PidTemp MultiZone DOC V11 en

Multi-Zone Control
with "PID_Temp”
Siemens
SIMATIC S7-1200/S7-1500 and STEP 7 (TIA Portal) Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/109740463 Support
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PID control with PID_Compact

Entry-ID: 109740463, V1.1, 07/2019 2
Table of contents
Table of contents
Legal information ..................................................................................................... 2
1 Task................................................................................................................. 5
1.1 Overview ........................................................................................... 5
2 Solution........................................................................................................... 6
2.1 Overview ........................................................................................... 6
2.2 Hardware and software components .................................................. 8
2.2.1 Validity .............................................................................................. 8
2.2.2 Components used.............................................................................. 8
3 Basics ........................................................................................................... 10
3.1 Pretuning ......................................................................................... 10
3.1.1 Adjusting the delay time ................................................................... 10
3.1.2 Temporarily switching off cooling ..................................................... 10
3.1.3 Procedure........................................................................................ 10
3.2 Fine tuning....................................................................................... 12
3.2.1 Temporary tuning offset for heating/cooling controller ...................... 12
3.2.2 Synchronizing several fine tunings ................................................... 12
Procedure........................................................................................ 12
4 Mode of Operation ........................................................................................ 14
4.1 General overview ............................................................................. 14
4.2 FB "SimMultizone” ........................................................................... 17

4.2.1 Simulation of a coupled thermal stretch ............................................ 17
4.2.2 Configuration explanations............................................................... 19
4.2.3 Configuring the FB "SimMultizone”................................................... 21
4.3 FB "MultizoneSut” ............................................................................ 22
4.3.1 Program flow chart........................................................................... 24
4.4 FB "MultizoneTir” ............................................................................. 25
4.5 FB "Waiting” .................................................................................... 28
4.6 FC "TirOffset” .................................................................................. 31
4.7 FC "TirTuningMode” ........................................................................ 32
4.8 FC "DeactivateMode”....................................................................... 33
4.9 FB "StopWatch” ............................................................................... 34
4.10 Data block/PLC data types............................................................... 35
4.10.1 DB "Tags” ........................................................................................ 35
4.10.2 "typeSimMultizoneIn" ....................................................................... 35
4.10.3 "typeMultizoneIn" ............................................................................. 35
4.10.4 "typeZone” ....................................................................................... 36
4.10.5 "typePidTemp" ................................................................................. 36
4.10.6 "typeSimMultizoneArray".................................................................. 36
4.10.7 "typeWaitingIn” ................................................................................ 36
5 Configuration and Settings .......................................................................... 37
5.1 Configuring the technology "PID_Temp” .......................................... 37
5.2 Extension of control zones ............................................................... 39
6 Installation and Commissioning .................................................................. 42
6.1 Installing the hardware ..................................................................... 42
6.2 Commissioning ................................................................................ 43
6.2.1 Network connections ....................................................................... 43

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Table of contents
6.2.2 Setting PG/PC interface ................................................................... 44

6.2.3 Downloading to the controller ........................................................... 45
7 Operating the Application Example ............................................................. 46
7.1 Preparation ...................................................................................... 46
7.2 Pretuning ......................................................................................... 47
7.2.1 Disturbance variable compensation ................................................. 48
7.3 Fine tuning....................................................................................... 51
Disturbance variable compensation ................................................. 53
7.3.1 Tuning of the opposite energy type .................................................. 54
Disturbance variable compensation ................................................. 56
8 Further Notes, Tips and Tricks .................................................................... 58
8.1 Adjusting simulation ......................................................................... 58
8.2 Fine tuning in the event of strong coupling ....................................... 60
9 Links & Literature ......................................................................................... 62
10 History .......................................................................................................... 62

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1 Task
1.1 Overview
1 Task
1.1 Overview
Introduction
For a multi-zone control several subsections, so called zones, of a plant are
simultaneously controlled at different temperatures. The mutual impact on the
temperature zones by thermal coupling is characteristic for multi-zone control. This
means that the actual value of a zone can influence the actual value in another
zone by heat coupling. It depends on the structure of the plant and the selected
operating points of the zones how heavily the zones influence each other.
An example of a multi-zone control is an extrusion plant, as it used in plastics
processing, among others.
Mode of Operation
The material is filled in with the help of a funnel (for example, plastic granulate).
The screw conveyor transports the material through the heated and/or cooled
screw cylinder. The material is melted via different temperature zones (by heating,
friction and shearing). In parts, this creates so much heat that the material has to
be cooled. A forming aperture at the end of the extruder (outlet nozzle) presses the
melt into shape. Before shaping, the material has to be cooled.
Overview of the application example

The following figure gives you an overview of the automation task.
Figure 1-1
The control parameters of the individual zone controllers in the application example
are determined simultaneously, despite the temperature influence on the zones.

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2 Solution
2.1 Overview
2 Solution
2.1 Overview
Schematic layout
The figure below shows you a schematic illustration of the main components of this
solution.
Figure 2-1
SP1 PID_Temp
1
SP3 PID_Temp
3
SP2 PID_Temp
Configuration
In order to control the individual zones, the technology object "PID_Temp” of the
SIMATIC S7-1200 controller family or SIMATIC S7-1500 is used.
This technology object presents a continuous PID controller with integrated tuning
and is designed especially for temperature control. "PID_Temp” is suitable for
heating or heating/cooling applications. Two outputs are available for this purpose,
one for heating and one for cooling.
When using the technology object "PID_Temp” in multi-zone controllers, each
temperature zone is controlled by its own "PID_Temp” instance.
To keep the influence of neighboring zones as low as possible, you can
synchronize the individual "PID_Temp” controller instances in the two tuning types
"pretuning” and "fine tuning”.
Note Pure cooling control is realized with the technology object "PID_Compact” and
the "inverting the control direction” option.
More information on the control types can be found in the function manual
"SIMATIC S7-1200, S7-1500 PID control” \3\.
https://support.industry.siemens.com/cs/ww/en/view/108210036

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2 Solution
2.1 Overview
Advantages
The solution presented here offers the following advantages:
• Overview of factors you have to observe for a multi-zone control.
• Overview of options to use the technology object "PID_Temp” and to determine
the control parameters.
• Time and cost savings through synchronized tuning.
• Expandability: The solution is introduced on the example of a multi-zone
controller with three zones. However, you can expand the application as
desired.
Topics not covered by this application

This application example relates particularly to the multi-zone control with the
technology object "PID_Temp”. This technology object can only be used in
SIMATIC S7-1200 or S7-1500.
This application example introduces mechanisms that optimize the control
parameters of a multi-zone controller with three zones.
The application example provides you with the following blocks:
• Simulation of the coupled controlled system
• Synchronized pretuning for heating and cooling
• Synchronized fine tuning with selectable energy type (heating or cooling)
These blocks are designed for three zones. Chapter 5.2 and the comments in the
program code show you how to expand zones.
Zone 1 in the present example is designed as pure heating controllers.
With the configuration, you can select whether the technology object "PID_Temp”
is used as heating or as heating/cooling controller.
The program code included can be used for both controller designs.
For the real operation, you have to adjust the application example to your actuators
used and the actual value sensors. Basic knowledge is assumed.
Note More information on the technology object "PID_Temp” can be found in

Chapter 6 of the function manual "SIMATIC S7-1200, S7-1500 PID control” \3\.
Assumed knowledge
The following basic knowledge is required and is not explicitly discussed in this
description:
• Control engineering
• STEP 7 (TIA Portal)
• The SCL/LAD/FBD programming languages.

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2 Solution
2.2 Hardware and software components

2.2.1 Validity
This application example is valid for the following components:

▪ STEP 7 V15.1 or higher
▪ S7-1200 CPU firmware as of V4.2 or S7-1500 CPU firmware as of V2.0
▪ Technology object "PID_Temp” V1.1
2.2.2 Components used
The application example has been created with the following components.
Hardware components
Table 2-1
Component Qty. Article number Note
SIMATIC S7-1200 1 6EP1332-1SH71 Any other SIMATIC power
POWER MODULE supply with 24V DC can be
PM1207 CONTROLLED used.
POWER SUPPLY INPUT:
120/230 V AC OUTPUT:
24V/2.5 A DC
SIMATIC S7-1200, CPU 1 6ES7215-1AG40- As of firmware V4.2.
1215C, compact CPU, 0XB0 Alternatively, any other S7-
DC/DC/DC, 2 PROFINET 1200 CPU as of firmware
Port, onboard I/O: 14 DI V4.2 can also be used.
24VDC; 10 DO 24VDC;
0,5A; 2 AI 0-10V DC, 2
AO 0-20mA DC, power
supply: 20.4-28.8V DC,
125 kB program/data
storage
SIMATIC S7-1500 1 6ES7511-1CK00- As of firmware V2.0.
compact CPU 1511C-1 0AB0 Alternatively, any other S7-
PN, central module with 1500 CPU as of firmware
175 kB main memory for V2.0 can also be used.
program and 1 MByte for
data, 16 digital inputs, 16
digital outputs, 5 analog
inputs, 2 analog outputs,
6 fast counter, 1 interface:
PROFINET IRT with 2
port switch, 60 NS bit
performance, incl. push-in
front plug, SIMATIC
memory card required
SIMATIC S7, memory 1 6ES7954-8LF02-0AA0 Required when using a S7-
card for S7-1x 00 1500 CPU.
CPU/SINAMICS, 3, 3 V
flash, 24 MByte

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2 Solution
Note Other hardware components for controlling real actuators and temperature
acquisition can be found in:
• System Manual "SIMATIC S7 S7-1200 Programmable controller” in
Chapter A "Technical data” (\4\)
• Manual "SIMATIC S7-1500/ET 200MP Automation system In a nutshell” (\10\)
• TIA Selection Tool (\5\)
http://w3.siemens.com/mcms/topics/en/simatic/tia-selection-tool/Pages/tab.aspx
• Hardware catalog in the TIA Portal
Software components
Table 2-2
Component Qty. Article number Note
STEP 7 Basic V15.1 1 6ES7822-0A.05-.. Minimal license for configuring
the S7-1200
STEP 7 1 6ES7822-1..05-.. Enables configuration of S7-
Professional V15.1 1200 and S7-1500
Example files and projects

The following table contains all files and projects used in this example.
Table 2-3
Component Note
109740463_PidTemp_MultiZone_PROJ_v11.zip This zip file contains the STEP 7
project.
109740463_PidTemp_MultiZone_DOC_v11_en.pdf This document.

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3 Basics
3.1 Pretuning
3 Basics
This chapter discusses the tuning types of the technology object "PID_Temp” and
how to use them, in order to achieve a stable setting of your multi-zone controller
on the basis of the function manual "SIMATIC S7-1200, S7-1500 PID control (\3\),
chapter "Multi-zone controlling with PID_Temp”.
3.1 Pretuning
The initial commissioning of a plant usually starts by carrying out a pretuning to
perform a first setting of the PID parameters and to control the operating point. The
pretuning for multi-zone controllers is often done simultaneously for all zones.
Carry out the pretuning for heating separate from the pretuning for cooling in order
to decrease the mutual influence of thermal coupling between the zones during the
tuning.
Only start the pretuning for cooling the controllers with active cooling and PID
parameter switching when all zones have completed the pretuning for heating and
their operating point has been reached.
3.1.1 Adjusting the delay time
With the pretuning for heating, a jump on the output value heating is returned, the
PID parameters for heating are calculated and afterwards the setpoint is controlled
in automatic mode.
The "AdaptDelayTime” tag determines the adjustment of the delay time for heating
on the operating point.
With the "AdaptDelayTime” = 0 default, the delay time is only determined during
the step "Determine turning point heating ("PIDSelfTune.SUT.State” = 300).
Only for "AdaptDelayTime” = 1 the delay time is additionally checked by
temporarily switching off the heating on the operating point and, if necessary,
adjusted ("PIDSelfTune.SUT.State” = 1000).
This is not desired for the multi-zone control because the adjustment of the delay
time in this phase may be false due to the thermal coupling of neighboring zones.
This is why you have to make sure that the adjustment of the delay time is disabled
for all PID_Temp instances ("PIDSelfTune.SUT.AdaptDelayTime” = 0).
3.1.2 Temporarily switching off cooling
For controllers with active cooling ("Config.ActivateCooling” = TRUE), you can

temporarily disable the cooling in automatic mode with "PID_Temp”. To do this, set
"DisableCooling” = TRUE.
This is how you can prevent that this controller cools in automatic mode during
commissioning, whilst the controllers of the neighboring zones have not yet
completed the tuning of the heating.
3.1.3 Procedure
For the synchronized pretuning of multi-zone controllers, proceed as follows:

1. Disable the adjustment of the delay time for all controllers
("PIDSelfTune.SUT.AdaptDelayTime” = 0).
2. Disable the cooling ("DisableCooling” = TRUE) for all controllers with active
cooling ("Config.ActivateCooling” = TRUE).

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3 Basics
3.1 Pretuning
3. Specify the desired setpoint ("Setpoint” parameter) and simultaneously start

the pretuning for heating for all controllers ("Heat.EnableTuning” = TRUE,
"Cool.EnableTuning” = FALSE, "Mode” = 1, "ModeActivate” = TRUE) from the
"Inactive” ("State” = 0) mode.
4. Wait until all controllers have successfully completed the heating pretuning.
5. Enable the cooling ("DisableCooling” = FALSE) for all controllers with active
cooling ("Config.ActivateCooling” = TRUE).
6. Wait until all zones have reached the operating point in automatic mode
("State” = 3).
Note The heating or cooling actuator is too weak, if the setpoint cannot be reached
permanently for a zone!
7. Start the cooling pretuning ("Config.ActivateCooling” = TRUE) simultaneously

for all controllers with active cooling ("Heat.EnableTuning” = FALSE,
"Cool.EnableTuning” = TRUE, "Mode” = 1).
8. Wait until all controllers have successfully completed the cooling pretuning.
CAUTION Exceeding the limit value of the actual value

When you are disabling the cooling in automatic mode
("DisableCooling” = TRUE), the actual value can exceed the setpoint and the
actual value limits.

If you are using "DisableCooling”, monitor the actual values and if required take
action.
CAUTION Multi-zone controllers

The thermal coupling between the zones in multi-zone controllers can cause
increased overshoots or the temporary exceeding of the limit values and
permanent or temporary control deviations during commissioning and during
operation.
Monitor the actual values and, if required, take action.
Depending on the plant it may be necessary to deviate from the approach
described above.

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3 Basics
3.2 Fine tuning
3.2 Fine tuning

The fine tuning generates a constant, limited oscillation of the actual value. From
the amplitude and frequency of this oscillation, the PID parameters for the
operating point are optimized. The PID parameters are recalculated from the
results. The PID parameters from the fine tuning mostly show a better
management and disturbance behavior than the parameters from the pretuning.
You get the best PID parameters when you do the pretuning and the fine tuning.
3.2.1 Temporary tuning offset for heating/cooling controller
If "PID_Temp” is used as heating and cooling controller ("Config.ActivateCooling” =

TRUE), the PID output value ("PidOutputSum”) must fulfil the following
prerequisites so that an actual value oscillation is created and fine tuning can be
performed successfully:
• Positive PID output value for heating fine tuning
• Positive PID output value for cooling fine tuning
If this prerequisite is not fulfilled, you can specify a temporary offset for the fine
tuning that is returned on the output that has the opposite effect.
• Offset for cooling output ("PIDSelfTune.TIR.OutputOffsetCool”) for fine tuning
heating
Before starting the tuning, specify a negative tuning offset cooling that is
smaller than that of the PID output value ("PidOutputSum”) on the setpoint in
the stationary state.
• Offset for heating output ("PIDSelfTune.TIR.OutputOffsetHeat”) for fine tuning
cooling
Before starting the tuning, specify a positive tuning offset heating that is larger
than that of the PID output value ("PidOutputSum”) in the stationary state.
The specified offset is than balanced out by the PID algorithm so that the actual
value on the setpoint remains. For the PID output value to fulfil the above
mentioned prerequisites, you can increase the offset. With the level of the offset,
the PID output value can therefore be adjusted accordingly so that it fulfils the
above mentioned prerequisites.
In order to avoid larger overshoots of the actual value when the offset is specified,
it can also be increased in several steps.
If "PID_Temp” leaves the "Fine tuning” mode, the tuning offset is reset.
3.2.2 Synchronizing several fine tunings
If the fine tuning is started in automatic mode with "PIDSelfTune.TIR.RunIn” =

FALSE, "PID_Temp” tries to reach the setpoint of the current PID parameters.
Only when the setpoint is reached, does the actual tuning start.
The time that is required to reach the setpoint may vary for the individual zones of
a multi-zone controller.
If you want to start the fine tuning for several zones at the same time, you can
synchronize the fine tuning with "PID_Temp”. To do this, the "PID_Temp” waits
until all zones have reached the setpoint before it carries out the next tuning step.
Procedure
This is how you can make sure that all controllers have reached their setpoint
before the actual tuning steps start. This prevents mutual influence of thermal
coupling between the zones during the tuning.

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3 Basics
3.2 Fine tuning
For controllers, where you want to carry out the fine tuning of their zones
simultaneously, proceed as follows:
1. Set "PIDSelfTune.TIR.WaitForControlIn” = TRUE for all controllers. These
controllers have to be in automatic mode with "PIDSelfTune.TIR.RunIn” =
FALSE.
2. Set the desired setpoints with the "Setpoint” parameter and start the fine tuning
for all controllers.
3. Wait until "PIDSelfTune.TIR.ControlInReady” = TRUE is set for all controllers.
4. Set "PIDSelfTune.TIR.FinishControlIn” = TRUE for all controllers.
Thus, all controllers start the actual tuning simultaneously with the calculation of
the standard deviation (filtering of noise of actual value signal).

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4 Mode of Operation
4.1 General overview
4 Mode of Operation
Figure 4-1 shows the block diagram of a multi-zone controller with three zones.
Each zone is controlled by an individual instance of the technology object
"PID_Temp”. The individual zone controller "PID_Temp” in the application example
is configured as follows:
• Zone 1: Heating controller
• Zone 2: Heating/cooling controller
• Zone 3: Heating/cooling controller
The application example includes the simulation of the controlled system that
replicates the thermal coupling of the zones. The controlled system simulation is
described in more detail in chapter 4.2.
Figure 4-1
TempAmbient
Controller Simulation Controlled System

heat1 PT1
SP1 PID_Temp Temp1
cool1 - + - PT2 +
1
PT1
2 Kint
KFw
KBw
heat2 PT1
SP2 PID_Temp Temp2
cool2 - + - PT2 +
2
PT1
2 Kint
KFw
KBw
heat3
PT1
SP3 PID_Temp Temp3
cool3 - + - PT2 +
3
PT1
2 Kint

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4 Mode of Operation
Program overview
Figure 4-2 shows the call structure of the blocks for a multi-zone controller with
three zones, a controlled system simulation and a synchronized sequence for
pretuning and fine tuning.
Figure 4-2
Organization Controller Instance data blocks
blocks
Inst
PID_Temp
PidTemp1
Inst
PID_Temp
PidTemp2
Cyclic
Inst
Interrupt PID_Temp
PidTemp3
[OB 30]
Sim
Multizone
Multizone
Waiting
Sut
ModeDe
activate
Multizone
Waiting
Tir
TirOffset
TirTuning
Tags
User program Mode
ModeDe
activate

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4 Mode of Operation
All instructions and functions are called in the interval of the "CyclicInterrupt”
interrupt OB. For each controller zone the technology object "PID_Temp” with
individual instance DB ("InstPidTempX”) is called.
Note The configuration and commissioning interface is only available to you when you
call the technology object "PID_Temp” as individual instance.
The FB "SimMultizone” simulates the temperature curves of the coupled zones and
is switched according to the specification of Figure 4-1 with the calls of
"PID_Temp”.
As of STEP 7 the instance DBs of the "PID_Temp” are transferred to the InOut
interface of the function blocks as parameter instance.
This feature is used for the synchronized tuning processes:
• FB "MultizoneSut” starts a simultaneous pretuning heating for all zones,
followed by a simultaneous pretuning cooling (if configured).
• FB "MultizoneTir” synchronizes the fine tuning of all selected zones (according
to energy type specification heating or cooling, depending on zone).
The following subfunctions are used by these optimization blocks:

• FB "Waiting” has the effect that all zones wait until the control deviations are
within a specified tolerance range and a waiting period has lapsed.
• FC "TirOffset” calculates heating or cooling according to the specified energy

type for the fine tuning depending on zone of the temporary offset on the
opposite output.
• FC "TirTuningMode” implements the energy type specification heating or
cooling for the fine tuning depending on zone.
• FC "DeactivateMode” resets the input bit "ModeActivate” of all "PID_Temp”
calls.
The DB "Tags” includes the parameters for transfer to the block interfaces.

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4 Mode of Operation
4.2 FB "SimMultizone”
The FB "SimMultizone” simulates the temperature curves of the coupled zones and
is switched according to the specification of Figure 4-1 with the calls of
"PID_Temp”.
4.2.1 Simulation of a coupled thermal stretch
As mathematic model, the discrete solution of a partial differential equation of a

simple heat conductor with n grid points is used (\7\).
Figure 4-3: Flow chart of a coupled thermal controlled system
T1 T2 T3
+
TAmbient +
+
Heat conductor model
y1 y2 y3
Kint KFw KBw Kint KFw KBw Kint KFw

PT2 PT2 PT2

-2 -2 -2
u1 u2 u3
+ + +
uInp1 uInp2 uInp3
+ + +
-1 -1 -1
Actuators
PT1 PT1 PT1 PT1 PT1 PT1
dist1 dist2 dist3

uHeat1 uCool1 uHeat2 uCool2 uHeat3 uCool3
Zone 1 Zone 2 Zone 3
The dynamic of a gird point is exemplary as second-order aperiodic delay element.

However, depending on the desired controlled system behavior, you can also use
other elements here.

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4 Mode of Operation
The simulated zone temperature 𝑇𝑧 is the result of equation 4.2.1:
Equation 4.2.1: Calculating the zone temperature 𝑻𝒛 :

𝑇𝑧 = 𝑦𝑧 + 𝑇𝐴𝑚𝑏𝑖𝑒𝑛𝑡
𝑇𝐴𝑚𝑏𝑖𝑒𝑛𝑡 = ambient temperature
𝑧 = Zone
Equation 4.2.2: Transfer function of the PT2 delay element

𝑔𝑎𝑖𝑛𝑃𝑇2
𝑦𝑧 = ∗𝑢
(𝑡𝑚𝐿𝑎𝑔1𝑃𝑇2 ∗ 𝑝 + 1) ∗ (𝑡𝑚𝐿𝑎𝑔2𝑃𝑇2 ∗ 𝑝 + 1) 𝑧
Equation 4.2.3: Equation for calculating the PT2 input

𝑢𝑧 = 𝑘𝐹𝑊𝑧 −1 ∗ 𝑦𝑧 −1 − 2 ∗ 𝑘𝐼𝑁𝑇𝑧 ∗ 𝑦𝑧 + 𝑘𝐵𝑊𝑧+1 ∗ 𝑦𝑧+1 + 𝑢𝐼𝑛𝑝𝑧
𝑘𝐹𝑊 = coupling factor forward
𝑘𝐼𝑁𝑇 = coupling factor internal
𝑘𝐵𝑊 = coupling factor backward
Equation 4.2.4: Summation of the manipulated variable delay by PT1

𝑔𝑎𝑖𝑛𝐻𝑒𝑎𝑡 𝑔𝑎𝑖𝑛𝐶𝑜𝑜𝑙
𝑢𝐼𝑛𝑝𝑧 = ∗ 𝑢𝐻𝑒𝑎𝑡𝑧 − ∗ 𝑢𝐶𝑜𝑜𝑙𝑧 + 𝑑𝑖𝑠𝑡𝑧
𝑡𝑚𝐿𝑎𝑔1𝐻𝑒𝑎𝑡 ∗ 𝑝 + 1 𝑡𝑚𝐿𝑎𝑔1𝐶𝑜𝑜𝑙 ∗ 𝑝 + 1
𝑢𝐻𝑒𝑎𝑡 = manipulated variable heating
𝑢𝐶𝑜𝑜𝑙 = manipulated variable cooling
𝑑𝑖𝑠𝑡 = disturbance variable
The model can be expanded to any number of zones by copying the pattern
(Figure 4-3).
In equation 4.2.3 it has to be observed that for the peripheral zones, the previous
zone or the following zone is omitted and the terms are therefore to be set to z-1 or
z+1 here = 0.
Through the coupling factors K FW and KBW (0 to 1), the thermal influence to
neighboring zones can be varied.
You can vary the static end value of the zone temperatures through the internal
coupling factors Kint (0 to 1) and the gain factors of the PTx delay elements.

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Chronological sequence
In terms of time, a test jump of 100% in zone 2, for example, is divided according to
t seconds to the neighboring zones as follows:
Wie schaut
Figure 4-4 es zeitlich aus?
Heizsprung Zone2 100
schwache Vorwärts- und Rückwärtskopplung
250
200
GainPT2 = 5,0
t=15s
150 Kint = 0,2
t=30s
100 t=45s
KFW = 0,2
t=60s
KBW = 0,2
50
0
Zone1 Zone2 Zone3
Heizsprung Zone2 100 – verstärkte Vorwärts- und

abgeschwächte Rückwärtskopplung
250
200 GainPT2 = 5,0
t=15s Kint = 0,2
150
t=30s KFW = 0,3
100 t=45s KBW = 0,1
50 t=60s
0
Zone1 Zone2 Zone3
4.2.2 Configuration explanations
The FB "SimMultizone” is called in the interrupt OB in which the controllers

"PID_Temp” are also called.
Table 4-1: Parameters of SimMultizone
Name P type Data type Comment
velocity IN SInt Transport velocity of the extruder screw in %
ambTemp IN Real Ambient temperature 𝑇𝐴𝑚𝑏𝑖𝑒𝑛𝑡
reset IN Bool Resets all relevant parameters including "outputX” to
‘0’.
cycle IN Real Cycle time of the calling cyclic interrupt OB in seconds
error OUT Bool FALSE: No errors
TRUE: Block error, "statusID” specifies the error
source, "status” specifies the error code.
statusID OUT UInt Error source: Ten digits specify the zone,
One digit specifies the subfunction:
1 = instZxHeat (LSim_PT1)
2 = instZxCool (LSim_PT1)
3 = instZxPT2 (LSim_PT2aper)
status OUT Word Error code of the respective subfunction "LSim_PT1”
or "LSim_PT2aper”
maxReached OUT Bool For "maxReached” = TRUE at least one output tag

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"output” of the subfunctions "LSim_PT1” or
"LSim_PT2aper” has been limited by the respective
static parameter "maxOut”.
minReached OUT Bool For "minReached” = TRUE at least one output tag
"output” of the subfunctions "LSim_PT1” or
"LSim_PT2aper” has been limited by the appropriate
static parameter "minOut”.
zones IN_OUT Array[1..#MAX] 1 of PLC data type with the required interface parameters
"typeZone" for each temperature zone
(The size of the field is specified via the local constant
"MAX”.)
Note Detailed information on the subfuntions "LSim_PT1” and "LSim_PT2aper”used

and their error codes ("status”) can be found in the Closed-Loop Control of
Simulated Controlled Systems in the S7-1500 with PID_Compact V2 (\6\).
SimMultizone
SInt velocity error Bool
Real ambTemp statusID UInt
Bool reset status Word
Real cycle maxReached Bool
minReached Bool
zones
Array[1..#MAX] of "typeZone" Array[1..#MAX] of "typeZone"
1
The local constant “MAX” has to match the number of zones of the multi-zone controller.

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Transport velocity
The coupling factors in the application example depend on the transport "velocity”
(0..100%) of the extruder granulate.
Due to the increase of the transport velocity, an increase of the forward coupling
and a reduction of the backward coupling is assumed.
Figure 4-5
K_FOR_MAX KFW
0,3
0,2 K_INT KInt
0,1 K_BACK_MIN KBW
100 v[%]
25 50 75
Through the constants "K_BACK_MIN”, "K_INT” and "K_FOR_MAX” the influence
of the transport velocity to coupling factors and therefore the energy flow, can be
changed accordingly.
4.2.3 Configuring the FB "SimMultizone”
The controlled system properties of the simulated coupled temperature curves can
be adjusted via the local constants of the FB "SimMultizone”.
Table 4-2
Name Data type Default Comment
value
MAX DInt 3 Number of the zones
TMLAG_HEATER Real 5.0 Time constant of the actuator delay heating (PT1) in
seconds
TMLAG_COOLER Real 10.0 Time constant of the actuator delay cooling (PT1) in
seconds
GAIN_ZONE Real 5.0 Gain factor temperature curve (PT2)
TMLAG1_ZONE Real 20.0 Time constant 1 temperature curve (PT2)
TMLAG2_ZONE Real 3.0 Time constant 2 temperature curve (PT2)
K_BACK_MIN Real 0.1 Minimum coupling factor backward (to previous zone)
K_FOR_MAX Real 0.3 Maximum coupling factor forward (to next zone)
K_INT Real 0.2 Internal coupling factor (feedback)
PT2_MAX_OUT Real 1000.0 Maximum output limit temperature curve (PT2)
PT2_MIN_OUT Real -1000.0 Minimum output limit temperature curve (PT2)

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4.3 FB "MultizoneSut”
The FB "MultizoneSut” enables the simultaneous pretuning of all zones (first
heating, then cooling with heating/cooling controllers).
It is called in the interrupt OB in which the controllers "PID_Temp” are also called.
Table 4-3: Parameters of MultizoneSut
done OUT Bool Error free processing of the block
busy OUT Bool Block being processed
error OUT Bool FALSE: No errors
TRUE: Error in block, "status” specifies the error code.
status OUT Word Error code:
0: no error
16#8000: At least for one zone controller the pretuning
heating cannot be enabled.
16#8001: At least one zone controller has completed
the pretuning heating with error.
16#8002: At least one zone controller has completed
the pretuning cooling with error.
start IN_OUT Bool Starts the processing and is reset after completion.
reset IN_OUT Bool Resets the block and is set to FALSE after completion.
zones IN_OUT Array[*] of PLC data type with the required interface parameters for
"typeZone" each temperature zone
(the size of the field is read.)
Only the parameters "*[x].pidTemp” are accessed.
instPidTemp1 IN_OUT PID_Temp Technology instance transfer for zone 1

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MultizoneSut
done Bool
busy Bool
error Bool
status Word
start
Bool Bool
reset
Bool Bool
zones
Array[*] of "typeZone" Array[*] of "typeZone"
instPidTemp1
PID_Temp PID_Temp
instPidTemp2
PID_Temp PID_Temp
instPidTemp3
PID_Temp PID_Temp

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4.3.1 Program flow chart
Figure 4-6
Start/Stop
#start ?
Ja
Disable determination of delay time PIDSelfTune.SUT.AdaptDelayTime := 0;
Pretuning DisableCooling = TRUE;
Disable cooling of contdrollers Heating Heat.EnableTuning := TRUE;Cool. EnableTuning := FALSE;
simulateous pretuning heating Mode := 1; ModeActivate := TRUE;
No
Are all controllers in „pretuning“ error = TRUE;
#state = 1 ?
mode? status := 16#8000;
Yes
1
Wait until all zones have successfully completed #SUT.state ? error = TRUE;
the pretuning heating status := 16#8001;
9900
Enable cooling of controllers Ready DisableCooling = FALSE;
Wait until all zones have reached

Waiting
their operating point
Config.ActivateCooling = TRUE &

Heating/cooling ?
Config.AdvancedCooling = TRUE ?
controller?
Heat.EnableTuning := FALSE;
Simultaneous pretuning cooling Pretuning Cool.EnableTuning := TRUE;
(for all heating/cooling controllers) Cooling Mode := 1; ModeActivate := TRUE;
1
Wait until all zones have successfully error = TRUE;
#SUT.state ?
completed the pretuning cooling status := 16#8002;
9900
Start/Stop
Prerequisite for the pretuning heating is that the actual value is not too near the
setpoint. This is why it is a good idea to start FB "MultizoneSut" when all controller
instances "PID_Temp” are in the "inactive” operating state.
When setting the "start” input the simultaneous pretuning heating of the multi-zone
controller is started with the required preconditions from chapter 3.1:
• Disabling the specification of the delay time
PIDSelfTune.SUT.AdaptDelayTime:= 0
• Disabling the cooling of the controller: "DisableCooling” = TRUE
• Simultaneous pretuning for heating:
Heat.EnableTuning := TRUE; Cool.EnableTuning := FALSE;
Mode := 1; ModeActivate := TRUE;
When the controller instances do not report an error and the pretuning of all zones
has been completed successfully, the cooling for all heating/cooling controllers is
re-enabled ("DisableCooling” = FALSE).
Now it is waited until all zones have reached their operating point.
For all heating/cooling controllers the synchronous pretuning cooling is then
started.
The synchronized pretuning of the multi-zone controller is stopped when it is
successfully completed. This is continuously signaled by the "done” bit, until "start”
is reset or the message is deleted with "reset”.

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4.4 FB "MultizoneTir”
The FB "MultizoneTir” enables the synchronized fine tuning of selected zones with
energy type specification (heating or cooling).
It is called in the interrupt OB in which the controllers "PID_Temp” are also called.
Table 4-4: Parameters of MultizoneTir

done OUT Bool error free processing of the block
error OUT Bool FALSE: no error
TRUE: Error in block, "status” specifies the error code.
status OUT Word Error code: 0 no error,
16#8000: at least one zone controller to be optimized is in
"automatic” mode
16#8001: at least one zone controller reports an error
16#8002: at least one zone controller has stopped the fine
tuning with error.
16#8003: at least one zone controller did not return to
automatic mode after fine tuning
start IN_OUT Bool starts the processing and is reset after completion.
reset IN_OUT Bool resets the block and is set to FALSE after completion
zones IN_OUT Array[*] of PLC data type with the required interface parameters for
"typeZone" controller calls

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MultizoneTir
done Bool
busy Bool
error Bool
status Word
start
Bool Bool
reset
Bool Bool
zones
instPidTemp1
PID_Temp PID_Temp
instPidTemp2
PID_Temp PID_Temp
instPidTemp3
PID_Temp PID_Temp

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Figure 4-7
Start/Stop
#start ?
Yes
Controlling the setpoint with the existing PID parameters PIDSelfTune.TIR.RunIn := FALSE;
Preperation
Wait until the operating point has reached the zones to be PIDSelfTune.TIR.WaitForControlIn := TRUE;
synchronized
No
error = TRUE;
Automatic mode? #state = 3 ?
status := 16#8000;
Yes
Wait until all zones have reached the operating Wait

point
heating cooling
Specifying tuning energy type (for each zone) TuningMode ?
OutputOffsetCool <0
Determining tuning := 2 * PidOutputSum?
>0 OutputOffsetHeat
PidOutputSum? := 2 *
offset PidOutputSum PidOutputSum
>0 <0
Simultaneous Heat.EnableTuning := TRUE; Heat.EnableTuning := FALSE;
TIR (heating) Cool.EnableTuning := FALSE; TIR (cooling) Cool.EnableTuning := TRUE;
fine tuning of all zones Mode := 2; ModeActivate := TRUE; Mode := 2; ModeActivate := TRUE;
Wait unitl all zones have reached ControlInReady? ControlInReady?

PIDSelfTune.TIR.ControlInReady
the setpoint
PIDSelfTune.TIR.FinishControlIn
Synchronize all zones Synchronization
:= TRUE;
1
Wait until all zones have successfully completed #TIR.state ?
error = TRUE;
the fine tuning status := 16#8002;
9900
Start/Stop
Before starting the synchronous fine tuning, specify the energy type to be
optimized for each zone controller via the InOut tag "zones[x].tuningMode”:
• 0: No fine tuning
• 1: Heating
• 2: Cooling
All controllers where fine tuning ("tuningMode” = 1 or 2) is to be performed have to
be in automatic mode as a precondition.
Setting the "start” input creates the required preconditions for synchronizing
several fine tunings from chapter 3.2.2:
• It is controlled to the setpoint with the exiting PID parameters:
"PIDSelfTune.TIR.RunIn” = FALSE
• During the fine tuning it is waited that the setpoints of the other controllers to
be optimized are reached before the standard deviation is calculated:
"PIDSelfTune.TIR.WaitForControlIn” = TRUE
When the controllers to be optimized are in automatic mode, it is waited until they
have reached their operating point. This is required to determine the energy type of
the controller in the operating point.
If a controller is not in the selected energy type, an according offset is calculated
and output on the opposite output of the controller in order to get to the selected
energy type.

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4.5 FB "Waiting”
Example:
The controller is in heating mode, but it is to carry out the fine tuning cooling.
Therefore an additional offset is set on the controller’s heating output so that the
controller has to cool to reach the setpoint.
Afterwards the fine tunings for each zone are started.
When all controllers to be optimized have reached their setpoint, the actual fine
tuning of all zones start synchronously with the respective calculation of the
standard deviation.
The synchronized fine tuning of the multi-zone controller is concluded when it is
successfully completed. This is continuously signaled by the "done” bit, until "start”
is reset or the message is deleted with "reset”.
4.5 FB "Waiting”
When the specified controller difference tolerance of the "PID_Temp” instances is
maintained, the FB "Waiting” waits for a specified time (number of cycles).
It is used in FB "MultizoneSut” and in FB "MultizoneTir”.
Table 4-5: Parameters of waiting
tolerance IN Real Tolerance specification of the control differences in %
cycles IN Real Specification of the number of waiting cycles

deviation OUT Array[1..#MAX] 2 of Control differences of the "PID_Temp” instances (the size
Real of the field is specified via the local constant "MAX”.)
progress OUT Real Progress of the wait time in %
start IN_OUT Bool Starts the processing and is reset after completion.
pidTemp1 IN_OUT PID_Temp Technology instance transfer for zone 1
2
The local constant “MAX” has to match the number of zones of the multi-zone controller.

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4.5 FB "Waiting”
Waiting
Real tolerance deviation Array[1..3] of Real
Real cycles progress Real
done Bool
busy Bool
start
Bool Bool
pidTemp1
PID_Temp PID_Temp
pidTemp2
PID_Temp PID_Temp
pidTemp3
PID_Temp PID_Temp

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4.5 FB "Waiting”
Figure 4-8
Start/Stop
start ?
yes
#done := FALSE;
Initialization #busy := TRUE;
#statCounter := 0.0;
Tolerance check of all no

|deviation| < tolerance ? counter := 0
zones
ja >0
Counting up INC counter
no
Check cycles counter > cycles ?
ja
#busy := FALSE;
#done := TRUE;
Ready
#start := FALSE;
#statCounter := 0.0;
Start/Stop
When starting the FB "Waiting” the initialization is performed:

• #done := FALSE;
• #busy := TRUE;
• #statCounter := 0.0;
In each cycle of the interrupt the percentage of the control deviation for each zone
z is calculated via the following formula:
𝑠𝑒𝑡𝑝𝑜𝑖𝑛𝑡𝑧 − 𝑖𝑛𝑝𝑢𝑡𝑧
𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛𝑧 = ∗ 100
𝑠𝑒𝑡𝑝𝑜𝑖𝑛𝑡𝑧
The cycle counter "counter” is incremented if all the amounts of the control
deviations are within the proportional "tolerance” specification. Otherwise the
counter is reset.
FB "Waiting” is completed if the specified number of cycles "cycles” are exceeded.
This is continuously signaled by the "done” bit, until "start” is reset.

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4.6 FC "TirOffset”
4.6 FC "TirOffset”
The FC "TirOffset” calculates the tuning offset for heating/cooling controller
"PID_Temp” to enable fine tuning for the opposite energy type (heating or cooling).
It is called in FB "MultizoneTir” for each zone.
Table 4-6: Parameters of TirOffset

tuningMode IN USInt Fine tuning energy type: 0 = none, 1 = heating, 2 = cooling
factor IN Real Multiplier (Offset = factor * PidOutputSum); must be >1
pidTemp IN_OUT PID_Temp Technology instance transfer for the respective zone
TirOffset
USInt tuningMode
Real factor
pidTemp
PID_Temp PID_Temp
Figure 4-9
Start/Stop
Tuning requirement heating 1 2 cooling

tuningMode ?
Current mode PidOutputSum < 0 ? PidOutputSum > 0 ?
cooling yes yes heating
Determine OutputOffsetCool OutputOffsetHeat:

:= factor * = factor *
tuning offset PidOutputSum PidOutputSum
Example:
The controller is to carry out the fine tuning heating, but is in cooling mode. This is
why a higher offset is returned in the cooling output so that the controller has to
heat in order to reach the setpoint and to determine the parameters for heating
from the oscillation.
The offset on the controller is reset after completing the fine tuning.

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4.7 FC "TirTuningMode”
4.7 FC "TirTuningMode”
FC "TirTuningMode” sets the tuning bits according to the desired energy type of
the fine tuning according to Table 4-8.
It is called in FB "MultizoneTir” for each zone.
Table 4-7: Parameter of TirTuningMode

tuningMode IN USInt Fine tuning energy type: 0 = none, 1 = heating, 2 = cooling
pidTemp IN_OUT PID_Temp Technology instance transfer for the respective zone
TirTuningMode
USInt tuningMode
pidTemp
PID_Temp PID_Temp
Table 4-8
tuningMode Heat.EnableTuning Cool.EnableTuning
0 (none) FALSE FALSE
1 (heating) TRUE FALSE
2 (cooling) FALSE TRUE

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4.8 FC "DeactivateMode”
4.8 FC "DeactivateMode”
FC "DeactivateMode” resets the input bit "ModeActivate” of all "PID_Temp” calls.
It is used in FB "MultizoneSut” as well as in FB "MultizoneTir”.
Table 4-9: Parameters of DeactivateMode

max IN DInt Number of the zones
zones IN_OUT Array[*] of PLC data type with the required interface parameters for each
"typeZone" temperature zone (the size of the field is read)
Only the parameters "*[x].pidTemp.modeActivate” are accessed.
DeactivateMode
DInt max
zones

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4.9 FB "StopWatch”
4.9 FB "StopWatch”
The auxiliary function FB "StopWatch” measures the recovery time of disturbance
variables.
It is called in the interrupt OB in which the controller "PID_Temp” is also called.
Table 4-10: Parameters of StopWatch

tolerance IN Real Tolerance specification of the control differences in %
cycles IN UInt Specification of the number of waiting cycles
cycle IN Real Cycle time of the calling cyclic interrupt OB (in seconds)
time OUT Real Recovery time in seconds
start IN_OUT Bool Starts the processing and is reset after completion
instPidTemp IN_OUT PID_Temp Technology instance transfer
StopWatch
Real tolerance time Real
UInt cycles done Bool
Real cycle busy Bool
start
Bool Bool
instPidTemp
PID_Temp PID_Temp
After starting the FB "StopWatch” the block will wait until the proportional control
deviation leaves the tolerance band "tolerance”. From this time on the
"recoveryCycles” are counted until the control deviation is again within the
tolerance band for the number of cycles waited after presenting the FB "Waiting”.
As a result, the recovery time "time” is calculated:
𝑡𝑖𝑚𝑒 = (𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦𝐶𝑦𝑐𝑙𝑒𝑠 − 𝑐𝑦𝑐𝑙𝑒𝑠) ∗ 𝑐𝑦𝑐𝑙𝑒

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4.10 Data block/PLC data types

4.10.1 DB "Tags”
The data block "Tags” includes the parameters to transfer the block interfaces and
looks as follows:
Table 4-11
Name Data type Description
simMultizone "typeSimMultizoneIn" Includes the individual parameters for transferring the
interface to the FB "SimMultizone”
multizoneSut "typeMultizoneIn" Includes the input parameters for the pretuning of the
multi-zone controller (FB "MultizoneSut")
multizoneTir "typeMultizoneIn" Includes the input parameters for the fine tuning of the
multi-zone controller (FB "MultizoneTir")
zones Array[1..3] 3 of "typeZone" Includes interface parameters for the transfer to the
block calls, depending on the number of zones.
stopWatch "typeWaitingIn" Includes the interface parameters for the recovery time
calculation
4.10.2 "typeSimMultizoneIn"
The PLC data type "typeSimMultizoneIn” includes the individual parameters for the
interface transfer to the FB "SimMultizone” (independent from the number of
zones).
Table 4-12
velocity SInt Transport velocity of the extruder screw in %
ambTemp Real Ambient temperature
reset Bool Resets all relevant parameters
4.10.3 "typeMultizoneIn"
The PLC data type "typeMultizoneIn” includes the input parameters for transferring
the interface to the FB "MultizoneSut” or FB "MultizoneTir”.
Table 4-13
start Bool Starts the processing and is reset after completion.
reset Bool Resets the block and is set to FALSE after completion.
3
The upper limit of the field has to match the number of zones of the multi-zone controller.

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4.10.4 "typeZone”
PLC data type "typeZone" includes the parameters of the block interfaces for each
temperature zone.
Table 4-14
pidTemp "typePidTemp" PLC data type with the required interface parameters
for the "PID_Temp” controller call.
simMultizone "typeSimMultizoneArray" PLC data type with the input parameters for
temperature simulation (FB "SimMultizone”).
tuningMode USInt Energy type specification for fine tuning
(0 = none, 1 = heating, 2 = cooling).
4.10.5 "typePidTemp"
PLC data type "typePidTemp” includes the required interface parameters for the
"PID_Temp” controller call.
Table 4-15
setpoint Real Setpoint specification

mode Int Mode selection
modeActivate Bool Release mode
outputHeat Real Output value heating in REAL format
outputCool Real Output value cooling in REAL format
4.10.6 "typeSimMultizoneArray"
PLC data type "typeSimMultizoneArray” includes interface parameters for the

temperature simulation (FB "SimMultizone”) depending on the number of zones.
Table 4-16
disturbance Real Disturbance variable on the input
output Real Simulated zone temperature
4.10.7 "typeWaitingIn”
PLC data type "typeWaitingIn" includes the input parameters for the FBs "Waiting”
and "StopWatch”.
Table 4-17
start Bool Starts the processing and is reset after completion.
tolerance Real Tolerance specification of the control differences in %
cycles UInt Specification of the number of waiting cycles

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5 Configuration and Settings
5.1 Configuring the technology "PID_Temp”

This chapter describes the steps necessary to tailor the example project to your
applications.

The storage locations of the controller block calls "PID_Temp” are created as
individual instances. As a result, each controller can be conveniently configured as
follows, via the appropriate wizard in the technology object.
Table 5-1
No. Action
1. Open the configuration editor of the "PID_Temp” individual instance to be
configured in "Technology objects” in STEP 7 (TIA Portal).
2. Open the "Controller type” menu in the basic settings and select the temperature
unit for the display in the commissioning window.
Enable the specification of the mode for the first start und select "Inactive”.
3. Open the input/output parameter and specify whether the controller is a heating or
heating/cooling controller ("Activate cooling”).
Select the signal course for each interface (floating-point number/analog/PWM).
For more information see Input or Output Value Heating or Cooling (\3\).
Function Manual: SIMATIC S7-1200, S7-1500 PID control
When using the simulation block "SimMultizone” use input as floating-point number
("Input”). The manipulated variable as floating-point number is also output when
selecting "OutputX_PWM” or "OutputX_PER (analog)”.

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No. Action
4. Specify the actual value limits in the actual value settings in such a way that they
are not violated. Otherwise, in the event of a violation, the tuning is cancelled.
Specify the actual value scaling if you are using the analog input signal
"Input_PER”.
5. Open the Basic settings of output and select the "Switch PID parameter for
heating/cooling” as method for heating/cooling controllers.
Only when this method is selected, is pretuning and fine tuning for cooling made
available.
Specify the response in the event of an error

6. Make the settings for Output value limits and scaling when selecting
"OutputX_PWM” or "OutputX_PER (analog)”.
Make the settings for PWM limits in the advanced settings if you have selected the
pulse width modulation output signal "OutputX_PWM”.

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5.2 Extension of control zones

Proceed as follows to expand the number of control zones of the application
example.
Table 5-2
No. Action
1. Call the technology instruction "PID_Temp” V1.1 in the interrupt.
2. Select the individual instance as call option

Configure the technology object according to Table 5-1.

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No. Action
3. Adjust the upper limit of the "zones” tag in DB "Tags”.
Specify the setpoint for the new zone as start value.

4. Switch the input interfaces in accordance with the other "PID_Temp” calls.

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5. Add an InOut parameter of data type "PID_Temp” to the FBs "MultizoneSut”,

"multizoneTir” and "Waiting”.
6. Adjust the local constant "MAX” of the FBs "Waiting” and "SimMultizone” to the
number of zones.
7. Update the block call and switch the newly created individual instance of the
"PID_Temp” to the InOut parameter of the FBs "MultizoneSut” and "MultizoneTir”
and loop through the call of the FB "Waiting” to the FBs "MultizoneSut” and
"MultizoneTir”.
Furthermore, you have to expand the program code by the added zone, according
to the comments in the FBs "MultizoneSut”, "MultizoneTir” and "Waiting”.

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6 Installation and Commissioning
6.1 Installing the hardware

This chapter describes the steps necessary for commissioning the example project
with the hardware and software used (from chapter 2.2.2).
6.1 Installing the hardware

The figure below shows the hardware configuration of the application:
Figure 6-1
IP-Adresse: 192.168.0.2
IP-Adresse: 192.168.0.242 Subnetz: 255.255.255.0
IP-Adresse: 192.168.0.1 Subnetz: 255.255.255.0
Subnetz: 255.255.255.0 S7-1500
PC/PG
24 V DC
S7-1200
L+ M
STEP 7
(TIA Portal)
L+ M
PROFINET IE
24 V DC
Note Always follow the installation guidelines in order to connect all the components.
• Manual SIMATIC S7-1200 (\4\)
• Manual SIMATIC S7-1500 (\8\)
Table 6-1
No. Action Remark
8. Wire and connect the SIMATIC S7-1200 or See S7-1200 manual (\4\)
S7-1500 as described. or S7-1500 manual (\8\)
9. Plug the empty memory card into the S7-1500 See Chapter "Plug/Pull SIMATIC Memory
CPU (Table 2-1). Card on the CPU” (S7-1500 manual \8\)
10. Connect the SIMATIC PM 1207 power supply -
module to the low voltage network (230 V).

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6.2 Commissioning
6.2 Commissioning
This chapter describes the steps for installing the sample code.
6.2.1 Network connections
The LAN network card of the programming device requires a static IP address to
configure the controller.
The configuration of the LAN connection is described below.
Table 6-2
No. Action Remark
11. Click "Start > Control Panel > Network and
Sharing Center > Change adapter settings”
to open the network connections.
• Select your network connection.
• Right-click to open the properties.
12. Select the "Internet Protocol Version 4

(TCP/IPv4)” element in "Networking” and
open the properties.

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6.2 Commissioning
No. Action Remark

13. • Select "Use the following IP address”.
• Select an IP address in the CPU's
subnet mask.
• Confirm the settings with "OK” and
"Close”.
6.2.2 Setting PG/PC interface

Table 6-3
No. Action Remark
14. Open the PG/PC interface settings via
"Start > Control Panel” to set the correct
access path for STEP 7.
• Select "S7ONLINE (STEP 7)” as the
application's access point.
• Select your network card with
"Parameter assignment of your NDIS
CP with TCP/IP protocol (RFC-1006)”
as the interface configuration used.
Confirm the settings with "OK”.

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6.2 Commissioning
6.2.3 Downloading to the controller
Below, the successful installation of STEP 7 (minimum "Basic” license for SIMATIC
S7-1200 or "Professional” license for SIMATIC S7-1500) is assumed.
Table 6-4
No. Action Remark
15. Set the IP address via the display if using the See Figure 6-1 or "Display of CPU” (\8\)
S7-1500 CPU. When using the S7-1200, the IP address is
transferred with the project.
16. Unzip the application example from Siemens -
Industry Online Support (\2\) and open the
project.
17. In order to compile the configuration of the
S7-1200 or S7-1500 CPU, right-click on the
CPU and click on the "Compile > Hardware
and software (only changes)” command.
18. Load the project in the S7-1200 or S7-1500

CPU. For this purpose, select the CPU and
select the "Online > Download and reset PLC
program”.
Now select your access point to the S7-1500
CPU and load the project into the CPU.
Note For more information on the "Loading blocks for S7-1200/1500” topic, please
refer to the STEP 7 manual (see \9\).

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7 Operating the Application Example
7.1 Preparation

The application example is operated via the "WatchTable”.
Note You can also simulate the controller part of the S7-1500 of the application
example with PLCSIM. To do this, follow the notes in the function manual (\3\),
chapter "Simulating PID_Temp with PLCSIM".
7.1 Preparation
Selecting the technology objects "PID_Temp” as individual instance enables you
can to use the commissioning wizard and to watch the courses of the curves.
Table 7-1
No. Action Remark
19. Open the commissioning window of
the respective "PID_Temp” instance
in "Technology objects’”.
20. Start each measurement with the

"Start” button.
21. The measurement is started.

The controller is in the "Disabled –
inactive” state and the tuning status
shows: "Tuning has not been started
yet”.
Note You get to the state before the first commissioning with the start values of all PID
parameters, by selecting the controller and via the "Online > Download and reset
PLC program (\3\).

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7.2 Pretuning
7.2 Pretuning
Carry out the following steps for the synchronous pretuning (first heating, then
cooling for heating/cooling controllers) of multi-zone controllers.
Table 7-2
No. Action Remark
22. Open the "WatchTable” in "Watch and force -
tables”.
23. Click on the "Watch all” button.
24. Between the pretuning heating and the fine

tuning cooling, it is waited with FB "Waiting”
until all zones are located in the operating
point.
Check the proportional tolerance and the
number of waited cycles and adjust them if
required.
25. Check the setpoints of the individual zone
controllers and make sure that all controllers
are in the "Inactive” (state = 0) mode.
26. Start the synchronized pretuning for all

zones by setting the
"Tags”.multizoneSut.start bit.
27. You can monitor the progress of the

pretuning through the courses of the curves
in the commissioning windows (Figure 7-1)
and in the watch table.
In the figure, FB "MultizoneSut” is in step
"statStep" = 40 and waits until the control
deviations of the zones "deviation[x]” are
within the specified proportional "tolerance”
and it is waited for the specified "cycles”.
The lapse of the waiting period can be read
via the proportional "progress”.

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7.2 Pretuning
Figure 7-1
Pretuning heating Wait until Pretuning cooling

Automatic operating points Automatic
mode + mode
are reached
The pretuning heating is started with the calculations of the standard deviation,
followed by simultaneous setpoint jumps heating with the determination of the
turning points of the temperature curves. Afterwards the automatic mode of the
controllers waits that the respective operating point is reached, before the
pretuning cooling is carried for the heating/cooling controllers (zone 2 and 3).
During this time the controller of zone 1 remains in automatic mode. With the
completion of the last pretuning cooling (zone 2) the FB "MultizoneSut” is
successfully processed.
7.2.1 Disturbance variable compensation
A statement regarding quality of the parameters found can be made through the
compensation of disturbance variables.
This can take place in real operation, for example, through the switching on of a hot
air blower on the extruder housing.
To do this in the simulated application example, proceed as follows:
Table 7-3
No. Action Remark
28. Remove all ticks in the option boxes for the
selection of the tags to be controlled in the
"WatchTable”.
29. Check the proportional tolerance and the

number of waited cycles for the
measurement of the recovery times and
adjust them if required.
Start the measurement of the recovery
times via "Tags”.stopWatch.start tag.

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7.2 Pretuning
No. Action Remark

30. For each zone, enter the following as
control word for the disturbance variables:
"Tags”zones[x].simMultizone.disturbance =
10.0
Click on the "Modify now” button.
31. Monitor the course of the curve and the
watch table.
After compensation of the disturbance
variables, the required times are displayed
via the "instStopWatchX".time.
You can also stop the course of the curve
via and then determine the

recovery time via the vertical
measurement cursor (Figure 7-2).
32. Then remove the disturbance variables

again from the control loop:
"Tags”zones[x].simMultizone.disturbance =
0.0.
Figure 7-2
Δt ≈ 59 s
Δt ≈ 75 s
Δt ≈ 68 s
Switching disturbance variable Switching off of disturbance variable

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7.2 Pretuning
For the disturbance variable compensation in the opposite energy type, the
controller has to change into this energy type first. Proceed as follows:
Table 7-4
No. Action Remark
"WatchTable”.
34. Select a higher tuning offset heating than
the stationary setpoint heating
("OutputHeat”) for each zone of the
heating/cooling controller in automatic
mode (for example, 2 x "OutputHeat”), in
order to force the cooling mode.
35. Watch the course of the curve.
Now wait until all zones have reached their
stationary operating point.
36. Start the measurement of the recovery
times via "Tags”.stopWatch.start tag.
37. As control word for the disturbance value,

enter
"Tags"zones[x].simMultizone.disturbance =
10.0 for each zone.
38. Monitor the course of the curve and the
watch table.
After compensation of the disturbance
variables, the required times are displayed
via the "instStopWatchX".time.
You can also stop the course of the curve
with and determine the

recovery time via the vertical measurement
cursor (Figure 7-3).
39. Then remove the disturbance variables

again from the control loop via
"Tags"zones[x].simMultizone.disturbance =
0.0 and the offsets
"InstPidTempX".PIDSelfTune.TIR.OutputOf
fsetHeat = 0.0.

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7.3 Fine tuning
Figure 7-3
Δt ≈ 56 s
Δt ≈ 49 s
Output offset Wait

+ until operating points are reached
Δt ≈ 46 s
Switching of disturbance variable
Since the controller for zone 1 is a pure heating controller, the previously
determined disturbance variable recovery time is confirmed here.
7.3 Fine tuning

Perform the following steps to synchronize the fine tuning of multi-zone controllers.
Table 7-5
No. Action Remark
40. Before fine tuning is started, it is waited with
FB "Waiting” until all zones are located in
the operating point.
This procedure is important if one zone is to
be fine-tuned in the opposite energy type.
In the present example, first, the fine tuning
is done in the energy type of the operating
point. This is why these settings must not to
be observed.
41. Check the setpoints "setpoint” of the
individual zone controllers and make sure
that all controllers are in "Automatic” (State
= 3) mode.

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7.3 Fine tuning
No. Action Remark

42. You should do the fine tuning first of all in
the energy type of the operating point.
After the pretuning, all controllers in the
current example are in heating mode.
As a result, select the energy type of each
zone "tuningMode = 1” for heating.
Start the synchronized fine tuning with
these specifications by setting the bit
”Tags".multizoneTir.start.
43. You can monitor the progress of the fine
tuning through the courses of the curves in
the commissioning windows (Figure 7-1)
In the figure, FB "MultizoneTir" is in step
"statStep" = 50 and waits during the fine
tuning that all zone controllers report that
the setpoints have been reached via the
"ControlInReady" bits. Then the
"FinishControlIn” bits are set and the fine
tuning for all zones is continued with the
calculation of the standard deviation.

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7.3 Fine tuning
Figure 7-4
Try to reach setpoint heating with PID control
Standardabweichung Heizen berechnen

Wait until operating points are reached
Oszillation
Fine tuning heating Automatic mode

The FB "MultizoneTir” waits until all operating points have been reached (only
required if the opposite energy type is to be fine-tuned).
Afterwards it is tried to reach the setpoints with the existing PID parameters as part
of the fine tuning, in order to calculate the standard deviation synchronously and to
initiate the oscillation of the actual values via variation of the manipulated variables.
The PID parameters for each zone are recalculated from amplitude and frequency
of the actual value oscillations.
With the completion of the last fine tuning (zone 2) the FB "MultizoneTir” is
Disturbance variable compensation

Repeat the procedure from Table 7-3, to be able to evaluate the control quality of
the parameters found.
In the process, keep the tolerance specification and the number of waited cycles to
be able to compare the detected times for the disturbance variable compensation
with each other.

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7.3 Fine tuning
Figure 7-5
Δt ≈ 12 s
Δt ≈ 22 s
Δt ≈ 11 s
Switching disturbance variable
7.3.1 Tuning of the opposite energy type
With the FB "MultizoneTir” you can also fine tune the other energy type (other than
the present one) for heating/cooling controllers. In the present example this is the
energy type cooling for zone 2 and 3.
Table 7-6
No. Action Remark
44. Before fine tuning is started, it is waited with
FB "Waiting” until all zones are located in
the operating point.
This procedure guarantees that the
calculation of the tuning offset happens in
the steady-state control loop.
If required, adjust the percentage of the
"tolerance” and/or the number of waited
"cycles”.
45. Check the setpoints "setpoint” of the
individual zone controllers and make sure
that all controllers are in "Automatic” (State
= 3) mode.

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7.3 Fine tuning
No. Action Remark

46. Select "tuningMode = 2” for the energy type
cooling in zones 2 and 3.
Since the heating controller of zone 1 has
already run through the fine tuning, select
"tuningMode = 0” here for no tuning.
”Tags".multizoneTir.start .
In the figure, FB "MultizoneTir" is in step
"statStep" = 60 and calculates the standard
deviation during the fine tuning after the two
zone controllers 2 and 3 have reported that
the setpoints have been reached
("ControlInReady") and "FB "MultizoneTir”
has been set.
Figure 7-6
Wait unitl operating points are reached
Calculate standard deviation cooling
Calculate / output offset Oszillation

+
Try to reach setpoint cooling with
PID control
Fine tuning cooling Automatic mode

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7.3 Fine tuning
The FB "MultizoneTir” waits until all operating points have been reached before the
FCs "TirOffset” calculate and output the heating tuning offsets.
This increase of the heating manipulated variables forces the zone controllers 2
and 3 to energy type cooling, in order to maintain the setpoint.
Afterwards it is tried to reach the setpoints with the existing PID parameters as part
of the fine tuning, in order to calculate the standard deviation synchronously and to
initiate the oscillation of the actual values via variation of the manipulated variables.
The PID parameters for each zone are recalculated from amplitude and frequency
of the actual value oscillations.
With the completion of the last fine tuning (zone 2) the FB "MultizoneTir” is
Disturbance variable compensation

Repeat the procedure from Table 7-4, to be able to evaluate the control quality of
the parameters found.
In the process, keep the tolerance specification and the number of waited cycles to
be able to compare the detected times for the disturbance variable compensation
with each other.
Figure 7-7
Δt ≈ 13 s
Δt ≈ 35 s
Output offset + wait until operting points are reached
Δt ≈ 25 s
Switching the disturbance variable
Since the controller for zone 1 is a pure heating controller, the previously
determined disturbance variable recovery time is confirmed here.

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7.3 Fine tuning
Table 7-7: Disturbance variable recovery time according to tuning types

Zones Energy type Pretuning Fine tuning
1 Heating 58 s 12 s
2 Heating 75 s 22 s
Cooling 49 s 35 s
3 Heating 68 s 11 s
Cooling 46 s 25 s
Table 7-7 shows that the fine tuning leads to a faster compensation of manipulated
variables then the pretuning.

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8 Further Notes, Tips and Tricks

8.1 Adjusting simulation
During the handling processing of an extruder, at times so much heat is created
through friction and shearing of the material (for example, plastic granulate) that
cooling is necessary.
In order to recreate this behavior within the simulation block, a disturbance variable
can be connected for the respective zone.
For example, zone 2 is to cool after commissioning through the pretuning in
automatic mode to reach the setpoint.
To do this, empirically determine the value for the
"Tags".zones[2].simMultizone.disturbance disturbance value (for example, 40.0).
First of all, the synchronous fine tuning of the zones takes place in the respective
energy type of the controller:
• Zone 1: Heating ("Tags".zones[1].tuningMode = 1)
• Zone 2: Cooling ("Tags".zones[1].tuningMode = 2)
• Zone 3: Heating ("Tags".zones[1].tuningMode = 1)
Table 8-1
No. Action Remark

"WatchTable”.
49. Enter
"Tags"zones[2].simMultizone.disturbance =
40.0 as control value of the disturbance
value for zone 2.
50. Follow step 1 and 2 from Table 7-5. -
51. Select the following energy types for the
fine tuning:
• Zone 1: Heating
("Tags".zones[1].tuningMode = 1)
• Zone 2: Cooling
• Zone 3: Heating

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No. Action Remark

Figure 8-1
Wait until oprating points are reached
Try to reach setpoing with PID control
Calculate standard deviation
Oszillation
Fine tuning Automatic mode

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8.2 Fine tuning in the event of strong coupling

In the event of strong thermal coupling of the zones, the neighboring zones should
not be fine-tuned simultaneously.
Here you should put the neighboring zones during the fine tuning to manual mode
by maintaining the manipulated variable.
If the system tends to oscillate during the disturbance variable compensation after
the fine tuning, this points towards a negative influence of the neighboring zones to
finding parameters of the fine-tuned zones.
In chapter 7.3.1 zone 1 was not fine-tuned but left in automatic mode during the
fine tuning of zones 2 and 3.
Analog to this, the neighboring zones are put into manual mode by the respective
commissioning editor and are assigned with "Tags".zones[x].tuningMode = 0 (do
not carry out fine tuning) for the fine tuning energy type specification.
For the complete fine tuning of all zones, this approach is carried out once for
even-numbered zones and is this then repeated with the odd-numbered zones.
Table 8-2
No. Action Remark
53. To increase the forwards coupling factors,
set the medium transport velocity to 100 %:
"Tags".simMultizone.velocity = 100.0
54. Wait until all zones have reached their -

operating point.
55. Put the controller in the commissioning
editor of zone 2 to manual mode.
The "OutputHeat” heat output maintains the
last value and the status of the controller
displays manual mode.

"WatchTable”.
57. Select the predominant tuning energy types
for the odd zones of the multi-zone
controller
• Zone 1: Heating
• Zone 2: none
• Zone 3: Heating

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No. Action Remark

58. The synchronous fine tuning for the zones See Figure 8-2
1 and 3 is carried out.
59. Then repeat this procedure for -
synchronous fine tuning for the even zones.
To do this, the odd zones (1 and 3) are put
in steady-state control loop in manual mode
and zone 2 is fine tuned.
Figure 8-2
Automatic mode
Oszillation
Try to reach setpoint heating with PID control
Wait until operating points are reached
Calculate standard deviation heating
Manual mode
Oszillation
Automatic mode
Fine tuning heating

Entry-ID: 109740463, V1.1, 07/2019 61
9 Links & Literature
9 Links & Literature

Table 9-1
Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Download page of the entry

\3\ Function Manual: SIMATIC S7-1200, S7-1500 PID Control

\4\ SIMATIC S7 S7-1200 Programmable controller manual

\5\ TIA Selection Tool

http://w3.siemens.com/mcms/topics/en/simatic/tia-selection-tool/Pages/tab.aspx
\6\ Application example: "Closed-Loop Control of Simulated Controlled Systems in the

S7-1500 with PID_Compact V2.2”
\7\ Günther Schmidt: Simulationstechnik
Published by: Oldenbourg Wissenschaftsverlag (1980)
ISBN-13: 978-3486251814
\8\ Manual SIMATIC S7-1500, ET 200MP Automation system

\9\ SIMATIC STEP 7 Basic/Professional V15.1 and SIMATIC WinCC V15.1

\10\ Manual
SIMATIC S7-1500/ET 200MP Automation system In a nutshell
10 History
Table 10-1
Version Date Modifications
V1.0 12/2016 First version
V1.1 07/2019 Update TIA Portal V15.1

Entry-ID: 109740463, V1.1, 07/2019 62

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Multi-Zone Control

PID control with PID_Compact

4.2 FB "SimMultizone” ........................................................................... 17

PID control with PID_Compact

6.2.2 Setting PG/PC interface ................................................................... 44

PID control with PID_Compact

Overview of the application example

PID control with PID_Compact

PID control with PID_Compact

Topics not covered by this application

Note More information on the technology object "PID_Temp” can be found in

PID control with PID_Compact

2.2 Hardware and software components

This application example is valid for the following components:

2.2.2 Components used

PID control with PID_Compact

Example files and projects

PID control with PID_Compact

3.1.1 Adjusting the delay time

3.1.2 Temporarily switching off cooling

For controllers with active cooling ("Config.ActivateCooling” = TRUE), you can

For the synchronized pretuning of multi-zone controllers, proceed as follows:

PID control with PID_Compact

3. Specify the desired setpoint ("Setpoint” parameter) and simultaneously start

7. Start the cooling pretuning ("Config.ActivateCooling” = TRUE) simultaneously

CAUTION Exceeding the limit value of the actual value

actual value limits.

CAUTION Multi-zone controllers

PID control with PID_Compact

3.2 Fine tuning

3.2.1 Temporary tuning offset for heating/cooling controller

If "PID_Temp” is used as heating and cooling controller ("Config.ActivateCooling” =

3.2.2 Synchronizing several fine tunings

If the fine tuning is started in automatic mode with "PIDSelfTune.TIR.RunIn” =

PID control with PID_Compact

PID control with PID_Compact

Controller Simulation Controlled System

PID control with PID_Compact

PID control with PID_Compact

The following subfunctions are used by these optimization blocks:

• FC "TirOffset” calculates heating or cooling according to the specified energy

PID control with PID_Compact

4.2.1 Simulation of a coupled thermal stretch

As mathematic model, the discrete solution of a partial differential equation of a

Kint KFw KBw Kint KFw KBw Kint KFw

PT2 PT2 PT2

PT1 PT1 PT1 PT1 PT1 PT1

dist1 dist2 dist3

Zone 1 Zone 2 Zone 3

The dynamic of a gird point is exemplary as second-order aperiodic delay element.

PID control with PID_Compact

The simulated zone temperature 𝑇𝑧 is the result of equation 4.2.1:

Equation 4.2.1: Calculating the zone temperature 𝑻𝒛 :

Equation 4.2.2: Transfer function of the PT2 delay element

Equation 4.2.3: Equation for calculating the PT2 input

Equation 4.2.4: Summation of the manipulated variable delay by PT1

PID control with PID_Compact

Heizsprung Zone2 100 – verstärkte Vorwärts- und

4.2.2 Configuration explanations

Array[] of "typeZone" Array[] of "typeZone"

Array[] of "typeZone" Array[] of "typeZone"