Industrial Controllers

Introduction
 Controllers are devices that are used to provide the control function in process control and in
automation.
 A controller basically receives signals from sensors (for process feedback or process state) and
processes these signals into control signals that will be supplied to the actuators.
 In addition, a typical controller may also provide the following functions:
o Display of process variables and controller parameters
o Configuration of operation mode (PID terms, SP, alarms etc)
o Communication with other devices or other control equipment
o User interface

Panel keys
(configurations, Display
user commands)

Computer

Communication
Controller link

Sensors
(feedback, Control signals
process states)

PLANT

Figure 4.1

 Controllers can be closed loop controllers or logic controllers

 Closed loop controllers are used to implement the control law in closed loop control systems
 Logic controllers are used to sequence steps in an event-sequencing system.

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Loop Controllers
 A loop controller is basically used to implement the control in closed loop control systems. The
control law could be:
o 2-step control – actuator is either on or off depending on the process value as compared to
the set point.
o PID control
 The SP is input via any input device like a keypad or an input potentiometer. It may also be obtained
from a remote device.
 The controller also displays the control variable and generates alarms when the process variable
goes outside certain limits. The alarms can be in form of displays or output signals to input into
external devices.
 It can receive external digital inputs and provide control functions that depend on their states.
 It allows configuration of the operation mode of the controller.
 Connections to other external components are available via terminals usually located at the backside
of the controller. These are the control outputs, the communication link, external analog and digital
inputs, alarms, power supply, etc. Figure 4.2 illustrates.

Figure 4.2 Loop controller connections

Process variable input

 A typical controller can take in any of the following types of inputs
o 0 – 20mA or 4 – 20mA current input
o Voltage input (mV or V range)
o Thermocouple output
o RTD output
 Typically, 3 or 4 input terminals are provided and connections to the pins are made according the
type of sensor output to be used. Figure 4.3 illustrates.
 A thermocouple output or a voltage PV signal is connected directly to the signal input lines.

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  An RTD is connected across the input terminals and the VI terminal provides a current to generate a
voltage input into the controller.
 For current PV signals, a current sensing resistor is connected across the input terminals to change
the current to a voltage signal for inputting into the controller.

Figure 4.3

Control outputs
 Control outputs are generated from output modules. Depending on relationship between SP and PV,
a module generates an output to suit 2-step control, PID control or alarm generation.
 A typical controller allows more than one output module to be used. These modules are generally
available as plug in cards. For any given application, the necessary modules are implemented.
 Types of modules are:
o Relay output – the module opens or closes relay contacts depending on comparisons made
on the PV and the SP. It can be used in 2-step control, program event and alarms. The relay
can switch ac or dc circuits.
o Logic output – the module provides a logic voltage output depending on comparisons made
on the PV and SP. It can be used in 2-step control and in program event. E.g. 0/18V at 20mA.
o Triac output – the module turns on or off a triac depending on comparisons made on the PV
and SP. It can be used in 2-step control and in program event. The triac is used to switch ac
circuits.
o dc output – the module gives a variable dc output usually control action generated by the
PID control algorithm. The dc output is used to drive continuous actuators.
o Relay changeover – the module changes over the relay contacts depending on comparisons
made on the PV and SP. It can be used in 2-step control, alarms and in program event.
 Each output module can be configured for “heating” or “cooling”. They will work in contra-
situations: heating when PV is below SP; cooling when PV is above the SP.
 Two or three connection points are used for each output module.

Communication interface
 A communication terminal is available to enable communication with other control equipment, for
example linking to a computer.

Logical input
 Takes in logical inputs, for example alarm acknowledge signal.

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Current transformer input
 Takes in outputs of current transformers.

Set point input or retransmit

 The device may have a module to receive the set point as an analog signal from a remote device.
 It may also retransmit the SP to further controllers.

Voltage supply
 The controller may be provided a supply point for 24VDC control equipment.

Figure 4.4 Basic connections

 Terminals starting with V are for connection to the PV source.

 Connections starting with H are for connection to the communication link.
 Connections starting with 1 and 2 are for connections to the output modules.
 Connections starting with A are for alarm connections (crossover relay).
 L and N are the power supply connections.

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 Figure 4.5 A controller with several module options

 Modules requiring two connections use points A and B.

 Those needing more, will then also use C and D as necessary.

Display and key panel

 The controller has a display to enable display of the process variable as well as information that a
user may need to see. The display is generally in the form of an LCD.
 It also has a keypad for entering commands into the device.
 Keys normally implemented are up/down scroll keys, function keys, enter key and return key.

Figure 4.6

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Configuration of the loop controller for operation
 The controller with the needed modules is acquired or the necessary modules needed are installed
on available plug in slots of the device.
 The device is configured in software via the control panel and the display (operation modes for each
module, SPs, e.t.c.). Alternatively, the device can be configured from a conventional computer via a
communication link.

Architecture of a Loop Controller

 In modern day control environment, controllers are microprocessor-based or microcontroller-based
devices. Some controllers are specialised computers meant for control functions. Conventional
computers also form part of the control system, mainly used at higher control levels.
 Figure 4.7 gives a typical block diagram for a loop controller.

Sensor Keypad
interface and user
and ADC switches

DAC and Display

actuator Processor devices
interface (μp OR μc
Digital
based Communic
input system) ation
interface interface

Digital
Remote SP
output
interface
interface

Figure 4.7

 The processor is made up of a microprocessor, memory and ports interconnected by a system bus as
found in microprocessor-based systems.
 All the interface circuits, the display and the keypad are connected to the I/O ports and are
controlled and operated under control of the microprocessor program.
 If a microcontroller is used, some of the interface circuits may be implemented using the peripheral
circuits found within the microcontroller, for example ADC and communication may be handled by
peripherals within the microcontroller.

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  A loop controller basically reads in the analog process variable input, converts it into digital,
compare it to the set point to generate an error, apply the control algorithm to generate the control
action which is then written out to the actuator(s).

Closed loop configurations

Closed loop systems may be configured for:
 Standalone operation – the controller operates as a standalone device.
 Supervisory control – each controller has its own control loop. A supervisory computer is provided to
monitor and control the loop controllers.

Assignment following a visit to a plant

1. On which process did you recognise a closed loop controller? What was the control mode?
2. On what process did you recognise supervisory control? What functions could be carried out from the
supervisory computer?

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