118
How Program Functions Handle Numerical Data
120
Real Numbers
121
Errors in Real Numbers and Operations
121
Time-Tick Contacts
122
10 Instruction Set Reference
123
Bit Operation Functions
124
Data Lengths for the Bit Operation Functions
124
Bit Operation Functions Logical AND, Logical or
124
Bit Operation Functions Exclusive or
126
Bit Operation Functions Exclusive or
127
Bit Operation Functions Logical Invert (NOT)
127
Bit Operation Functions Shift Bits Right, Shift Bits Left
128
Bit Operation Functions Rotate Bits Right, Rotate Bits Left
129
Bit Operation Functions Bit Test
130
Bit Operation Functions Bit Set and Bit Clear
131
10Bit Operation Functions Masked Compare
132
11Bit Operation Functions Bit Position
134
12Bit Operation Functions Bit Sequencer
135
Control Functions
138
Control Functions Do I/O
138
Control Functions Call
140
Control Functions End of Logic
141
Control Functions Master Control Relay (MCR) / End MCR
142
Control Functions Jump, Label
143
Control Functions Comment
144
Control Functions Drum Sequencer
144
Data Move Functions
147
Data Move Functions Move Data
147
Data Move Functions Block Move
149
Data Move Functions Block Clear
150
Data Move Functions Shift Register
151
Data Move Functions Communication Request
153
Data Type Conversion Functions
156
Data Type Conversion Functions Convert Signed Integer Data to BCD-4
156
Data Type Conversion Functions Convert to Signed Integer
157
Data Type Conversion Functions Convert to Double Precision Signed Integer
158
Data Type Conversion Functions Convert to Real Data
159
Data Type Conversion Functions Convert Real Data to Word Data
160
Data Type Conversion Functions Truncate Real Number
160
Math and Numerical Functions
162
Math and Numerical Functions Add, Subtract, Multiply, Divide
162
Math and Numerical Functions Modulo Division
164
Math and Numerical Functions Scaling
165
Math and Numerical Functions Square Root
166
Math and Numerical Functions Trigonometric Functions
167
Math and Numerical Functions Logarithmic / Exponential Functions
169
Math and Numerical Functions Radian Conversion Functions
170
Relational Functions
171
Relational Functions Equal, Not Equal, Less Than, Less/Equal, Greater Than, Greater/Equal
171
Relational Functions Range
172
Relay Functions
174
Relay Functions Normally-Open, Normally-Closed, Continuation Contacts
174
Relay Functions Coils
175
Table Functions
179
Table Functions Search for Array Values
181
Timer and Counter Functions
184
Timer and Counter Functions on Delay Stopwatch Timer
185
Timer and Counter Functions on Delay Timer
187
Timer and Counter Functions Off-Delay Timer
189
Timer and Counter Functions up Counter
191
Timer and Counter Functions down Counter
192
11 The Service Request Function
195
SVCREQ Function Numbers
196
Format of the SVCREQ Function
197
Parameters of the SVCREQ Function
197
Example of the SVCREQ Function
197
SVCREQ 1: Change/Read Constant Sweep Timer
198
Input Parameter Block for SCVREQ 1
198
SVCREQ 2: Read Window Times
200
Output Parameter Block for SVCREQ 2
200
SVCREQ 3: Change Programmer Communications Window Mode
201
Changing the Programmer Communications Window Mode
201
SVCREQ 4: Change System Communications Window Mode
202
Changing the System Communications Window Mode
202
Change/Read Number of Words to Checksum
203
Parameter Block Formats for SVCREQ 6
203
SVCREQ 7: Read or Change the Time-Of-Day Clock
205
Parameter Block Format for SVCREQ 7
205
SVCREQ 7 Parameter Block Content: BCD Format
206
SVCREQ 7 Parameter Block Content: Packed ASCII Format
207
SVCREQ 8: Reset Watchdog Timer
210
Parameter Block Format for SVCREQ 8
210
Example of SVCREQ 8
210
SVCREQ 9: Read Sweep Time from Beginning of Sweep
211
1Output Parameter Block Format for SVCREQ 9
211
SVCREQ 10: Read Folder Name
212
1Output Parameter Block Format for SVCREQ 10
212
2Example of SVCREQ 10
212
SVCREQ 11: Read PLC ID
213
1Output Parameter Block Format for SVCREQ 11
213
2Example of SVCREQ 11
213
SVCREQ 13: Shut down (Stop) PLC
214
1Parameter Block for SVCREQ 13
214
2Example of SVCREQ 13
214
SVCREQ 14: Clear Fault
215
1Input Parameter Block for SVCREQ 14
215
2Example of SVCREQ 14
215
SVCREQ 15: Read Last-Logged Fault Table Entry
216
1Input Parameter Block for SVCREQ 15
216
2Long/Short Value
217
3Example of SVCREQ 15
217
SVCREQ 16: Read Elapsed Time Clock
218
1Output Parameter Block for SVCREQ 16
218
2Example of SVCREQ 16
218
SVCREQ 18: Read I/O Override Status
219
1Output Parameter Block for SVCREQ 18
219
2Example of SVCREQ 18
219
SVCREQ 23: Read Master Checksum
220
1Output Parameter Block for SVCREQ 23
220
2Example of SVCREQ 23
220
SVCREQ 24: Reset Ethernet Daughter Board
221
SVCREQ 26/30: Interrogate I/O
222
1Example of SVCREQ 26
222
SVCREQ 29: Read Elapsed Power down Time
223
1Output Parameter Block for SVCREQ 29
223
2Example of SVCREQ 29
223
12 Serial I/O / SNP / RTU Protocols
225
Format of the Communication Request Function
226
Parameters of the COMMREQ Function
226
Command Block for the COMMREQ Function
227
Example of the COMMREQ Function
227
Configuring Serial Ports Using the COMMREQ Function
228
Timing
228
Sending Another COMMREQ to the same Port
228
Invalid Port Configuration Combinations
229
RTU Slave/Snp Slave Operation with Programmer Attached
229
Example COMMREQ Command Block for Configuring SNP Protocol
230
Example COMMREQ Data Block for Configuring RTU Protocol
231
Example COMMREQ Data Block for Configuring Serial I/O Protocol
232
Calling Serial I/O Commreqs from the PLC Sweep
233
Compatibility
233
Status Word for Serial I/O Commreqs
233
Serial I/O COMMREQ Commands
236
Overlapping Commreqs
236
Commreqs that Can be Pending While Others Execute
237
Initialize Port Function (4300)
237
Set up Input Buffer Function (4301)
238
Flush Input Buffer Function (4302)
238
Read Port Status Function (4303)
239
Write Port Control Function (4304)
242
Cancel Commreq Function (4399)
243
10Autodial Function (4400)
243
11Write Bytes Function (4401)
245
12Read Bytes Function (4402)
246
13Read String Function (4403)
247
13 Ethernet Communications
249
Overview of the Ethernet Interface
250
Ethernet Global Data
250
SRTP Server
251
SRTP Channels
251
Attachment to the Ethernet LAN
251
The Station Manager Software
251
IP Addressing
252
Routers
253
Ethernet Global Data
254
The Frequency of Sending/Receiving an Exchange
254
The Consumer Update Timeout Period
254
Ethernet Global Data Groups
255
Timestamping of Ethernet Global Data Exchanges
255
Configuring NTP for the CPUE05 Ethernet Interface
257
The Content of an Ethernet Global Data Exchange
258
Data Types for Ethernet Global Data
258
Effect of PLC Modes and Actions on Ethernet Global Data
259
EGD Synchronization
259
Diagnostic Tools
261
What to Do if You Cannot Solve the Problem
261
Checking the Ethernet Leds
261
Using the PLC Fault Table
264
Checking the Status of the Ethernet Interface
265
Checking the Status of an Ethernet Global Data Exchange
266
Using the Ethernet Station Manager Function
268
Troubleshooting Common Ethernet Difficulties
269
PLC Timeout Errors
269
Unexpected Ethernet Restart or Runtime Errors
270
EGD Configuration Mismatch Errors
271
Receive Resource Exhaustion Errors
271
Station Manager Lockout under Heavy Load
272
PING Restrictions
272
SRTP Connection Timeout
272
14 PID Built-In Function Block
273
Operands of the PID Function
274
Parameters of the PID Function Block
274
Reference Array for the PID Function
275
Scaling Input and Outputs
275
Reference Array Parameters
275
Operation of the PID Function
282
Automatic Operation
282
Manual Operation
282
Time Interval for the PID Function
283
PID Algorithm Selection (PIDISA or PIDIND) and Gain Calculations
284
Error Term
284
Derivative Term
285
CV Bias Term
285
CV Amplitude and Rate Limits
286
Sample Period and PID Function Block Scheduling
287
Determining the Process Characteristics
288
Setting Tuning Loop Gains
289
Basic Iterative Tuning Approach
289
Setting Loop Gains Using the Ziegler and Nichols Tuning Approach
289
Ideal Tuning Method
290
Example
290
15 The EZ Program Store Device
293
Read/Write/Verify Data with a Programmer Present
295
Including All the Necessary Information
295
Matching OEM Protection
295
Adjusting the Configuration Timeouts
295
Writing Data to RAM or Flash
296
Using the EZ Program Store Device with the Programmer
296
Update a PLC CPU Without a Programmer Present
298
Error During Update
300
Appendix A Performance Data
301
Base Sweep Time
301
Boolean Instruction Time
301
Function Block Timing
302
Sweep Impact Times
302
Sizes of Timers, Counters, Math Functions, Trig Functions, Log Functions
302
Sizes of Exponential Functions, Radian Conversion, Relational Functions
304
Sizes of Bit Operations, Data Move Functions
305
Sizes of Table Functions
306
Sizes of Conversion and Control Functions
308
I/O Module Scan Times
309
Reference to Discrete Module Types in the Scan Time Tables
309
Modules Located in Main PLC Rack
310
Modules Located in Single-Ended Expansion Rack
311
Modules Located in Multiple Remote Expansion Rack
312
Modules Located in Single-Ended Isolated Expansion Rack
313
Byte Transfer Time
314
Ethernet Global Data Sweep Impact
314
Exchange Overhead
314
Support for Large Ethernet Global Data Configurations
315
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GE VersaMax PLC Specifications
General
Brand
GE
Model
VersaMax PLC
Category
Controller
Language
English
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