0% found this document useful (0 votes)

68 views139 pages

EquipmentModules PCS7V91 en V52

Uploaded by

Naga Ananth

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

68 views139 pages

EquipmentModules PCS7V91 en V52

Uploaded by

Naga Ananth

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 139

Siemens

Industry
Online
Support

APPLICATION EXAMPLE

Equipment Modules for

PCS 7 using the
example of the
Chemical Industry
SIMATIC PCS 7 V9.1
Table of contents

Legal information
Use of application examples
Application examples illustrate the solution of automation tasks through an interaction of several components in the
form of text, graphics and/or software modules. The application examples are a free service by Siemens AG and/or a
subsidiary of Siemens AG (“Siemens”). They are non-binding and make no claim to completeness or functionality
regarding configuration and equipment. The application examples merely offer help with typical tasks; they do not
constitute customer-specific solutions. You yourself are responsible for the proper and safe operation of the products in
accordance with applicable regulations and must also check the function of the respective application example and
customize it for your system.
Siemens grants you the non-exclusive, non-sublicensable and non-transferable right to have the application examples
used by technically trained personnel. Any change to the application examples is your responsibility. Sharing the
application examples with third parties or copying the application examples or excerpts thereof is permitted only in
combination with your own products. The application examples are not required to undergo the customary tests and
quality inspections of a chargeable product; they may have functional and performance defects as well as errors. It is
your responsibility to use them in such a manner that any malfunctions that may occur do not result in property damage
or injury to persons.

Disclaimer of liability
Siemens shall not assume any liability, for any legal reason whatsoever, including, without limitation, liability for the
usability, availability, completeness and freedom from defects of the application examples as well as for related
information, configuration and performance data and any damage caused thereby. This shall not apply in cases of
mandatory liability, for example under the German Product Liability Act, or in cases of intent, gross negligence, or
culpable loss of life, bodily injury or damage to health, non-compliance with a guarantee, fraudulent non-disclosure of a
defect, or culpable breach of material contractual obligations. Claims for damages arising from a breach of material
contractual obligations shall however be limited to the foreseeable damage typical of the type of agreement, unless
liability arises from intent or gross negligence or is based on loss of life, bodily injury or damage to health. The foregoing
provisions do not imply any change in the burden of proof to your detriment. You shall indemnify Siemens against
existing or future claims of third parties in this connection except where Siemens is mandatorily liable.
By using the application examples you acknowledge that Siemens cannot be held liable for any damage beyond the
liability provisions described.

Other information
Siemens reserves the right to make changes to the application examples at any time without notice. In case of
discrepancies between the suggestions in the application examples and other Siemens publications such as catalogs, the
content of the other documentation shall have precedence.
The Siemens terms of use (https://support.industry.siemens.com) shall also apply.

Security information
Siemens provides products and solutions with industrial security functions that support the secure operation of plants,
systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and
continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions constitute
one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such
systems, machines and components should only be connected to an enterprise network or the internet if and to the
extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network
segmentation) are in place.
For additional information on industrial security measures that may be implemented, please visit
https://www.siemens.com/industrialsecurity.
Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly
recommends that product updates are applied as soon as they are available and that the latest product versions are used.
Use of product versions that are no longer supported, and failure to apply the latest updates may increase customer’s
exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under
https://www.siemens.com/cert.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 2

Table of contents

Table of contents
1. Introduction ............................................................................................................... 5

1.1. Overview ................................................................................................................................ 5

1.2. Mode of operation .................................................................................................................. 6
1.3. Components used ................................................................................................................... 8

2. Preparation and commissioning .................................................................................. 9

2.1. Preparation ............................................................................................................................. 9

2.2. Commissioning ..................................................................................................................... 10

3. Integrating the Equipment Module in the user project .............................................. 11

3.1. Preparation ........................................................................................................................... 11

3.2. Copying templates ................................................................................................................ 11
3.3. Copying Equipment Module .................................................................................................. 12
3.4. Adapting the OS project ........................................................................................................ 13

4. Control Module......................................................................................................... 14

4.1. Introduction.......................................................................................................................... 14
4.2. Basic Control Module Type Library.......................................................................................... 16
4.3. "ModPreCon" 4x4 multivariable controller .............................................................................. 17
4.3.1. Standard multivariable controller ........................................................................................... 17
4.3.2. Predictive controller for only one controlled variable ............................................................... 19
4.4. "PIDCon” controller ................................................................................................................ 22
4.4.1. Standard controller ............................................................................................................... 22
4.4.2. Ratio controller ..................................................................................................................... 23
4.4.3. Split range controller ............................................................................................................. 26

5. Equipment Modules.................................................................................................. 29

5.1. "Level-Control" in process plants ............................................................................................ 30

5.1.1. Exact level control ................................................................................................................. 30
5.1.2. Buffer level control with feedforward disturbance compensation "Buffer-Control" .................... 35
5.1.3. Simulation - structure and parameterization ........................................................................... 43
5.1.4. Comparison of exact level control with buffer control including feedforward disturbance
compensation ....................................................................................................................... 46
5.2. "Split-Range-Pressure" control ................................................................................................ 49
5.3. "Ratio-Control" ...................................................................................................................... 54
5.4. "Split-Range-Temperature" control ......................................................................................... 62

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 3

Table of contents
5.5. pH value control using a standard controller ........................................................................... 69
5.6. pH value control using predictive controller ............................................................................ 75
5.7. "Temperature-Flow-Cascade" ................................................................................................. 83
5.8. Coarse-/Finestream-Control "Stream-Control” ......................................................................... 88
5.9. Gradient limits in actuators "Gradient-Limit" ........................................................................... 95
5.9.1. Control behavior without active method ................................................................................ 98
5.9.2. Method 1 "External Reset" ................................................................................................... 100
5.9.3. Method 2 "Tracking output value in case of excessive deviation" ........................................... 102
5.9.4. Method 3 "Blocking integrator" ............................................................................................ 103
5.9.5. Method 4 "Blocking integrator with gradient calculation" ...................................................... 105
5.9.6. Methods comparison ........................................................................................................... 107
5.10. Instance-specific adaptations ............................................................................................... 108

6. Additional information ........................................................................................... 110

6.1. General Information ............................................................................................................ 110

6.2. Standardized plant units ...................................................................................................... 111
6.3. Design and structure ........................................................................................................... 113
6.3.1. CFC naming convention ...................................................................................................... 113
6.3.2. Plant view ........................................................................................................................... 114
6.4. Controllers and control response.......................................................................................... 115
6.4.1. Tracking standard and cascade controllers ............................................................................ 115
6.4.2. Tracking ratio controllers ..................................................................................................... 116
6.4.3. Tracking split range temperature ......................................................................................... 117
6.4.4. Faults and maintenance for temperature throughflow cascade ............................................. 118
6.4.5. Faults and maintenance for ratio controllers ......................................................................... 121
6.4.6. Faults and maintenance of split range temperature .............................................................. 127
6.5. Block description of "pHTitrBlock" ......................................................................................... 131
6.6. Block description of "SimpHTitr" ........................................................................................... 134
6.7. Block description of "ComStruIn" and "ComStruOut" .............................................................. 135

7. Appendix ............................................................................................................... 137

7.1. Service and support ............................................................................................................. 137

7.2. Links and literature.............................................................................................................. 138
7.3. Change documentation ....................................................................................................... 139

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 4

Introduction

1. Introduction
1.1. Overview
The standardization of automation engineering for processing plants, such as in the chemical industry, is a major
challenge. Different process steps and procedures, different equipment and flexibility in the production make the task
even more difficult.
One approach for standardization is structuring the plant according to the physical model of ISA 106. This specifies the
lower four levels, i.e. plant, unit, plant unit and control module. A plant always consists of units. The plant sections can, in
turn, contain standardized plant sections that are based on equipment modules. An equipment module comprises both
the physical equipment and the user program.

This application example contains standardized equipment modules in the form of software typicals that are provided in
SIMATIC PCS 7 as a multiproject.
Using them offers the following benefits:

• A reduction in the expertise necessary to develop applications

• Less effort needed for configuration
• Re-use of field-proven control strategies
• Harmonized structures
• Flexible structuring and adjustment of partial automation solutions

The equipment modules offer a template that comprises the typical components of a partial automation solution, incl.
open- and closed-loop control, the necessary logic and visualization.
An equipment module is configured independently of the automation hardware and is a component of a pre-configured
PCS 7 project including the process visualization system. Due to hardware-independent configuration and the modular
structure, it is possible to integrate and use the equipment modules in PCS 7 projects in any way you like.
Equipment modules are composed of control modules (CMs). Function blocks of the PCS 7 Advanced Process Library (APL)
are used to create a control module.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 5

Introduction

1.2. Mode of operation

The equipment module concept provides pre-engineered and unified components for creating an automation solution,
e.g. metering or temperature control.
The diagram below shows the equipment modules as components of a partial automation solution as an example.

Inflow of input material Pressure control

Stirred tank

Temperature
control
Outflow of product

Equipment module Partial automation solution

The equipment module concept provides pre-engineered and unified components for creating an automation solution,
e.g. metering or temperature control.
The equipment modules are implemented in the PCS 7 multiproject as follows:

• One project for the automation system (AS) and one project for the operator station (OS) are contained in the
component view.
• A hierarchy folder has been created in the plant hierarchy for each equipment module.
• The master data library contains all of the control module types in use.
In the AS project, all the open- and closed-loop control functions are implemented in the form of Continuous Function
Charts (CFCs). Apart from this, the AS project contains a simulation that approximately simulates a procedure, e.g. a filling
level change within an equipment module.
The OS project contains visualization by means of one process picture per equipment module and shows:

• Schematic representation of the equipment module

• Approximately simulated process response
• Relevant parameters (KPI: Key Performance Indicator)
• Monitoring of control performance
The overview picture and the structure of a process picture of an equipment module are described below. For a detailed
description of the core functionality of an equipment module, please refer to Chapter 5 "Equipment Modules".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 6

Introduction
Visualization interface

The visualization interface of the equipment modules consists of an overview picture and a process picture for each
equipment module.

Overview picture
The overview picture contains a schematic representation in the form of a material flow diagram of the process
engineering system that includes all the equipment modules in the example project.
Using the pushbutton of an equipment module, you switch to the respective process picture that contains the
functionality and the specific information of an equipment module. The system represents the process pictures in the
form of an appropriate section of the P&ID of a system.

Process picture
The process picture of an equipment module consists of the following parts:

• Schematic representation (P&ID)

• Simulation
• Faceplates for controlling the individual components (units)
• Trend curve representation to visualize control response
In the process picture, operators are provided with an overview of the respective equipment module and can understand
the runtime response on a time basis.

Delimitation
The process behavior is not simulated in detail within the equipment module.

Required knowledge
Basic knowledge of the following specialist fields is a prerequisite:

• Configuring using SIMATIC PCS 7 CM technology and the APL

• Knowledge of control technology
• Basic knowledge of process technology

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 7

Introduction

1.3. Components used

This application example has been created with the following hardware and software components:
Component Note

SIMATIC PCS 7 ES/OS IPC647E For the PCS 7 V9.1 example project
W10

SIMATIC PCS 7 V9.1 Part of SIMATIC PCS 7 ES/OS IPC647E W10

Advanced Process Library V9.1 Part of SIMATIC PCS 7 V9.1

S7-PLCSIM Not part of SIMATIC PCS 7 V9.1; appropriate licenses are required.

NOTE In case of different hardware, please take heed of the minimum requirements for installing the
software components. The minimum requirements can be found in the Readme of the PCS 7 under
follow link:
https://support.industry.siemens.com/cs/ww/de/view/109780270.

This application example consists of the following components:

Component Note

53843373_EquipmentModules_PROJ_PCS7V91.zip Example project

53843373_EquipmentModules_DOC_PCS7V91_en.pdf This document

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 8

Preparation and commissioning

2. Preparation and
commissioning
2.1. Preparation
The following instructions describe commissioning of the equipment modules by simulating the controller using the "S7-
PLCSIM" program. If you are using a real controller, you must configure existing hardware components in the hardware
settings.
1. Copy file "53843373_EquipmentModules_PROJ_PCS7V91.zip" to any folder on the configuration PC and then open
SIMATIC Manager.
2. Click on "File > Retrieve" on the menu bar and select file "53843373_EquipmentModules_PROJ_PCS7V91.zip". Then
click on "Open" to confirm.
3. Choose the folder where you want to save the project and click on "OK" to confirm.
The project is retrieved.
4. Confirm the "Retrieve" dialog by clicking on the "OK" button and then click on "Yes" in the dialog to open the project.
5. Right-click on "EquipmentModules_OS > OS01 > WinCC Appl. > OS" and then click on the "Open object" menu
command.
6. Confirm the "Configured server not available" dialog with "OK".
7. In the WinCC Explorer, open the properties of your computer and, in the opened Properties dialog, click on the "Use
local computer name" button.

8. Confirm the "Change computer name" message with "OK".

9. In the WinCC Explorer, click on "File > Exit" and in the subsequent dialog select "Terminate WinCC Explorer and close
project".
10. Then confirm with "OK".
11. Reopen the WinCC Explorer as described in step 5.
12. Open by double-clicking on "Variables library".
13. In the "WinCC Configuration Studio", open "Variables library > SIMATIC S7 Protocol Suite > TCP/IP" and select the menu
command "System parameters".
14. In the "Unit" tab, check the "Logical device names" setting. If the "S7 PLCSIM" program is used, the device name
"PLCSIM.TCPIP.12" is selected.
A restart is required after a device name change.

NOTE If the OS cannot establish a connection with the AS (grayed out module icons), select the logical
device name "CP_H1_1" and restart the OS runtime.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 9

Preparation and commissioning

2.2. Commissioning
You can commission the equipment modules after starting the simulation.
You can find a detailed description in Chapter 5.

Starting the simulation (S7 PLCSIM)

To start the simulation, proceed according to the following instructions:
1. Select "Extras > Simulate Modules" from the menu.
The "S7 PLCSIM" dialog window opens.
2. In the "Open project" dialog, select "Open project from file".
3. Select file "EquipmentModules.plc" from path <project path>\Function\EM\EquipmentModules.plc>.
4. In the menu, change "PLCSIM(MPI)" to "PLCSIM(TCP/IP)".
5. In the menu, select "Execute > key switch position > RUN-P".

Activate OS (WinCC runtime)

To activate the OS, proceed according to the following instructions:
1. Right-click on the OS and select the menu "Open object".
2. To activate the OS (WinCC Runtime), select the menu command "File > Activate" in WinCC Explorer.
3. In the "System Login" dialog, enter user name "Equipment" as the "Login" and "Modules" as the password and then
click on "OK" to confirm.
4. In the picture area, select an equipment module; in this example, it is "temperature flow cascade".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 10

Integrating the Equipment Module in the user project

3. Integrating the Equipment

Module in the user project
3.1. Preparation
1. Copy the file "53843373_EquipmentModules_PROJ_PCS7V91.zip" to the configuration PC and then open the SIMATIC
Manager.
2. Click on "File > Retrieve" in the menu bar and select the file "53843373_EquipmentModules_PROJ_PCS7V91.zip". Then
confirm by clicking on "Open".
3. Select the folder in which the project will be saved and confirm with the "OK" button.
The project will be extracted.
4. In the "Retrieve" dialog, click on the "OK" button and then click on "Yes" in the dialog to open the project.
5. Switch to the "Plant view".
6. At the same time, open the project in which the Equipment Modules is to be integrated.

3.2. Copying templates

NOTE If you have already worked with CMTs in your existing project, then check that they are identical
before skipping to the following steps, since this can lead to errors in your existing project or in the
Unit Template you want to integrate.

1. Switch to the plant view.

2. Copy the "BCM" and "pH" folder containing the CMTs from the master data library into the target project.

3. Copy the Enumerations from the master data library into the target project.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 11

Integrating the Equipment Module in the user project

3.3. Copying Equipment Module

1. Copy the hierarchy folder with the desired Equipment Module from the AS project of the Equipment Module to the
plant view of the target project.

2. Copy the corresponding process screens from the OS project of the Equipment Module to the plant view of the target
project as well. If you wish, you can also copy the pictures "Help" and "Overview".

NOTE When copying the process screens, make sure that you copy the pictures to the hierarchy level of the
target project, which is configured as an OS area.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 12

Integrating the Equipment Module in the user project

3.4. Adapting the OS project

In order to facilitate the changing of colors in the process screen from a central point, a central color palette was created
in the OS project. To display these colors in the process screen of your own project, you must import the relevant color
palette.
1. Select the "OS" in WinCC Explorer and choose "Object properties..." in the shortcut menu.
2. Choose the "User Interface and Design" tab and click the "Edit" button.
3. Import the palette into your own project by means of the "Overwrite" option. The color palette is located in the project
folder of the Unit Template at the path: "<Project path>\EquipmentModules\EM_OS\wincproj\OS\GraCS\
UnitTemplate.xml>". All existing colors will be replaced.

NOTE Please note that all colors are always used when exporting/importing color palettes. It is not possible
to export partial color tables.

If you have created your own color tables in your project, you can also export them and use an editor to merge the tables
in the XML file. Otherwise, you can create a new color table in your project and configure the colors individually. Make
sure, too, that the color index does not change, otherwise you will have to adjust the color settings of the objects in the
process screen. Of course, it is up to you to change the colors according to your requirements.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 13

Control Module

4. Control Module
4.1. Introduction
A control module is used to control individual pieces of equipment, like motors, valves, and controllers, for example. The
necessary blocks for carrying out this job, e.g. controlling a valve, are combined in a control module (CM). If a control
module is used several times in the project, e.g. with different characteristics, you create a control module type (CMT)
from it in PCS 7 and store it in the master data library. You can use this CMT in a flexible way anywhere in the project as
an instance with different characteristics (variants).
Using the technology allows to test automation projects using the program logic even if you do not have the real
hardware.

NOTE The application example "Control Module (CM) Technology - Efficient Engineering with SIMATIC PCS 7"
gives you a general overview of how to create, extend, and instantiate a CMT. The application example
is available at the following link: https://support.industry.siemens.com/cs/ww/en/view/109475748

Master data library

This chapter gives you detailed information about the structure and mode of operation of the CMTs on which the
equipment modules are based. All of the CMTs are stored in the "EquipmentModules_Lib" master data library of the PCS 7
projects.

The CMTs are sub-divided as follows:

• Multivariable controller in the "ModPreCon" folder

• Analog measured value display in the "MonAn" folder
• Digital measured value display in the "MonDi" folder
• Motor in the "Mot" folder
• Analog value input in the "OpAn" folder
• Digital value input in the "OpDi" folder
• Controller in the "PIDCon" folder
• Valve in the "Vlv" folder
CMTs are of compact structure, i.e. all the relevant blocks are at defined locations. For example, channel blocks are always
in chart partition B of a CFC.

NOTE Folder "pH" contains the source files of the pH simulation and the conversion block from pH value to
concentration difference. The functions and structure of the block are described in Section 6.5.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 14

Control Module
Selecting a variant
A variant and the options that are necessary for solving an automation task are determined in the instance.
1. To do this, the system displays the technological I/Os in the CFC,
2. the available variants are displayed via the shortcut menu and
3. the functionality that is necessary for the automation task is determined by selecting the options.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 15

Control Module

4.2. Basic Control Module Type Library

The Basic Control Modules (BCM) in the form of a Type Library are available for SIMATIC PCS 7 as a master data library and
contain typical, pre-projected and tested CMT. The BCM are created with CM technology and enable more efficient
engineering through standardized program components.
The following benefits are achieved by using the BCM Type Library:

• Extensive library for different applications and industries

• Reduction of the project planning effort
• Reduced maintenance
• Standardized structures
The BCM Type Library offers typical components as a template for building automation solutions. The CMT of the BCM
Type Library contain all necessary function and channel blocks and can be adapted to the project-specific conditions by
instantiation.
The BCM's are based on the SIMATIC PCS 7 Advanced Process Library (APL) and Industry Library (IL), are hardware-
independent, pre-configured and modular.
The library provides the following CMT groups:

• MonAn: Analog measured value display

• MonDi: Digital measured value display (binary signal)
• OpAn: Setting an analog value by the operator
• OpDi: Setting a binary value by the operator
• PIDConL Controller for standard and cascade control loops
• Mot: Motor control with simple speed control
• MotSpdC: Motor control with variable speed control
• Vlv: Valve actuation with two defined positions
• VlvAn: Valve control with analog control valve

NOTE The BCM library uses the name of the central technology block of the APL.

NOTE A detailed description of each CMT with function description, supported variants and control elements
you can find in the application example "Control Module (CM) Technology - Efficient Engineering with
SIMATIC PCS 7" under the link:
https://support.industry.siemens.com/cs/ww/en/view/109475748

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 16

Control Module

4.3. "ModPreCon" 4x4 multivariable

controller
The multivariable controller CMTs contains controller blocks, a control performance monitoring system, interface blocks
(slave/actuator) and the link to sequential function charts.
The CMTs are pre-configured for different areas of application. Using options, you select or deselect blocks, e.g. the
channel blocks, that are needed for the application.
The following CMTs are available:

• "ModPreCon" for multivariable control using up to four controlled variables

• "ModPreCon4Valve" for one controlled variable with several disturbance variables

4.3.1. Standard multivariable controller

CMT "ModPreCon" is used for multivariable controllers. Unlike the "PIDCon", multivariable controllers master up to four
manipulated and controlled variables that are interacting with each other.
The instance receives the process variables with standardization from the "MonAn" process tags via "from_Indicate_x". The
number of controlled variables is determined by activating options "Ctrl_PV_3” and "Ctrl_PV_4”. It is not possible to
deselect "Ctrl_PV_1" and "Ctrl_PV_2" and they correspond to the smallest configuration. Each "Ctrl_PV_x" option contains
the monitoring of control performance, interface blocks for the process variable ("MonAn") and controller process tag as
well as the setpoint tolerance limits and manipulated variable tracking.
Due to the complex control tasks (affected by up to four manipulated variables) and the required computing power, the
multivariable controller is used by preference for slow control loops.
Examples of multivariable controllers include:

• Control of drying processes (product quality)

• Control of distillation columns (rectification)

Structure
Chart partion A

Sheet 1 Sheet 4

Sheet 2 Sheet 5

Sheet 3 Sheet 6

Chart partition A
The following blocks are located on sheet 1:

• MPC ("ModPreCon"): Multivariable controller

• AutoExcitation ("AutoExci"): Process excitation signals for the MPC (during commissioning of the controller only)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 17

Control Module
Blocks for static operating point optimization of controlled variables of the MPC controller are located on sheet 2:

• SP1OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP1

• SP1OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP1
• SP2OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP2
• SP2OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP2
• SP3OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP3
• SP3OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP3
• SP4OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP4
• SP4OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP4

NOTE In the case of operating point optimization, you do not specify an exact setpoint (e.g. SP1) for a
controlled variable; rather, a tolerance range is specified. The associated command value (CV1) may be
within this tolerance. Due to this tolerance definition, the controller works more flexibly and more
economically, since it does not have to control continuously to a fixed value.

The following blocks are located on sheet 3:

• MV1_TrkOn ("Or04"): Forced manipulated variable (MV1) for the MPC controller in the case of a hardware fault
(CV_Bad) or if cascade switching is interrupted between the MV1 PID controller and the slave controller
• MV2_TrkOn ("Or04"): Forced manipulated variable (MV2) for the MPC controller in the case of a hardware fault
(CV_Bad) or if cascade switching is interrupted between the MV2 PID controller and the MV2 slave controller
• MV3_TrkOn ("Or04"): Forced manipulated variable (MV3) for the MPC controller in the case of a hardware fault
(CV_Bad) or if cascade switching is interrupted between the MV3 PID controller and the MV3 slave controller
• MV4_TrkOn ("Or04"): Forced manipulated variable (MV3) for the MPC controller in the case of a hardware fault
(CV_Bad) or if cascade switching is interrupted between the MV4 PID controller and the MV4 slave controller

The blocks below for monitoring and display of the control performance and the control deviation are located on sheet 4:

• Suppr_CPM_Calc_1 ("Or04"): Suppression of CPI calculation and message if message suppression was caused at an
"MPC_CPM_x" (CPI_SuRoot = 1) or a warning is active due to low control performance (CPI_WL_Act = 1).
• Suppr_CPM_Calc_2 ("Or04"): Suppression of CPI calculation and message if message suppression was caused at an
"MPC_CPM_x" (CPI_SuRoot = 1) or a warning is active due to low control performance (CPI_WL_Act = 1).
• Suppr_CPM_Calc_3 ("Or04"): Suppression of CPI calculation and message if message suppression was caused at an
"MPC_CPM_x" (CPI_SuRoot = 1) or a warning is active due to low control performance (CPI_WL_Act = 1).
• Suppr_CPM_Calc_4 ("Or04"): Suppression of CPI calculation and message if message suppression was caused at an
"MPC_CPM_x" (CPI_SuRoot = 1) or a warning is active due to low control performance (CPI_WL_Act = 1).
• MPC_CPM_1 ("ConPerMon"): Block for permanent monitoring of control performance (SP1Out, MV1 and CV1Out)
• MPC_CPM_2 ("ConPerMon"): Block for permanent monitoring of control performance (SP2Out, MV2 and CV2Out)
• MPC_CPM_3 ("ConPerMon"): Block for permanent monitoring of control performance (SP3Out, MV3 and CV3Out)
• MPC_CPM_4 ("ConPerMon"): Block for permanent monitoring of control performance (SP4Out, MV4 and CV4Out)
• QI_1 ("MonAnL"): Display and limit monitoring of the average value of control deviation for the TimeWindow specified
in "MPC_CPM_1"
• QI_2 ("MonAnL"): Display and limit monitoring of the average value of control deviation for the TimeWindow specified
in "MPC_CPM_2"
• QI_3 ("MonAnL"): Display and limit monitoring of the average value of control deviation for the TimeWindow specified
in "MPC_CPM_3"
• QI_4 ("MonAnL"): Display and limit monitoring of the average value of control deviation for the TimeWindow specified
in "MPC_CPM_4"

The following blocks are located on sheet 5:

• from_Indicate_1 ("ComStruOut"): Reception of signals (measured value, unit, scaling and messages) of the first
process value to be controlled
• from_Indicate_2 ("ComStruOut"): Reception of signals (measured value, unit, scaling and messages) of the second
process value to be controlled
• from_Indicate_3 ("ComStruOut"): Reception of signals (measured value, unit, scaling and messages) of the third
process value to be controlled

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 18

Control Module
• from_Indicate_4 ("ComStruOut"): Reception of signals (measured value, unit, scaling and messages) of the fourth
process value to be controlled
• SPLim_1 ("StruScIn"): Upper and lower setpoint limit of the first process value
• SPLim_2 ("StruScIn"): Upper and lower setpoint limit of the second process value
• SPLim_3 ("StruScIn"): Upper and lower setpoint limit of the third process value
• SPLim_4 ("StruScIn"): Upper and lower setpoint limit of the fourth process value
• CSF ("Or04"): Formation of an OR output signal of the hardware faults of the channel blocks of the process values for
tracking the respective controller
• OosAct ("Or04"): Formation of an OR output signal of the "OosAct" message of the channel blocks (field device is being
maintained) of the controlled variables for the MPC

The link blocks below, which are used for rapid engineering, are located on sheet 6:

• from_CTRL_1 ("ComStruOu"): Reception of control commands of the lower level PID controller for the MPC controller
parameters ("MV1ManHiLim", "MV1ManLoLim", and "MV1Trk") and the "MV1_TrkOn" block.
• to_CTRL_1 ("ComStruIn"): Output of the manipulated variable as a setpoint to the lower-level PID controller.
• from_CTRL_2 ("ComStruOu"): Reception of control commands of the lower level PID controller for the MPC controller
parameters ("MV2ManHiLim", "MV2ManLoLim", and "MV2Trk") and the "MV2_TrkOn" block.
• to_CTRL_2 ("ComStruIn"): Output of the manipulated variable as a setpoint to the lower-level PID controller.
• from_CTRL_3 ("ComStruOu"): Reception of control commands of the lower level PID controller for the MPC controller
parameters ("MV3ManHiLim", "MV3ManLoLim", and "MV3Trk") and the "MV3_TrkOn" block.
• to_CTRL_3 ("ComStruIn"): Output of the manipulated variable as a setpoint to the lower-level PID controller.
• from_CTRL_4 ("ComStruOu"): Reception of control commands of the lower level PID controller for the MPC controller
parameters ("MV4ManHiLim", "MV4ManLoLim", and "MV4Trk") and the "MV1_TrkOn" block.
• to_CTRL_4 ("ComStruIn"): Output of the manipulated variable as a setpoint to the lower-level PID controller.

NOTE The process value is made available to the MPC by linking the MonAn control module ("to_Indicate"
block) with the "from_Indicate_x" block.

4.3.2. Predictive controller for only one controlled

variable
The "ModPreCon4Valve" CMT is used for fixed value controllers where the controlled variable is affected by one or more
measurable disturbance variables, e.g. pH value control.
The MPC gets the units and standardization automatically from the connected interface blocks, from the controlled and
manipulated variables, and from at least one disturbance variable.

NOTE The number of disturbance variables is determined by activating option '"Opt_DVx" and
interconnecting the respective process value. The disturbance variables are interconnected with the
following MPC inputs:

• 1st disturbance variable at the DV1 input of the MPC (activated as standard)
• 2nd disturbance variable at the MV2Trk input of the MPC (optional)
• 3rd disturbance variable at the MV3Trk input of the MPC (optional)
• 4th disturbance variable at the MV4Trk input of the MPC (optional)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 19

Control Module
Structure

Chart partion „A“

Sheet 1 Sheet 4

Sheet 2 Sheet 5

Sheet 3 Sheet 6

Chart partition A
The following blocks are located on sheet 1:

• MPC ("ModPreCon"): Multivariable controller

• AutoExcitation ("AutoExci"): Process excitation signals for the predictive MPC (during commissioning of the controller
only)
Blocks for static operating point optimization of the controlled variable of the MPC controller are located on sheet 2:

• SP1OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP1

• SP1OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP1

The blocks below for monitoring and display of the control performance and the control deviation are located on sheet 4:

• MPC_CPM ("ConPerMon"): Block for permanent monitoring of control performance (SP1Out, MV1 and CV1Out)
• QI ("MonAnL"): Display and limit monitoring of the average value of control deviation for the TimeWindow specified in
"MPC_CPM"

The following blocks are located on sheet 5:

• from_CV ("ComStruOut"): Receiving of signals (measured value, unit, scaling and messages) of the controlled variable
• CV_Lim ("StruScIn"): Upper and lower setpoint limit of the controlled variable
• from_DV1 ("ComStruOut"): Receiving of signals (measured value, CSF-signal and unit) of the first disturbance variable
• from_DV2 ("ComStruOut"): Receiving of signals (measured value, CSF-signal and unit) of the second disturbance
variable
• from_DV3 ("ComStruOut"): Reception of signals (measured value, CSF-signal and unit) of the third disturbance
variable
• from_DV4 ("ComStruOut"): Reception of signals (measured value, CSF-signal and unit) of the fourth disturbance
variable

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 20

Control Module
• CSF ("Or04"): Formation of an OR output signal of the hardware faults of the controlled variable channel blocks and
the control valve for tracking the manipulated variable
• OosAct ("Or04"): Formation of an OR output signal of the "OosAct" message of the channel blocks (field device is being
maintained) of the controlled variables and the control valve for the MPC

NOTE The process values of the controlled variable and the disturbance variables are made available to the
MPC by linking the MonAn control modules ("to_Indicate" block) with the "from_CV", "from_DVx"
block.

The link blocks below, used for rapid engineering, are located on sheet 6.

• to_Actor ("ComStruIn"): Transfer of the manipulated variable (MV1), and the locking status (OosAct) to the actuator.
• from_Actor ("ComStruOu"): Reception of signals and standardization and unit of the actuator for the MPC (CSF,
OosAct, ScaleOut, Unit).
• MV1_Scale ("StruScIn"): Upper and lower manipulated variable limit for limiting the manipulated variable in the
controller in manual and automatic modes.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 21

Control Module

4.4. "PIDCon” controller

The controller CMTs contain controller blocks, additional monitoring and interlock functions, interface blocks
(master/actuator), and a link to sequential function charts.
The CMTs are pre-configured for different areas of application.
The following controller CMTs are available:

• "PIDCon” for standard PID controllers

• "PIDConRatio" for ratio controllers
• "PIDConSplitRange” for controllers with one manipulated variable and two actuators

4.4.1. Standard controller

The "PIDCon” CMT is used for fixed-value and cascade controllers and is a component from the Basic Control Modules
(BCM). The detailed description of the you can find in the application example "Control Module (CM) Technology -
Efficient Engineering with SIMATIC PCS 7" under the link:
https://support.industry.siemens.com/cs/ww/en/view/109475748

Examples of standard controllers include:

• Fill level controller with inflow and outflow

• Temperature control

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 22

Control Module

4.4.2. Ratio controller

The "PIDConRatio” control module type is used for ratio controllers. Ratio controllers are composed of a flow controller (for
the main component) and a flow controller for each additional component. The instance of "PIDConRatio” is used for the
component that is to be added in a defined ratio, e.g. the blended component.

NOTE In "Plant View”, you activate master/slave operation by selecting "Opt_IF_Master”. After activation, the
"to_Master” and "from_Master” link blocks are available.

Using variants, the corresponding channel block is selected or deselected based on measured value transfer.
In addition, it is possible to use options to activate further functions without configuration at the CMT instance.
Variants and options are listed and described below.

Variant 1: Controller for analog measurement and manipulated variable (4-20 mA)
Variant 1 is activated by selecting functions PV_In and Opt_PV_Scale at the instance.

Variant 2: Controller for thermocouples

This variant is used for thermocouples that are connected to an analog input module for temperature measurement.
Variant 2 is activated by selecting function PV_TE_In at the instance.

NOTE Scaling on the channel block has already been preset for the range 0 to 1.
You must carry out process value scaling at input "NormPV” of display block "C”.

Variant 3: Controller for digital measurement (field bus)

This variant is used if you are using measuring devices with Profibus PA or Fieldbus Foundation (FF).
Variant 3 is activated by selecting functions PV_Fb_In and Opt_PV_Scale on the instance.

Variant 4: Controller for software signal

Variant 4 is the default setting without additional functions activated at the instance. In this variant, the process value is
obtained by direct CFC connection from existing process tags. Using the optional DeltaCalc function, it is possible to apply
difference measurement for the controlled variable.
Optional functions for all variants:

• PV_Scale#: Standardization of the process value including the channel block

• CPM: Monitoring of the control quality
• IF_Master#: Connection to a master controller (cascade)
• PV_DeltaCalc#: Differentiation
• Interlock: Interlocking block

The figure below lists the available options.

PV_TE_In
PV_Fb_In
PV_DeltaCálc
IF_Master#
PV_Scale#

PV_In
Intlock
CPM

PIDConRatio
(CMT Master Data Library)

Variants Function Channel block Description

PIDConRatio_Std x o o o x Standard display (analog)
PIDConRatio_TE o o o o x Measured value display for thermocouples
PIDConRatio_Fb x o o o x Measured value display fieldbus
PIDConRatio_SW o o o o o Program logic without channel blocks
x = Selecting a variant o = Selectable functions

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 23

Control Module
Examples of ratio controllers include:

• Blending control of liquids or gases with a defined mixing ratio

• Air feed in a defined ratio to fuel gas feed for gas burners

NOTICE When using the Plant Automation Accelerator (PAA) V2.1, the variant "PV_Scale#" should not be used.
The scaling is set in PAA at the respective signal and adopted by the appropriate "Scale" input when
exporting to SIMATIC PCS 7.

NOTE In "plant view", you activate master/slave operation by selecting "IF_Master#". After activation, the
"to_Master" and "from_Master" link blocks are available.

Structure

Chart partion „A“ Chart partion „B“

Sheet 1 Sheet 4 Sheet 1

Sheet 2 Sheet 5 Sheet 2

Sheet 3 Sheet 6 Sheet 3

Chart partition "A"

The following blocks are located on sheet 1:

• PV_Scale: Standardization of the process value for a channel block and measured value display
• PV_Unit: Standardization of the unit for a channel block and displaying measured values
• C ("PIDConL"): PID controller
• CPM ("ConPerMon"): Block for permanent monitoring of control quality
The outputs, operating mode, setpoint, actual value and manipulated variable of the PID controller are interconnected
with the CPM block
The following blocks are located on sheet 2:

• AIF_SFC ("ConnPID"): A free block for SFC linking (not a component of the APL or the standard library)
• Logic blocks for selecting the operating mode and for interlocking
- SP_LiOp ("Or04"): Setpoint source internal/external
- SP_IntLi ("Or04"): Internal setpoint via interconnection
- MV_Forced ("SelA02In"): Forced manipulated variable with selection ("In1" undefined, "In2" SFC link)
- MV_ForOn ("Or04"): Activates forced manipulated variable "In2" (MV_Forced) on the PID controller
- ManModOpLi ("Or04"): Formation of an OR output signal from field device in maintenance (channel blocks PV and
MV) and invalid process value (channel block PV in chart partition "B", Sheet 1.)
- ModLiOp ("Or04"): Operating mode selection between operator and interconnection or SFC
- ManModLi ("Or04"): Manual mode via interconnection or SFC (controlled via ModLiOp = 1)
Using the SFC link, data that is relevant to production is transferred to the PID controlling via the logic blocks. In addition,
channel blocks and the interlocking block (chart partition "A", Sheet 3) affect the output signals of the logic blocks.
Sheet 3 contains the "Intlock" interlocking module, which combines signals for standardized interlocking with the option
of displaying them on the OS.
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 24
Control Module
The link blocks below, used for rapid engineering, are located on sheet 6.

Chart partition "B"

The channel blocks are located on sheet 1:

• PV ("Pcs7AnIn"): Channel block for signal processing of an analog measured value, e.g. 0/4 to 20mA
• PV_TE ("Pcs7AnIn"): Channel block for signal processing of a resistance thermometer
• PV_FB ("FBAnIn"): Channel block for signal processing of a digitized process value (PA or FF processing unit)

The modules for the difference display are located on sheet 2:

• PV_DeltaCalc ("Sub02"): Formation of a difference value from two process values, e.g. differential pressure
• FromDeltaIn1: Input 1 for the difference value
• FromDeltaIn2: Input 2 for the difference value
• PV_IN ("Add08"): Merging the "PV_In" signals (analog process value)
• CSF ("Or04"): Grouping of the "Bad" signals (invalid process value) and reporting to the motor block and the Permit
group block
• OosAct ("Or04"): Grouping of the "OosAct" signals (device being maintained) and reporting to the motor block

NOTE If a thermocouple is used, you must carry out scaling at channel block "PV_TE" measured value display
in addition to scaling at block PV_Scale (process value scaling).

NOTICE The channel block for the thermocouple has already been preset for the range 0.0 to 1.0.

On sheet 2, the system additionally acquires the messages of the valve process tag channel block at blocks CSF and
OosAct and transfers them to the controller.
In the case of a positive "OosAct" signal, the controller switches to manual mode.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 25

Control Module

4.4.3. Split range controller

The "PIDConSplitRange” control module type is used for controllers where one manipulated variable controls several
actuators (with a limited effective range and possibly the opposite direction of control action), i.e. the manipulated
variable is split to several actuators.

NOTE In "Plant View”, you activate master/slave operation by selecting "Opt_IF_Master”. After activation, the
"to_Master” and "from_Master” link blocks are available.

Variant 1: Controller for analog measurement and manipulated variable (4-20 mA)
Variant 1 is activated by selecting functions PV_In and Opt_PV_Scale at the instance.

Variant 2: Controller for thermocouples

This variant is used for thermocouples that are connected to an analog input module for temperature measurement.
Variant 2 is activated by selecting function PV_TE_In at the instance.

NOTE Scaling on the channel block has already been preset for the range 0 to 1.
You must carry out process value scaling at input "NormPV” of display block "C”.

Variant 3: Controller for digital measurement (field bus)

This variant is used if you are using measuring devices with Profibus PA or Fieldbus Foundation (FF).
Variant 3 is activated by selecting functions PV_Fb_In and Opt_PV_Scale on the instance.

Variant 4: Controller for software signal

• PV_Scale#: Standardization of the process value including the channel block

• CPM: Monitoring of the control quality
• IF_Master#: Connection to a master controller (cascade)
• PV_DeltaCalc#: Differentiation
• Interlock: Interlocking block

The figure below lists the available options.

PV_DeltaCalc#

PV_TE_In
PV_Fb_In
IF_Master#
PV_Scale#

PV_In
Intlock
CPM

PIDConSplitRange
(CMT Master Data library)

Variants Function Channel block Description

PIDConSplitRange_Std x o o o x Standard display (analog)
PIDConSplitRange_TE o o o o x Measured value display for thermocouples
PIDConSplitRange_Fb x o o o x Measured value display fieldbus
PIDConSplitRange_SW o o o o o Program logic without channel blocks
x = Selecting a variant o = Selectable functions

Examples of split-range controllers with opposite direction of control action include:

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 26

Control Module
• Temperature controllers with separate actuators for heating and cooling, e.g. valves for heating steam and cooling
water, or electric heating and fan cooling.
• Pressure control with separate valves for gas feed and purge

Moreover, there are split range applications with several actuators with the same direction of action (that individually
would not be strong enough), e.g.

• Oxygen control in bio fermenters via air feed and stirrer speed.
• Oxygen control in wastewater treatment plants via several compressors.

Structure

Chart partition „A“ Chart partition „B“

Sheet 1 Sheet 4 Sheet 1

Sheet 2 Sheet 5 Sheet 2

Sheet 3 Sheet 6 Sheet 3

The control module type is preconfigured for the following setpoint range:

• Manipulated variable 0 to 100 (from the controller)

• Manipulated variable 50 to 100 corresponds to travel range 0 to 100 with actuator 1
• Manipulated variable 50 corresponds to the neutral position, i.e. both actuators are closed
• Travel range 0 to 50 corresponds to travel range 100 to 0 with actuator 2

Chart partition "A"

The following blocks are located on sheet 1:

• AIF_SFC ("ConnPID"): A free block for SFC linking (not a component of the APL or the standard library)
• Logic blocks for selecting the operating mode and for interlocking
- SP_LiOp ("Or04"): Setpoint source internal/external
- SP_IntLi ("Or04"): Internal setpoint via interconnection
- MV_Forced ("SelA02In"): Forced manipulated variable with selection ("In1" undefined, "In2" SFC link)
- MV_ForOn ("Or04"): Activates forced manipulated variable "In2" (MV_Forced) on the PID controller
- ManModOpLi ("Or04"): Formation of an OR output signal from field device in maintenance (channel blocks PV and
MV) and invalid process value (channel block PV in chart partition "B", Sheet 1.)
- ModLiOp ("Or04"): Operating mode selection between operator and interconnection or SFC
- ManModLi ("Or04"): Manual mode via interconnection or SFC (controlled via ModLiOp = 1)
Using the SFC link, data that is relevant to production is transferred to the PID controlling via the logic blocks. In addition,
channel blocks and the interlocking block (chart partition "A", Sheet 3) affect the output signals of the logic blocks.
Sheet 3 contains the "Intlock" interlocking module, which combines signals for standardized interlocking with the option
of displaying them on the OS.
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 27
Control Module
The link blocks below, used for rapid engineering, are located on sheet 6.

• to_Actor_Slave ("ComStruIn"): Transfer of the manipulated variable (MV), setpoint value (SP), process value (PV), and
the locking status to the actuator or slave (slave in the case of cascade control)
• from_Actor_Slave ("ComStruOu"): Reception of the actuating signal feedback (Rbk), the message with invalid process
values, and field device maintenance of channel blocks MV and Rbk, of the out unit and scaling of the actuating
display and travel range (ScaleOut) of the actuator or slave (slave in the case of cascade control)
• to_Master ("ComStruIn"): The communication block forms a structure consisting of outputs (setpoint, block is "out of
service" message, message for cascade switching, process value), of the PID controller, of the CSF block (message of
the channel blocks in the case of an invalid process value), and of channel blocks PV and MV (unit and scaling of the
process value).
• from_Master ("ComStruOu"): The communication block receives from the controller process tag of the main
component the signals of the CSF block and the setpoint of the PID controller that are relevant to interlocking.
• SplitRange ("SplRange"): block to split the manipulated variable MV from the PID controller. The segmentation is based
on the set parameters.
• to_Actor_Slave2 ("ComStruIn"): Transfer of the manipulated variable (MV), setpoint value (SP), process value (PV), and
the locking status to the actuator or slave (slave in the case of cascade control)
• from_Actor_Slave2 ("ComStruOu"): Reception of the actuating signal feedback (Rbk), the message with invalid process
values, and field device maintenance of channel blocks MV and Rbk, of the out unit and scaling of the actuating
display and travel range (ScaleOut) of the actuator or slave (slave in the case of cascade control)
• SplitRangeCut ("Or04"): Grouping of the disconnect signals from the cascaded valves to the controller.

Chart partition "B"

The channel blocks are located on sheet 1:

The modules for the difference display are located on sheet 2:

NOTE If a thermocouple is used, you must carry out scaling at channel block "PV_TE" measured value display
in addition to scaling at block PV_Scale (process value scaling).

NOTICE The channel block for the thermocouple has already been preset for the range 0.0 to 1.0.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 28

Equipment Modules

5. Equipment Modules
In this chapter, you will find all the relevant information for each equipment module including specific properties. The
structure and basic functionality of the control module types that are used are described in Chapter 4 "Control Module".
The following equipment modules are described below:

• "Level-control"
• Buffer level control with feedforward disturbance compensation "Buffer-Control"
• "Split-Range-Pressure" control
• "Ratio-Control"
• "Split-Range-Temperature" control
• pH value control using the "pH-Control-Std" standard controller
• pH value control using the "pH-Control-MPC" model predictive controller
• Temperature cascade control via slave flow control loop "Temperature-Flow-Cascade"
• Coarse-/Finestream control using the "Stream-Control”
• Gradient limits in actuators "Gradient-Limit"

NOTE Below, we will use the designations CM for control module and CMT for control module type.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 29

Equipment Modules

5.1. "Level-Control" in process plants

Introduction
Depending on the tasks that a container (e.g. vessel, tank, reactor) has to fulfill in a process plant, there are different
objectives for a level controller. The two following control strategies are the most common in process industry:
1. Keeping a level as close as possible to a specified setpoint, e.g. in a reactor or the sump of a column. This is necessary
if the level affects chemical reactions or separation processes, i.e. it is significant to the process. Fluctuations in the
inflow are compensated via variation of outflow to keep the level constant.
2. Use a container (e.g. a tank) as a buffer to achieve an inflow or outflow that is as uniform as possible. In this context,
the system does not maintain a fixed level value exactly at the setpoint; the level just has to stay within permissible
limits. This task is called "buffering controller" and characterizes the majority of industrial applications.

5.1.1. Exact level control

In the case of exact level control, input materials are fed via inlet lines to a tank and the mixture is removed via an outlet.
The controller responds to deviations in the fill level (caused by differences between the amount flowing in and out) and
compensates for them by either decreasing or increasing inflow or outflow.
For exact control of fill levels, a standard design with the PID tuner makes sense. In this context, you should be aware that
most fill level processes have integrating behavior (e.g. outflow as a manipulated variable). In many cases, a proportional-
only controller (without integral action) is adequate, which harmonizes more easily with the integrating process dynamics
but shows permanent control errors if there are disturbances in the inflow. If the valve characteristic curve is non-linear, it
is recommended in practice to use a cascade structure. The master controller regulates the fill level via specification of
setpoints for the slave (out)flow controller, provided flow measurement at the outflow is available.
In the example below, level control is performed by directly manipulating the outlet valve, i.e. without slave flow
controller.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 30

Equipment Modules
Overview
Below, the structure in the P&ID schematic is shown and all of the CMs and the simulation of the equipment module are
described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and containers relevant to operation.

FI
Inlet

Inflow

LIC
Level

YC FI
Outlet_Level Outlet

Outflow

CM and variants
The "Level Control" equipment module consists of four connected CMs and one simulation chart. The fill level of a
container is simulated in the "Sim_Level” simulation chart with the help of a non-linear model. In addition, the response of
the valve is simulated in this chart, which leads to a more realistic description of dynamic valve behavior. In the
"Sim_Level” simulation chart, the inflow is simulated with the help of a valve module and the valve position provided for
disturbance compensation is added.
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

FI_Inlet_Level "MonAn" • PV Display of container inlet

• PV_Scale#

FI_Outlet_Level "MonAn" • PV Display of container discharge

• PV_Scale#

LIC_Level "PIDCon" • CPM Level control of a container

• PV
• PV_Scale#

YC_Outlet_Level "ValAn" • GI Outlet valve for container discharge with

• Intlock safety position to prevent overflow
• IF_Ctrl#
• MV_Scale#
• YC

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 31

Equipment Modules
In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_Level LIC_Level YC_Outlet_Level

PT1
PV V
In
SimPV_In MV

PV_in_percent
to_Actor1 from_Ctrl
OUT
Out Out

mul_p_Hydro
from_Actor1 to_Ctrl
OUT
In Out

ValvelDeadtime
VlvAnL
Out FI_Outlet_Level
Rbk
PV
ScaleInlet SimPV_In
OUT FI_Inlet_Level
PV
SimPV_In

Control "LIC_Level" acquires the fill level of the container ("Sim_Level” simulation chart) and regulates it using
"YC_Outlet_Level” control valve. In addition, the two process tags "FI_Outlet_Level" and "FI_Inlet_Level” serve the purpose
of displaying inflow and discharge in the OS.

Structure and parameterization

"Sim_Level" simulation
The structure and the parameterization of the "Sim_Level" simulation used is explained in Section 5.1.3.

LIC_Level
The instance has the following parameterization.
Block Connection Value Use

PV_Unit In 1342 Process value unit in %

C NegGain Activation of negative gain, since the controller is

used for the outflow

C Gain 2 Controller gain

C TI 111.96 Controller lag

C PV_AH_Li 95.0 Upper alarm limit for the process value

C PV_AH_En 1 Enable upper alarm limit

C PV_AH_Ac Interconnection to the outlet valve

(LIC_Level\to_Actor_Slave.BoStru3)

IF_SFC SP_Ext Connection for operator setpoint input for comparison

(Compare\SP_Level.PV_In)

to_Actor_Slave BoStru3 Interconnection to PID controller

(LIC_Level\C.PV_AH_Ac)

to_Actor_Slave Out Interconnection to the valve

(YC_Outlet_Level\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_Outlet_Level\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_Level\PV_in_percent.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 32

Equipment Modules
YC_Outlet_Level
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection to the valve simulation

(Sim_Level\PT1.In)

V SafePos 1 Safety position is open status

V Monitor 1 Display of Checkback signal in the OS

from_Ctrl In Interconnection to the controller

(LIC_Level\to_Actor_Slave.Out)

from_Ctrl BoStru3 Interconnection to the Interlock

(YC_Outlet_Level\Intlock.In1)

to_Ctrl Out Interconnection to the controller

(LIC_Level\to_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

Intlock InvIn01 1 Inversion of Input 01

Intlock Logic OR OR input interconnection

Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "LIC_Level" and change the operating mode of the controller to "Automatic".
4. Enter a setpoint of 50 %.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 33

Equipment Modules
5. Switch to "Sim_Level/Sim_Flow_Rate” valve and change the setpoint to 50 %

6. Wait for about 3 minutes and enter a new setpoint of 25 % for the "Sim_Level/Sim_Flow_Rate” valve.
7. Close the faceplate and observe the plotter for about two minutes until the new setpoint has been reached again.
8. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Evaluation

After the inflow reduction, the level drops below the setpoint. The controller observes the level change and then reduces
the setpoint of the discharge valve until the level once again reaches the setpoint. Control towards the setpoint, however,
causes permanent fluctuations in the manipulated variable for the discharge valve.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 34

Equipment Modules

5.1.2. Buffer level control with feedforward

disturbance compensation "Buffer-Control"
In process plants, tanks are often employed as buffer containers. An exact level control is not necessary provided the level
remains within defined limits. Instead, the controller has to work with as few interventions as possible. This reduces wear
on the valves and at the same time reduces resource consumption (compressed air, etc.). In some applications, the
primary aim is to achieve an outflow of the container that is as even as possible, such that subsequent apparatuses
receive an inflow which is as even as possible. Common controller design methods (e.g. PI control with deadband) deliver
less-than-satisfactory results, because the uncontrolled process is not asymptotically stable. Typically, there will be
oscillations at the edge or between high and low limit of the deadband.
In this example, we will show the advantages of buffer control including feedforward disturbance compensation.
Feedforward control reacts faster to disturbances and largely prevents leaving the dead zone. For this, any measured
variable representative of the tank inflow, for example a flow measurement, a valve position, or a pump rotational speed,
is connected as a feedforward disturbance compensation signal with its own deadband. The deadband of the buffer
controller is activated or deactivated dynamically.

Mode of operation
In the case of a closed-loop control with deadband, the manipulated variable is not changed as long as the controlled
variable moves within the parameterized limits of the deadband. Only if the values leave the deadband, the feedback
controller and consequently the final actuator become active.
If the controller is active, the deadband is dynamically switched off until the controlled variable is again in the center of
the deadband. This prevents a permanent fluctuation at the edge of the deadband.

NOTE The actuator activity can be further reduced by means of low-pass filtering of the disturbance variable.
This has no effect on the stability of the control loop because the low-pass filter is only in the
feedforward variable and not in the feedback path of the closed control loop. In addition, the
feedforward control is provided with its own deadband in order to further reduce actuator activity.

Controller design
In context of a buffer control task, the required behavior is different from exact level control. In buffer control, the tank
volume is used selectively to compensate for inflow fluctuations. Two options are available when doing this:

• The fill level is not measured continuously at all; rather, the minimum and maximum limits are monitored by binary
(e.g. capacitive) fill level switches. Continuous control is not used for this solution; rather, discrete-event control is
used, i.e. a binary signal is used to close the inflow or outflow.
• Controller tuning is purposefully set slower. Within the scope of the specification, the maximum permissible deviation
Δhmax of the fill level from the setpoint is defined, as well as the maximum hight d max of inflow step disturbances to be
expected. With regard to permanent control deviation, the gain of a P controller must be defined as greater than
Gain= dmax / Δhmax. You can also set up a PI controller such that the maximum deviation of fill level after step
disturbance is less than dmax. In the Dechema Seminar entitled "Process Controls – From the the Basics to Advanced
Control" (www.dechema.de), the formulas below are recommended:
- GainEff = 0.7358 dmax / Δhmax
- Ti = 5.4366/Ki * Δhmax / dmax

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 35

Equipment Modules

NOTE The physical controller gain is in units MV_Unit/PV_Unit. In case of normalization (NormPV ≠ NormMV),
gain must be converted according to the following formula:
Gain = GainEff * (NormPV.High - NormPV.Low) / (NormMV.High - NormMV.Low)

It is possible to determine the integration constant Ki of the controlled process in the unit PV_Unit/s using the PID tuner.
You can find the integration constants at "Gain" in the "Process parameter" sector.

• In order to avoid permanent control deviations, the proportional-only controller is enhanced with feedforward
disturbance compensation. This alternative is implemented in the template. In this case, the formulas with respect to
disturbance amplitude mentionend in the above paragraph are not relevant. The controller can be designed with any
standard approach considering stability and control performance, e.g. with PCS 7 PID-Tuner. During application of PID-
Tuner take care that the disturbance variable stays as even as possible during data logging for step testing. After
tuning, the level controller is temporarely run without deadband to verify loop dynamics, before activating deadband
in order to smooth outflow variations.

Overview

P&I Diagram
The P&I diagram below symbolically represents all of the components, such as field devices and tanks relevant to
operation.

Inflow FI
Inlet

DV (FFWD)

LIC
Buffer

YC FI
Outlet_Buffer Outlet

Outflow

CM and variants
The "BufferControl" equipment module consists of three connected control modules, a CFC chart for the dynamic
deadband of the feedforward disturbance compensation and a simulation plan. The level of a container is simulated in the
"Sim_Buffer” simulation chart with the help of a non-linear model. In addition, the dynamic response of the valve is
simulated in this chart, which leads to a more realistic model of valve behavior. In the "Sim_Buffer” simulation chart, the
inflow is simulated with the help of a valve module and valve position is provided as disturbance variable.
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 36
Equipment Modules
The following table provides an overview of the components of the equipment module including the associated control
modules.
CM CM Selected variants Description

FI_Inlet_Buffer "MonAn" • PV Display of the container inlet

• PV_Scale#

FI_Outlet_Buffer "MonAn" • PV Display of container discharge

• PV_Scale#

LIC_Buffer "Ctrl" • CPM Level control

• PV
• PV_Scale#

YC_Outlet_Buffer "ValAn" • GI Outlet valve for container discharge with safety

• Intlock position to prevent overflow
• IF_Ctrl#
• MV_Scale#
• YC

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_Buffer Dyn_Deadband YC_Outlet

Flow_Limit Flow_Smoothing
V
OUT In
MV

PT1 Flow_to_MV
from_Ctrl
In Out
Out

ValvelDeadtime
to_Ctrl
Out
Out

PV_in_percent LIC_Buffer VlvAnL

OUT
IF_SFC Rbk
FFwd
mul_p_Hydro
OUT FI_Outlet
PV
PV
ScaleInlet SimPV_In
SimPV_In
OUT
to_Actor1
Out
FI_Inlet
PV
from_Actor1
SimPV_In
In

Control "LIC_Buffer" acquires the fill level of the container and regulates it using "YC_Outlet_Buffer” control valve. In
addition the "Sim_Buffer” transmits the disturbance variable – the inflow into the container – to the "LIC_Buffer” process
tag which adds the "disturbance variable” to the manipulated variable of the controller. In addition, the simulation
generates from the valve state the inlet and outlet of the tank, which visualize over the both display monitors "FI_Inlet"
and "FI_Outlet".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 37

Equipment Modules
Structure and parameterization

Sim_Buffer
The structure and the parameterization of the "Sim_Buffer" simulation used is explained in Section 5.1.3.

LIC_Buffer
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 100.0 Scaling of the process value upper limit

PV_Unit In 1342 Process value unit in %

C NegGain 1 Activation of negative gain, since the controller is

used for the outflow

C Gain 0.8 Controller gain

C TI 0.0 Controller lag

C DeadBand 15.0 Deadband

C SP_InHiLim 100.0 Maximum value of the internal setpoint

C PV_AH_Li 95.0 Upper alarm limit for the process value

C PV_AH_En 1 Enable upper alarm limit

C SettliFa 0.0 Transient recovery time factor to return to deadband

C Feature.Bit30 1 Dynamic deactivation of deadband upon leaving

deadband

C PV_AH_Ac Interconnection to the outlet valve

(LIC_Buffer\to_Actor_Slave.BoStru3)

C PhaseDeadband Interconnection for deadband disabling upon

feedforward control
(DynDeadband\Deadband_disable.In)

IF_SFC SP_Ext Interconnection for operator setting of setpoint for

comparison
(Compare\SP_Level.PV_In)

IF_SFC FFwd Interconnection for disturbance dynamic deadband

(DynDeadband\DV_to_MV.In)

to_Actor_Slave BoStru3 Interconnection to PID controller

(LIC_Buffer\C.PV_AH_Ac)

to_Actor_Slave Out Interconnection to the valve

(YC_Outlet_Buffer\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_Outlet_Buffer\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_Buffer\PV_in_percent.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 38

Equipment Modules

NOTE Determined by the nature of the process, the level does not have to correspond exactly to the setpoint
but must instead be in a mid-container zone instead. For this reason, it is a P-controller with a
relatively small controller gain (<1) and an activated deadband. In order to avoid an oscillation around
the deadband limit, the dynamic deadband disabling is effected via the feature bit 30 of the "PIDConL”
function block. If the fill level leaves the deadband, this is deactivated and the fill level is brought to
the center of the dead zone by the now active control. Only then is the control deactivated again and
the manipulated variable is held.

NOTE Feedforward control is realized via the "PIDConL.FFwd" connection. The value of "FFwd" is internally
added to the manipulated variable "MV" by the controller and thus directly affects the position of the
actuator. The flow measurement of the container inlet is used as the disturbance variable.

Dyn_Deadband
Due to inflow fluctuations, feedforward control leads to a permanent actuator activity despite the active controller
deadband. This undesirable behavior is suppressed in the "Dyn_Deadband" CFC. In order to calculate the appropriate value
for feedforward control, a characteristic curve for the effect of the disturbance variable on level control is stored.
1 4

7
6
3

1. Filtering of steep signal gradients (first order lag with 3 seconds time-constant)
2. Calculation of the upper limit for the adoption of a new disturbance value (Addition)
3. Calculation of the lower limit for the adoption of a new disturbance value (Subtraction)
4. Evaluation as to whether a limit has been exceeded or undercut
5. Deactivation of disturbance variable deadband upon disabling of controller deadband
6. Switchover between new and old disturbance variable
7. Conversion of disturbance variable to manipulated variable signal with the help of a polygon function block

NOTE In practice you will have to determine the interpolation values of the polygon function block either
experimentally or based on pre-existing measurements. When the deadband is disabled, the
associated outflow valve positions are recorded for the various values of the disturbance variable
which lead to the desired constant level. The value pairs "disturbance variable measurement / valve
position" yield the different interpolation points "InX / OutX" of the polygon module.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 39

Equipment Modules
YC_Outlet_Buffer
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection to valve simulation

(Sim_Buffer\PT1.In)

V SafePos 1 Safety position is open status

V Monitor 1 Display of readback signal in the OS

from_Ctrl In Interconnection to the controller

(LIC_Buffer\to_Actor_Slave.Out)

from_Ctrl BoStru3 Interconnection to the Interlock

(YC_Outlet_Buffer\Intlock.In1)

to_Ctrl Out Interconnection to the controller

(LIC_Buffer\to_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

Intlock InvIn01 1 Inversion of Input 01

Intlock Logic OR OR input interconnection

NOTICE Container overflow

In the case of control with deadband, a safety logic must also be implemented in order to avoid
overflow of the container at all costs. For this purpose, an interlock is implemented which forces the
valve immediately into the safety position (in this case open) in the event of an overflow risk.

Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "LIC_Buffer" and change the operating mode of the controller to "Automatic".
4. Enter a setpoint of 50 %.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 40

Equipment Modules

5. Switch to "Sim_Buffer/Sim_Flow_Rate” valve and change the manipulated variable to 50 %

6. Wait for about 3 minutes and then enter a new setpoint of 25 % for the "Sim_Buffer/Sim_Flow_Rate” valve.
7. Close the faceplate and observe the plotter for about two minutes until the setpoint has been reached again.
8. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 41

Equipment Modules
Evaluation

1. After the inflow has been reduced, the feedforward compensation reduces the setpoint of the outflow valve such that
the tank level does not leave the deadband. In this case the controller does not need to intervene.
2. Thanks to the relatively wide deadband, the fill level does not reach the setpoint exactly again, but instead remains
slightly below the setpoint. However, for this no further intervention of the controller via the outlet valve is necessary,
so that the valve can be operated in a low-wear manner. Outflow keeps constant for longer time intervals.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 42

Equipment Modules

5.1.3. Simulation - structure and parameterization

"Sim_Buffer" and "Sim_Level" simulations are of identical structure and are valid for the level controls in Sections 5.1.1
and 5.1.2. This means the results obtained from the diverse control concepts can be compared with each other.
Each simulation consists of three separate sheets: Part 1 contains the simulation of the level and calculates the flow rate
of the outflow.
1

3 4 5

7 8

1. Calculation of the flow for the inlet (valve opened by 100 % corresponds to inflow of 250 l/s)
2. Calculation of the flow for the outlet (valve opened by 100 % corresponds to inflow of 0.48 m²)
3. Determination of level change (addition of inflow and subtraction of discharge)
4. Formation of an integral value by integrating the change in flow (every second)
5. Delay in level (PT1 response with 3.5-second delay)
6. Calculation of flow rate for discharge according to Torricelli’s Law
7. Creation of measurement noise
8. Conversion of level into percentage

NOTE According to Torricelli’s Law, the higher the level, the higher the flow speed in the container outflow,
proportional to the square root of the fill level. As a consequence, for the same valve position the
discharge rate will vary depending on the fill level of the container:

Torricelli’s efflux velocity theorem: v ~ √2 ∙ g ∙ h

q = A ∙v
v: Efflux rate g: Gravitational
constant
h: Fill height A: Efflux cross-section
q: Outflow quantity

On sheet 2 an equal percentage characteristic line for the outlet valve is simulated.
In addition, the valve reaction is delayed with respect to the valve position setpoint, and the valve position is discretized
to simulate the behavior of an electro-pneumatic valve positioner.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 43

Equipment Modules
The following figure shows a linear and an equal-percentage valve characteristic line:

NOTE For further information about the equal-percentage valve characteristic line please refer to standard
VDI-2173.

1. Delay in valve actuation (first order lag with time constant 2 seconds)
2. Valve actuation in integer numbers (1 % steps)
3. Dead time of valve actuation (delay of 1 second)
4. Approximation of the equal percentage valve characteristic by means of a polygon function block

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 44

Equipment Modules

NOTE The tank outlet valve is further adapted to a realistic valve behavior through a small first order lag, a
dead time and a discretization of the valve position to integer percentages.
This means that the valve position follows the manipulated variable of the master level controller with
a certain sluggishness. The discretization only allows integer percentage values, i.e. the valve
simulation cannot reach the setpoint position with infinite accuracy. The equal-percentage
characteristic leads to a non-linearity in the actuator.

NOTE Both the tank simulation and the actuator have a non-linear behavior. Therefore, a non-linear
characteristic curve must be inserted with the aid of a polygon function block between the disturbance
variable measurement and the feedforward control.
The interpolation points of this characteristic curve can be determined experimentally. To do this, for
different inflow rates the actuator must be adjusted until the container level stays constant at the
desired value (container mid-height). The registered value pairs "Inflow measured/Valve position” can
then be used for the polygon block.

On Sheet 3 of the CFC the inflow with disturbance and measurement noise is simulated.

1 2 5 6

1. Technological valve operating module for inflow modification in the OS

2. Delay in inflow (first order lag with time constant 2 seconds)
3. Generation of measurement noise (white noise)
4. Generation of inflow disturbance (colored noise)
5. Determination of inflow quantity with disturbance and measurement noise (addition)
6. Limitation of inflow to 0 to 100 %

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 45

Equipment Modules

5.1.4. Comparison of exact level control with buffer

control including feedforward disturbance
compensation
The two concepts presented for level control are compared against each other in this chapter. In order to be able to
compare the two simulations both must have the same setpoints and disturbance values. A comparison mode has been
implemented to enable these requirements to be fulfilled. This mode allows to simultaneously modify inflows and
setpoints for both simulations.
To start the comparison, proceed according to the following instructions:
1. Open the plant overview picture "Level Control" or "Buffer Control".
2. Click on the "Compare” button. The corresponding window opens.

3. Click on the SFC icon "Compare_Level_Buffer".

The corresponding window opens.
4. Start the sequence by clicking the "Start” button, and confirm the window that now opens by "OK”.

Wait for about 10 seconds until the SFC has run.

NOTE Now all the valves and controllers are pre-configured in such a manner that manipulated variable and
setpoint can be defined via the two analog input windows in the "Compare” window.

5. Switch to analog input window "SP_Level” and enter a setpoint of 50 %.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 46

Equipment Modules

6. Switch to analog input window "MV_InletValve” and enter a setpoint of 50 %.

7. Wait for about 3 minutes and enter a new inflow of 75 % in the "MV_InletValve” analog window.
8. Wait 2 more minutes and enter a new inflow of 25 % in the "MV_InletValve” analog window.
9. Wait 3 more minutes and enter a new inflow of 50 % in the "MV_InletValve” analog window.
10. Close the faceplate and observe the plotter for about two minutes until the setpoint has been reached.
11. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 47

Equipment Modules
Evaluation

1 2 3

Inlet PV-Level PV-Buffer MV-Level MV-Buffer

1. After the inflow increase, the level rises above the setpoint for both control concepts.
The PI controller for the exact level control detects the change in level and consequently increases the manipulated
variable of the outlet valve until the filling level has reached the desired setpoint again. Control towards the setpoint,
however, produces permanent fluctuations of the manipulated variable for the outlet valve.
In the case of the buffer level control with feedforward disturbance compensation, the changed inflow is detected as a
change in the disturbance variable and the manipulated variable is then moved accordingly. The immediate reaction
to the inflow change provides a faster intervention and the level rises less compared to PI control.
Thanks to the relatively wide deadband, the level does not leave the setpoint area and the controller has to re-adjust
less frequently, which eases the wear of the actuation mechanism.
2. With the inflow change from 75 % to 25 % of the maximum inflow, both fill levels sink and the fill level of the buffer
leaves the deadband. This activates the P controller and the deadband is temporarily deactivated. As soon as the level
approaches the setpoint again, the deadband is activated and the manipulated variable remains constant.
In a manner analogous to the inflow change described in point 1, the PI controller reacts to the exact filling level with
a change of the outflow valve until the fill level has reached the setpoint.
3. The third inflow change occurs before the PI controller has reached the fill level setpoint, the latter thus reacts by
overshooting the fill level more than with the inflow change under point 1.
In contrast to this, the buffer level controller is again within the setpoint range and therefore reacts only to a change
of the inflow with a change of the manipulated variable via the feedforward control.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 48

Equipment Modules

5.2. "Split-Range-Pressure" control

Pressure control in pipelines is similar to flow control and typically allows fast control loops. For pressure control in tanks,
time-constants depend on the ratio of tank volume to maximal inflow and outflow. The tank pressure is increased by
feeding an inert gas (e.g. nitrogen) via a supply line. Opening the purge valve allows the gas mixture to escape and the
container pressure is reduced. The controller responds to pressure changes and compensates them by opening the supply
line or the outlet valve.
In the following example, control of the container pressure is solved by pressure supply and purge valve.

Overview

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and tanks relevant to operation.
Venting

YC
Out

PIC YC
Split In

Inerting

CM and variants
The "Split-range pressure" equipment module consists of three connected CMs and one simulation chart. In the simulation
chart, a container pressure and the effects due to feeding and venting inert gas are simulated.
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 49
Equipment Modules
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

PIC_Split "PIDConSplitRange" • PV Pressure control with one manipulated variable and

• PV_Scale# two actuators

YC_In "ValAn" • IF_Ctrl# Control valve for supplying inert substances

• MV_Scale#
• RbkReturn
• YC

YC_Out "ValAn" • IF_Ctrl# Control valve for ventilation

• MV_Scale#
• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_PresLevel PIC_Split YC_In

PV V
In
SimPV_In MV
In1

Out to_Actor1 from_Ctrl

In1 Out In

PresLevel to_Actor2 to_Ctrl

OUT Out Out

from_Actor1
In YC_Out
V
from_Actor2
MV
In

from_Ctrl
In

to_Ctrl
Out

"PIC_Split" acquires the container pressure ("Sim_PresLevel" simulation chart) and regulates it with the help of the two
control valves "YC_In" and "YC_Out".

Structure and parameterization

"Sim_PresLevel" simulation
The pressure change in the container due to inerting or venting is simulated in the "Sim_PresLevel" CFC.
The figure below shows the sequence of the simulation.

1 2 3 4

1. Calculation of the pressure change starting from the proportionality factor (valve opened by 100 % corresponds to a
change in pressure of 0.1 bar)
2. Reduction in the pressure by 0.01 bar, e.g. due to container pressure loss
3. Time lag of the change in pressure
4. Time integral of pressure changes (every second)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 50

Equipment Modules
PIC_Split
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 10.0 Scaling of the process value upper limit

PV_Unit In 1137 Process value unit in bar

Reversal of the response characteristic for the valve (valve

1 opens in the case of a negative control difference instead
C NegGain.Value 1 of a positive one)

C Gain.Value 8.0 Controller gain

C TI.Value 75.0 Controller lag

C SP_InHiLim 10.0 Maximum value of the internal setpoint

ManLoLim Lower limit for the manipulated variable in manual mode

C (hidden) -100.0

InScale.High 100.0
Split range InScale.Low -100.0 Marginal range for the input signal

Split range NeutPos 0.0 Neutral position

Interconnection to the valve

to_Actor1 Out (YC_In\from_Ctrl.In)

Interconnection to the valve

to_Actor2 Out (YC_Out\from_Ctrl.In)

Interconnection to the valve

from_Actor1 In (YC_In\to_Ctrl.Out)

Interconnection to the valve

from_Actor2 In (YC_Out\to_Ctrl.Out)

Activation of simulation on the channel block

PV SimOn (Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_PresLevel\PresLevel.Out)

NOTE The program "PID Tuner" is available for commissioning the "PIC_Split" controller. At the beginning,
data recording for the "PID-Tuner" is done in an operating range where only positive values of the
manipulated variables are exptected. After this, a comparable experiment is made in an operating
range where only negative manipulated variables occur.
If both part transfer functions for venting and inerting show significantly different values for process
gain, this must be compensated by a different gradient of both branches of the split range
characteristic curve.
Further information and configuration guidelines can be found in the Online Help for the
"SplitrangeControl" process tag type.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 51

Equipment Modules

YC_In and YC_Out

The instances have the following parameterization.
Block Connection Value Use

V Interconnection for the simulation

(YC_In) (Sim_PresLevel\In.In1)
(YC_Out) MV (Sim_PresLevel\Out.In1)

from_Ctrl Interconnection to the controller

(YC_In) (PIC_Split\to_Actror1.Out)
(YC_Out) In (PIC_Split\to_Actor2.Out)

to_Ctrl Interconnection to the controller

(YC_In) (PIC_Split\from_Actror1.In)
(YC_Out) Out (PIC_Split\from_Actror2.In)

MV_Out Activation of simulation on the channel block

(YC_In) (Equipment_Modules\\
(YC_Out) SimOn Activate_Simulation\Sim_Act.Out)

Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to valve "YC_In" and change the operating mode to "Automatic”.
4. Switch to controller "PIC_Split" and change the operating mode of the controller to "Automatic".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 52

Equipment Modules
5. Enter "1 bar” as setpoint.

The new setpoint will have been reached after about two minutes. To compensate the pressure loss of the container, the
valve is opened to about 10 % for venting.
6. Specify "3 bar” as new setpoint for the controller.
7. Close the faceplate and observe the plotter for about two minutes until the new setpoint has been reached.

Evaluation

1
2

1. After the setpoint step, the manipulated variable is set to -100 and by this, the pressure feed valve is opened.
2. The process value slightly exceeds the setpoint; the pressure feed valve is closed evenly.
3. After reaching the setpoint, the pressure feed valve has been opened by about 10 %; this means that the pressure loss
of the container has been compensated.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 53

Equipment Modules

5.3. "Ratio-Control"
In case of ratio control, different gases or other input materials are fed in fixed mixing ratios into a tank via inlet lines.
The ratio control scheme consists of one controller for the main input material (master controller) and one controller for
each additional input material (slave controller).
The example below describes feed control with two input materials, and later on is expanded with another input material.

Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and containers relevant to operation.
FIC MV YC Legende
MainComp SP MainComp MV = Manipulated variable
SP = Active setPoint

1st Inflow
FFIC YC
Comp_1 Comp_1

2nd Inflow FI
CompFlow

Outflow

CM and variants
The "ratio control" equipment module consists of four connected CMs and one simulation chart. On the simulation chart,
the system calculates the total of all the inflows (input materials) and displays them.
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

FIC_MainComp "Ctrl" • PV Flow control of the main input material

• PV_Scale#

FFIC_Comp_1 "PIDConRatio • IF_Master# Flow control of the additional input material

" • PV
• PV_Scale#

YC_MainComp "ValAn" • IF_Ctrl# Control valve for the main input material
• MV_Scale#
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 54
Equipment Modules
CM CMT Selected variants Description

• RbkReturn
• YC

YC_Comp_1 "ValAn" • IF_Ctrl# Control valve for the additional input material
• MV_Scale#
• RbkReturn
• YC

FI_CompFlow "MonAn" • PV Display of the calculated overall inflow

• PV_Scale#

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_CompFlow FIC_MainComp
YC_MainComp
Scale_MainComp PV V
In1 SimPV_In MV

Scale_Comp_1 to_Actor_Slave
from_Ctrl
In1 Out
In

Lag_MainComp from_Actor_Slave
to_Ctrl
Out In
Out

Lag_Comp_1
Out
FFIC_Comp_1
SumOfFlow YC_Comp_1
PV
Out V
SimPV_In
MV
to_Actor_Slave
Out from_Ctrl
In
FI_CompFlow from_Master
In to_Ctrl
I
Out
PV from_Actor_Slave
In

Control "FIC_MainComp" acquires the flow of the main input material and regulates it using control valve "YC_MainComp".
In addition, "FIC_MainComp" transfers its own setpoint to process tag "FFIC_Comp_1". This means that "FIC_MainComp" is
the master controller for "FFIC_Comp_1".
Control "FFIC_Comp_1" acquires the flow of the additional input material and regulates it using control valve
"YC_Comp_1". "FFIC_Comp_1" receives the setpoint from control "FIC_MainComp"; this means that "FFIC_Comp_1" is the
slave controller.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 55

Equipment Modules
Structure and parameterization

"Sim_CompFlow" simulation
The flow of the main input material and the additional input material are simulated in the "Sim_CompFlow" CFC and the
overall flow rate is calculated too. Apart from this, the system displays the flow rate based on process tag type "MonAn".
The figure below shows the sequence of the simulation.

1 2 5

3 4

1. Calculation of the flow for the main input material (valve opened by 100 % corresponds to inflow of 2000 l/h)
2. Delay in change of flow (PT1 response with 5-second delay)
3. Calculation of the flow for the main input material (valve opened by 100 % corresponds to inflow of 500 l/h)
4. Delay in change of flow (PT1 response with 2-second delay)
5. Determination of the complete flow quantity (addition)
Inputs "In1" of highlighted blocks 1 and 3 get their manipulated variables from valve blocks "I" of process tags
"YC_MainComp" and "YC_Comp_1". The "Out" outputs of highlighted blocks 2 and 4 are interconnected with the channel
blocks of the controls.

FIC_MainComp
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 2000.0 Scaling of the process value upper limit

PV_Unit In 1353 Unit of the process value l/h (liters per hour)

C Gain.Value 0.05 Controller gain

C TI.Value 2.2 Controller lag

C SP_InHiLim 2000.0 Maximum value of the internal setpoint

to_Actor_Slave Out Interconnection to the valve and slave controller

(YC_MainComp\from_Ctrl.In)
(FFIC_Comp_1\from_Master.In)

from_Actor_Slave In Interconnection to the valve

(YC_MainComp\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_CompFlow\Lag_MainComp.Out)

NOTE In the current configuration, the master controller can carry out control regardless of the status of the
slave controller. If you do not want this behavior, you can, for example, interconnect the "CascaCut"
output of the slave controller to the "Interlock" input or block (can be selected optionally).
If you want to use other signals of the slave controller such as "LockAct" (locking active) or "OosAct"
(out of service) for locking, you can add another "ComStruOut" communication block to the slave
controller and interconnect block outputs BoStru1 thru BoStru3 to the locking block.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 56

Equipment Modules

NOTE The setpoint is transferred to the controller process tag(s) of the additional input material(s). Using the
setpoint instead of the manipulated variable means that the controller structure does not correspond
to a typical cascade controller.
The "PID Tuner" program is available for commissioning the controller. If there is a considerably
difference in closed loop response time after the optimization, you can try adapting and compensating
the parameters of both control loops manually. The highest priority however is the stability of the
transient response of both individual control loops. In this context, there can be a temporary deviation
from the specified ratio in the case of setpoint steps. If such temporary deviations in one direction
must not occur at all due to safety reasons, additional logic has to be implemented. E.g. burner control
with flow controllers for fuel gas and air in a fixed ratio: in this case you have to make sure that there
is always a little bit more air than required, because a deficiency of air can be dangerous even in short
time intervalls.

FFIC_Comp_1
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 500.0 Scaling of the process value upper limit

PV_Unit In 1353 Unit of the process value l/h (liters per hour)

C Gain.Value 0.25 Controller gain

C TI.Value 4.1 Controller lag

C SP_InHiLim 500.0 Maximum value of the internal setpoint

to_Actor_Slave Out Interconnection to the valve

(YC_Comp_1\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_Comp_1\to_Ctrl.Out)

from_Master In Interconnection to the master controller

(FIC_MainComp\to_Actor_Slave.Out)

Ratio RatHiLim 1 Upper limit (ratio)

Ratio RatLoLim 0 Lower limit (ratio)

Ratio RatLiOp 0 Ratio specification by user

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_CompFlow\Lag_Comp_1.Out)

YC_MainComp and YC_Comp_1

The instances have the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(YC_MainComp) (Sim_CompFlow\In.In1)
(YC_Comp_1) (Sim_CompFlowl\Out.In1)

from_Ctrl In Interconnection to the controller

(YC_MainComp) (FIC_MainComp\to_Actor_Slave.Out)
(YC_Comp_1) (FFIC_Comp_1\to_Actor_Slave.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 57

Equipment Modules
Block Connection Value Use

to_Ctrl Out Interconnection to the controller

(YC_MainComp) (FIC_MainComp\to_Actor_Slave.In)
(YC_Comp_1) (FFIC_Comp_1\to_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(YC_MainComp) (Equipment_Modules\\
(YC_Comp_1) Activate_Simulation\Sim_Act.Out)

FI_CompFlow
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 3000.0 Scaling of the process value upper limit

PV_Unit In 1353 Unit of the process value l/h (liters per hour)

Interconnection for the simulation:

I PV (Sim_CompFlow/SumOfFlow.Out)

Commissioning and operation

2. Enter the new ratio of "0.25".

The ratio corresponds to the factor of the flow setpoint at which the additional input material has to flow to the main
input material.
3. Switch to valve "YC_Comp_1" and change the operating mode to "Automatic".
4. Switch to slave controller "FFIC_Comp_1" and change the operating mode to "Automatic" and the setpoint
specification to "External".

NOTE While master controller "FIC_MainComp" is not working in automatic mode, it does not return a
setpoint (proportionally) to the slave controller either.

5. Switch to valve "YC_MainComp" and change the operating mode to "Automatic".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 58

Equipment Modules
6. Switch to master controller "FIC_MainComp" and change the operating mode to "Automatic".
7. Enter the setpoint "1000 l/h" in the master controller.

NOTE The system displays the current actual value of the ratio in the "Ratio" block, which results from the
setpoint directed to the slave controller.
Both controller setpoints will have been reached after about 1 minute.
8. Enter a new setpoint of "1500 l/h" in master controller "FIC_MainComp".
9. Wait for about 90 seconds and then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.
10. On the toolbar of the OnlineTrendControl, click on the "Ruler" icon and move the ruler to the lowest value with the
greatest deviation, as show in the evaluation below.

Evaluation
The "OnlineTrendControl" that is embedded in the process picture is set to the maximum value ranges. If the ratio
changes, the value range of the additional input material adapts automatically.

Due to the different response times of the controllers, the ratio is temporarily 29 % (0.29). Compared to the ratio setpoint
of 25 % (0.25), a deviation of 4 % results temporarely before the correct ratio is reached in the steady state.

In this case, it is not possible to improve the controller design for slave controller "FFIC_Comp_1" by means of PID
controller optimization, since the aim of the controller design is optimum tracking of the additional input material.

NOTE For further information and configuration guidelines, refer to the Online Help for the "RatioControl"
process tag type. You can find the process tag type in "PCS 7 – Advanced Process Library”.

The response curves from the OnlineTrendControl lead to the considerations below for the controller design to match the
transient responses of the master and slave loops as closely as possible to one another:

• The relatively large deviation at the start of step response indicates that the gain of the slave controller is too high, i.e.
the slave controller process value rises faster than the actual value of the master controller.
• The relatively slow speed with which the final value of the setpoint step-change is reached, indicates an integration
time of the master controller that is too high, i.e. the master controller enters the steady state slower than the slave
controller.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 59

Equipment Modules
A change in the gain of slave controller "FFIC_Comp_1" from 0.25 to 0.1 with a simultaneous change in the integral-
action time of master controller "FIC_MainComp" from 2.2 to 2 generates the result below with the same setpoint steps.

Due to the different response times of the controllers, the ratio after optimization is temporarily 25.6 % (0.256).
Compared to the set ratio of 25 % (0.25), a deviation of 0.6 % results briefly.

Adding another input material

Using the "Ratio Control" equipment module, you can set up a large number of ratio controllers. The number of additional
input materials is limited by the interlock block or the number of interlock inputs that it has.

NOTE If the number of locking signals of the slave controller has to be acquired in the master controller, the
options below are available for adapting the Ctrl type (CMT):
Group the signals of the communication blocks (from_Actor_Slave) using OR blocks. As a result, one
valve and seven additional input materials are interconnected by means of one interlock block.
Disadvantage:
Inaccurate error display, i.e. the system does not differentiate between errors in the cascade
controller, an "out of service” signal of the controller block, and a "Bad” status of the controller channel
blocks.
Duplicate the existing interlock block and group the two (Out) outputs of the interlock blocks using an
OR block. For interconnection (Out output) of the OR block, use the (Out output) interconnections of
the existing interlock block.
You can call up the faceplate of the first interlock block from the controller's faceplate. The faceplate of
the second interlock block is opened by means of its block display symbol in the process picture.
Replace the existing locking block with 8 input signals (Intlk08) with a locking block with 16 input
signals (Intlk16). Apply all the interconnections of the previous locking block.

Requirements
If different additional input materials are measured in different measurement units, the conversion factor in the ratio
block also includes conversion of the units.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 60

Equipment Modules

NOTE In the case of different physical units, you must specify the other measurement unit for the additional
input material. The ratio factor in the ratio function block now has to include the conversion from the
flow unit of the master controller to the flow unit of the slave controller.
Additionally, when displaying the trend curves in a common diagram, it is advisable to label clearly.

If different travel ranges are needed in the case of the partial control loops of a ratio controller, you must delete the
corresponding interconnections and parameterize them for the respective partial control loop.

Description
To add another additional input material to the equipment module, proceed as follows:
1. Copy CMs "FFIC_Comp_1" and "YC_Comp_1" at the same time. Paste the copied CMs back into the same hierarchy
folder. Rename the process tags appropriately (below, the CMs will be referred to as "FFIC_Comp_2" and
"YC_Comp_2").

NOTE When you copy the process tags at the same time (highlight the process tags and then click on Edit >
Copy on the menu bar), the connections between the highlighted process tags are retained.

2. Open process tag "FFIC_Comp_2" and make the following interconnections:

Block Connection Use

from_Master In Interconnection to the master controller

(FIC_MainComp\to_Actor_Slave.Out)

3. The simulation model is designed for two additional input materials. Make the interconnections below in CFC
"FFIC_Comp_2" to connect the second additional input material to the simulation.
Block Connection Use

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_CompFlow\Lag_Comp_1.Out)

4. Open process tag "YC_Comp_2" and make the following interconnections in chart partition "A" sheet 1:
Block Connection Use

V MV Interconnection for the simulation

(Sim_Level\Scale.In1)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

NOTE When additional input materials are added to the "Ratio-Control” equipment module, you must
compile and load the blocks and charts and compile the OS.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 61

Equipment Modules

5.4. "Split-Range-Temperature" control

Temperature control in tanks, heat exchangers, columns or reactors typically involves large heat capacities and results in
slow control loops. To achieve a specified temperature inside a tank, the system feeds either hot steam or cooling water
via supply lines with control valves into the service medium side of a heat exchanger or reactor jacket. The reactor jacket
can contain the service medium in the sense of a heat exchanger. On the other hand, there are external heat exchangers
for reactors, where the reactor content is pumped through pipes to the heat exchanger and back. Due to separation by
means of heat-permeable walls, all of these procedures are indirect heat transfers.
The usual assumption for temperature control of tanks is a complete mixture of tank content (e.g. via stirrer), such that it
is sufficient to measure temperature at one single point and assume that this temperature is representative for the whole
tank. Continuous turnover via pump provides homogenous temperature distribution in cooling jackets as well.
On the other hand, in heat exchangers that are not directly linked to a tank or reactor, typically only the outlet
temperature of the product medium is measured and controlled. Inside the heat exchanger there are significant
temperature gradients.

NOTE The "Split-Range-Temperature" equipment module can be used for tanks or reactors in which
temperature control is provided via the reactor jacket or an external heat exchanger.

In the following example, reactor temperature control is carried out using an external heat exchanger.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 62

Equipment Modules
Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and tanks relevant to operation.
TIC
Temp

TIC YC
Split Heat

Inflow
heating
medium
YC
Cool

Inflow
cooling
medium

Outflow

NS
PumpMixture

CM and variants
The "Split-range temperature" equipment module consists of four interconnected CMs, one CM for pump control, and one
simulation chart. The simulation chart simulates the internal temperature of a container (input material mixture), the
temperature of a heat exchanger, and the effect of changes in temperature (heating steam and cooling water).
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

TIC_Temp Ctrl • PV Master controller for temperature control

• PV_Scale#

TIC_Split PIDConSplit • IF_Master# Slave controller for split-range control with one
Range • PV manipulated variable and two actuators
• PV_Scale#

YC_Heat ValAn • IF_Ctrl# Control valve for the first manipulated variable
• MV_Scale#
• RbkReturn
• YC

YC_Cool ValAn • IF_Ctrl# Control valve for the second manipulated variable
• MV_Scale#
• RbkReturn
• YC

NS_PumpMixture Mot • 1Fbk# A pump (e.g. a flow pump) for continuous pumped
circulation of the contents of the container

NOTE The "NS_PumpMixture” CM is interconnected in the SFC (Sequential Function Chart) It is not necessary
to interconnect with other process tags in the "Split-Range Temperature” equipment module.
To ensure that the system does not generate an error message due to a missing feedback signal, the
"Start" output signal is interconnected with the "FbkRun" input signal of motor block "U".

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 63

Equipment Modules
In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_TempLevel TIC_Temp TIC_Split

Cool to_Actor_Slave to_Master

In1 Out Out

Heat from_Master
from_Actor_Slave
In1 In
In

HeatExchanger Splitrange
PV
OPEN1_11 SimPV_In Out1
OPEN1_1 Out2
Out1Act
TempLevel Out2Act
Out YC_Heat
PV from_Ctrl
HeatExchanger SimPV_In In
V
to_Actor1 to_Ctrl
Out Out

to_Actor2
Out YC_Cool

from_Actor1 from_Ctrl

In In

from_Actor2 to_Ctrl
In Out

Controller "TIC_Temp" uses the simulated internal container temperature from simulation chart "Sim_TempLevel" and
generates the setpoint specification for the split range control. The desired temperature progression is thus configured in
process tag "TIC_Temp".
Controller "TIC_Split" receives the setpoint specification from the master controller and regulates the simulated
temperature of a heat exchanger that transfers heat to the inside of the container.

Structure and parameterization

"Sim_TempLevel” simulation
In CFC "Sim_TempLevel", the system simulates a temperature change due to hot steam or cooling water onto the heat
exchanger and simulates the internal temperature of the container.
The figure below shows the sequence of the simulation.

1
2

1. Reduction of the manipulated variable for simulation. This makes it possible to represent the valve openings of the
heating and cooling valves with more emphasis in the trend display.
2. Calculation of the temperature of a heat exchanger. The change in temperature depends on the openings of both
valves (a bipolar signal is distributed to the heating steam and cooling water valve) and it is processed after passing
through a time-delay block.
3. Internal container temperature that changes depending on the inflow from the heat exchanger. The temperature in
the inside of the container is 40 % lower than in the heat exchanger (a factor of 0.6) and it is calculated after passing
through two delay elements. The output signal (internal container temperature) has small signal noise.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 64

Equipment Modules

NOTE Simulation behavior does not correspond to a real process and it is only used to demonstrate the
functionality and mode of operation of the "Split range temperature" equipment module. Block
"SIMU_AI" has integrating behavior whereby heating and cooling act with the same intensity. With real
heat exchangers, both heat losses into the surroundings and different behavior when heating (e.g.
steam) and cooling (e.g. flowing water) are to be expected.

TIC_Temp
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 100.0 Scaling of the process value upper limit

PV_Unit In 1001 Unit of the process value in degrees Celsius

C Gain 1.5 Controller gain

C TI 7.054 Controller lag

C TD 1.855 Controller differential time

C SP_InHiLim 100.0 Maximum value of the internal setpoint

to_Actor_Slave Out Interconnection to the slave controller

(TIC_Split\from_Ctrl.In)

from_Actor_Slave In Interconnection to the slave controller

(TIC_Split\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_TempLevel\TempLevel.Out)

TIC_Split
The instance has the following parameterization.
Block Connection Value Use

PV_Unit In 1001 Unit of the process value in degrees Celsius

C Gain 3.5 Controller gain

C DeadBand 0.2 Width of deadband

C SP_InHiLim 100.0 Maximum value of the internal setpoint

C ManLoLim -100.0 Lower limit for the manipulated variable in manual mode
(hidden)

Split range InScale.High 100.0 Marginal range for the input signal
InScale.Low -100.0

Split range NeutPos 0.0 Neutral position

Split range Out1 Interconnection for the simulation

(Sim_TempLevel\Cool.In1)

Split range Out2 Interconnection for the simulation

(Sim_TempLevel\Heat.In1)

Split range Out1Act Interconnection for the simulation

(Sim_TempLevel\HeatExchanger.OPEN1_11)

Split range Out2Act Interconnection for the simulation

(Sim_TempLevel\HeatExchanger.OPEN1_1)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 65

Equipment Modules
Block Connection Value Use

to_Actor1 Out Interconnection to the valve

(YC_Heat\from_Ctrl.In)

to_Actor2 Out Interconnection to the valve

(YC_Cool\from_Ctrl.In)

from_Actor1 In Interconnection to the valve

(YC_Heat\to_Ctrl.Out)

from_Actor2 In Interconnection to the valve

(YC_Cool\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_TempLevel\HeatExchanger.V)

NOTE The "PID Tuner" program is available for commissioning the "TIC_Split" controller.
At the beginning, experiments for data recording by "PID-Tuner" are conducted in an operating range
where only positive values of manipulated variables are expected. After this, a comparable experiment
is made in an operating range where only negative manipulated variables occur. If both part transfer
functions for heating and cooling show significantly different values for processgain, this must be
compensated by a different gradient in both branches of the split range characteristic curve. After the
slave controller including the split range has been completely commissioned and tested, the master
controller "TIC_Temp" is optimized using the "PID Tuner" program.
For further information and configuration guidelines, refer to the Online Help for the "CascadeControl"
process tag type of the PCS 7 Advanced Process Library.

YC_Heat
The instance has the following parameterization.
Block Connection Value Use

from_Ctrl In Interconnection to the controller

(TIC_Split\to_Actror1.Out)

to_Ctrl Out Interconnection to the controller

(TIC_Split\from_Actror1.In)

YC SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

YC_Cool
The instance has the following parameterization.
Block Connection Value Use

from_Ctrl In Interconnection to the controller

(TIC_Split\to_Actror2.Out)

to_Ctrl Out Interconnection to the controller

(TIC_Split\from_Actror2.In)

YC SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 66

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to "YC_Cool" valve and change the operating mode to "Automatic".
4. Switch to "TIC_Split" slave controller, change its operating mode to "Automatic" and the setpoint specification to
"External".
5. Switch to "TIC_Temp" master controller and change the operating mode of the controller to "Automatic".
6. In master controller "TIC_Temp", enter a setpoint of "30" °C for the operating range.
7. Wait for about one minute and enter a new setpoint of "40” °C.
8. Observe the plotter for about one minute until the new setpoint has been reached.
9. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

NOTE The motor can be started with the "Start" command on the faceplate.
In process mode, the motor is controlled via an SFC, e.g. at start-up of the plant.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 67

Equipment Modules
Evaluation

TIC_Temp TIC_Split

After setpoint change SP1, the master controller calculates a manipulated variable MV1 and forwards it in the cascade to
the slave controller. This manipulated variable is represented as setpoint SP2 for the slave controller in the curve chart.
The slave controller calculates manipulated variable MV2 from setpoint curve SP2. MV2 acts on the heating and cooling
valves and yields temperature curve PV2 of the heat exchanger.
Temperature PV1 in the container follows the temperature of heat exchanger PV2 with a delay.

Legend The noise of process variable PV1 leads to noise of manipulated variable MV1 and consequently of
setpoint SP2. The oscillation of manipulated variable MV2 in real world applications has to be avoided
1 (e.g. by definition of deadbands) especially around the neutral point of the split-range characteristic,
because this means alternating of heating and cooling. In the simulation, the oscillation is actually
centered around the neutral point because heat losses into the surroundings are neglected.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 68

Equipment Modules

5.5. pH value control using a standard

controller
The pH of the product is set in pH value control "pH-Control-Std". For this, a neutralizer is added to the product in
continuous operation to reach the desired pH value.
Due to the highly non-linear titration curve, this means that the gain of the controlled system may fluctuate severely,
depending on the operating point. Only for applications in which the pH value is to be kept constant in a very tight range
and the disturbances are limited, a simple PID controller with fixed parameterization is sufficient for pH value control. The
special feature of the equipment module presented here is the fact that the pH setpoint and the pH process value are
converted to concentration differences to achieve linearization of the controlled system characteristic. Unlike the pH
value, the difference in concentration between OH- and H30+ ions depend in a linear manner on the controller
manipulated variable, i.e. on the feed of neutralizing agents. Conversion is carried out based on an inverse titration curve
that describes the chemical reaction of the considered process at least approximately. Details on the titration curve can be
found in section 6.5.
In difficult applications with long dead times (due to the measurement dead time of the pH probe, the time needed for
mixing, and the response time of the neutralization reaction) and the need for dynamic feedforward control based on the
inflow pH value, we recommend using a predictive controller to compensate the influences.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 69

Equipment Modules
Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and containers to operation.

Neutralizing agent

YC
NeutSubst

QIC
pH_Control_Std

QI
pH_Tank

CM and variants
The "pH-Control-h" equipment module consists of three interconnected CMs and one simulation chart. In the simulation
chart, the system carries out pH setpoint specification (OpAnL block) and calculates the pH setpoint based on the
difference in concentration from the input substance and the neutralizing agent.
The controller gets the converted pH values (setpoint and actual values) as differences in concentration to control.
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

QI_pH_Tank MonAn • PV Display of the product pH value-

• PV_Scale#

QIC_pH_Control_Std PIDCon • PV_Scale# Standard PID controller without channel blocks for
controlling the difference in concentration
YC_NeutrSubst VlvAn • IF_Ctrl# Control valve for the neutralizing agent
• MV_Scale#
• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_pH QI_pH_Tank QIC_pH_Control_Std YC_NeutrSubst

pH_Std PV V
pHTitrConvert
Neutr_MV SimPV_In MV
CV
SP
pH_Std from_Ctrl
I
pH In
PV_Out to_Actor_Slave
Out
pH_SP to_Ctrl
SP_Out Out
from_Actor_Slave
In

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 70

Equipment Modules
Structure and parameterization

"Sim_pH” simulation
In CFC "pH_Std" the system calculates the pH value. On sheet 2, there is an OpAnL block to specify the pH setpoint.
The following figure shows parameterization of the simulation block.

In the block inputs, fictional parameters are entered for buffer parameter "Alfa" and the "Ampl_pH" amplitude range that
is to be crossed. In addition, fixed values are specified for the pH value and flow amount of input material. No deadtime is
set for the pH simulation value (simulation process).

NOTE You can find additional information in Section 6.6 "Block description of "SimpHTitr"".

QI_pH_Tank
The pH value of the product in the tank is acquired and displayed in the instance. The instance has the following
parameterization.
Block Connection Value Use

PV_Scale HiScale 15.0 Scaling of the pH process value upper limit

PV_Unit In 1422 Unit of the process value as a pH value

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_pH\pH_Std.pH)

PV SimPV_Out Interconnection to the controller

(QIC_pH_Control_Std\pHTitrConvert.CV)

QIC_pH_Control_Std
In the instance, the system converts the pH value provided by display "QI_pH_Tank" to a concentration difference using
block "pHTitrBlock". The concentration difference is used for control. The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 10000.0 Scaling of the concentration difference process value

LoScale -10000.0 limits

PV_Unit In 1399 Unit of the process value in mol/L (concentration

difference)

C Gain 40.0 Controller gain

C TI 8.0 Controller lag

C SP_InHiLim 10000.0 Maximum value of the internal setpoint

C SP_InLoLim -10000.0 Minimum value of the internal setpoint

pHTitrBlock Newly inserted as "pHTitrConvert" to convert pH

values to concentration differences

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 71

Equipment Modules
Block Connection Value Use

pHTitrConvert CV Interconnection to pH measured value display

(QI_pH_Tank\PV_In.PV_Out)

pHTitrConvert SP Interconnection to the OpAnL setpoint specification in

the simulation chart
(Sim_pH\pH_SP.SP_Out)

pHTitrConvert Alfa 35000 Buffer parameter

pHTitrConvert Ampl_pH 5.0 The amplitude range that is to be covered

pHTitrConvert CV_Out Interconnection to the controller block (C.PV)

pHTitrConvert SP_Out Interconnection to the SFC block (IF_SFC.SP_Ext)

to_Actor_Slave Out Interconnection to the valve

(YC_NeutrSubst\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_NeutrSubst\to_Ctrl.Out)

NOTE You must carry out parameterization of the titration curve for a concrete chemical process before
setting the PID controller using the PID tuner. If large variations in the inflow amount of the input
materials are to be expected, it is recommend to compensate the disturbance by means of linear
manipulated variable conversion using the "pHTitrBlock" block. You can find additional information
about converting the pH value into a concentration difference in the block description in Section 6.5.

NOTE The "PID Tuner" program is available for commissioning controller "QIC_pH_Control_Std". The system
first records data for the "PID-Tuner" in an operating range in which only positive manipulated
variables occur. After this, a comparable experiment is made in an operating range in which only
negative manipulated variables occur. Optimization of the pH value-control was carried out based on
the concentration difference using different manipulated variables (MV) with a constant (input
material) inflow amount.

NOTE The following messages of the measurement "QI_pH_Tank" are not displayed in the controller:

• for hardware fault (CSF)

• device being maintained (OosLi)
If they are needed, interconnect them additionally with blocks "CSF" and "OosAct" in chart partition "B"
sheet 3.
Alternatively, you can activate the "to_Indicate" option in the display process tag and add an
appropriate "from_Indicate" link block to the Ctrl CMT and interconnect it appropriately. As an
example, you can use the "ModPreCon" CMT as a guide.

YC_NeutrSubst
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_pH\pH_Std.Neutr_MV)

from_Ctrl In Interconnection to the controller

(QIC_pH_Control_Std\to_Actor_Slave.Out)

to_Ctrl Out Interconnection to the controller

(QIC_pH_Control_Std\from_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 72

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "QIC_pH_Control_Std" and change the operating mode of the controller to "Automatic" and the
setpoint specification to "External".

NOTE The controller uses the preset pH value of the OpAnL symbol display as the setpoint. In this symbol
display, 7 pH is set as the setpoint (neutral zone) based on which the amount of neutralizing agent is
fed (regulated).

4. Wait for about 2 minutes until the process value reaches its specified operating range.
5. Switch to operator control block "pH_SP" and specify a new setpoint of 6.5 pH.
6. Close the faceplate and observe the plotter for about one minute until the new setpoint has been reached.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 73

Equipment Modules

Evaluation

The controller is optimized without overshooting to reach the setpoint. After changing the setpoint, the controller
regulates the addition of neutralizer with a slight delay.

NOTE The controller is set for an operating point of ± 0.5 pH around the neutral zone 7 pH. Under some
circumstances, different operating points may make it necessary to optimize the controller again.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 74

Equipment Modules

5.6. pH value control using predictive

controller
pH value control using a "pH-Control-MPC" model predictive controller is used for the same tasks with the special features
due to the highly non-linear titration characteristic curve. In addition to pH value control using standard controller, the
MPC allows targeted compensation of dead times of the controlled system (due to the measurement dead time for
mixing, and the reaction time of the neutralization reaction) as well as model-based compensation of measurable
disturbances due to fluctuations of the pH value in the inflow.
In the following example of pH value control by addition of a neutralizing agent, we will consider the pH value and feed
flow of the input material besides the pH value in the tank.
The example is designed for continuous operation and it is possible to modify the pH value and the inflow of the input
material.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 75

Equipment Modules
Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as units and containers, etc. relevant to operation.

Neutralizing agent
CV
QIC MV YC
DV
pH_Control_MPC Neutralizer

QI FI
pH_Feed Feed

QI
pH_Product

Inflow

Outlet

CM and variants
The "pH-Control-MPC" equipment module consists of five interconnected CMs and one simulation chart. In the simulation
chart, the pH value of the product is determined from the pH value and the inflow amount of the input material and of
the neutralizer (manipulated variable of the valve).
Operators can adapt in the OS the pH value for the input material and the pH setpoint as well as the inflow amount. For
this, OpAnL blocks have been inserted in the simulation chart and the controller process tag.
For regulation, the controller uses the converted pH values (setpoint and actual values of the product and actual value of
the input material) as concentration differences. In addition, the inflow amount of the input material affects the inflow
amount of the neutralizer, since the maximum manipulated variable changes proportionally to the factor from the actual
inflow amount and the maximum inflow amount of the input material.

NOTE Additional information about calculating the manipulated variable or scaling in the block description
can be found in Section 6.5.

You specify the values below in the OpAnL blocks and can adjust them in the Operator Station:

• pH setpoint (product)
• pH value of the input material
• inflow amount of the input material
To simplify the project, an additional display process tag was not implemented for each value specification.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 76

Equipment Modules
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

QIC_pH_Control_MPC ModPreCon4Valve • Multivariable controller for regulating the pH

value of the product

QI_pH_Product MonAn • PV Display of the pH value of the product

• PV_Scale#
• To_Indicate

QI_pH_Feed MonAn • PV Display of the pH value of the input material

• PV_Scale#
• To_Indicate

FI_Feed MonAn • PV Throughflow display of the input material

• PV_Scale#

YC_Neutralizer VlvAn • IF_Ctrl# Control valve for the neutralizing agent

• MV_Scale#
• RbkReturn
• YC
In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_pH_MPC QI_pH_Product QIC_pH_Control_MPC YC_Neutralizer

to_Actor
pH_MPC PV from_Ctrl
Out
Neutr_MV SimPV_In In
from_Actor
To_Indicate to_Ctrl
pH_MPC In
Out Out
pH
from_CV
QI_pH_Feed In V
MV
PV
from_DV1
SimPV_In
pH_Feed In
SP_Out To_Indicate
Out
pHConverting
FI_Feed Feed_PV_Out
Flow_Feed Feed_PV_Out
PV
SP_Out
SimPV_In

PV
PV_Out IF_SFC
ScaleOut SP1

pH_SP
SP_Out

Multivariable controller "QIC_pH_Control_MPC" acquires the pH value of the input material, the pH value of the draining
product, and the pH setpoint specification as concentration differences. Depending on the pH difference (setpoint and
actual value of the product), the system feeds the necessary amount of neutralizer to the tank via control valve
"YC_Neutralizer".

Structure and parameterization

Simulation "Sim_pH_MPC"
In CFC "Sim_pH_MPC" the system calculates the pH value. On sheet 2, there is an OpAnL block to specify the pH setpoint,
the pH value, and the inflow amount of the input material.
The following figure shows parameterization of the simulation block.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 77

Equipment Modules

In the block inputs, fictional parameters are entered for buffer parameter "Alfa" and the "Ampl_pH" amplitude range that
is to be crossed. In addition, the manipulated variable of control valve "YC_Neutralizer" and the inflow amount of the
input material (OpAnL block on sheet 2) are used for the calculation.
A deadtime of 10 seconds, a neutralizer inflow delay of 10 seconds, and a gain factor of 3 are set for the pH simulation
value (simulation process).

NOTE You can find additional information in the block description in Section 6.5.

QI_pH_Product
The pH value of the product is acquired and displayed in the instance. The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 15.0 Scaling of the pH process value upper limit

PV_Unit In 1422 Unit of the process value as a pH value

to_Indicate Out Interconnection to the multivariable controller

(QIC_pH_Control_MPC\from_CV.In)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_pH_MPC\pH_MPC.pH)

QI_pH_Feed
The pH value of the input material is acquired and displayed in the instance.
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 15.0 Scaling of the pH process value upper limit

PV_Unit In 1422 Unit of the process value as a pH value

to_Indicate Out Interconnection to the multivariable controller

(QIC_pH_Control_MPC\from_DV1.In)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_pH_MPC\pH_Feed.SP_Out)

FI_Feed
The amount of the input material is acquired and displayed in the instance.
The instance has the following parameterization.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 78

Equipment Modules
Block Connection Value Use

PV_Scale HiScale 5000.0 Scaling of the amount

PV_Unit In 1038 Process value unit in L (liters)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_pH_MPC\Flow_Feed.SP_Out)

PV PV_Out Interconnection to the multivariable controller

(QIC_pH_Control_MPC\pHConverting.Feed_PV_Out)

PV Scale_Out Interconnection to the multivariable controller

(QIC_pH_Control_MPC\pHConverting.Feed_Scale)

QIC_pH_Control_MPC
In the multivariable controller, the system converts the pH value provided by display "QI_pH_Product" to a concentration
difference using block "pHTitrBlock". The concentration difference is used for control. In the same way, the system
converts the setpoint specification as well as the pH value of the input material disturbance variable to a concentration
difference.
The instance has the following changes and parameterization.
Block Connection Value Use

MPC CV1 Existing interconnection deleted. New interconnection to the

conversion block
(pHConverting.CV_Out)

MPC DV1 Existing interconnection deleted. New interconnection to the

conversion block
(pHConverting.DV_Out)

MPC SP1 Existing interconnection deleted. New interconnection to the

conversion block
(pHConverting.SP_Out)

MPC SP1HiLim 500 Upper setpoint limit for the concentration difference

MPC SP1LoLim -500 Lower setpoint limit for the concentration difference

MPC MV1HiLim Existing interconnection deleted. New interconnection to the

conversion block
(pHConverting.MVHiLim)

MPC CV1_Unit 1399 Existing interconnection deleted. Unit of measurement for

the controlled variable in mol/L (process value)

MPC DB_No 50 Data block with controller data

MPC MV1 Existing interconnection deleted. New interconnection to the

conversion block
(pHConverting.MV)

pHTitrBlock Newly inserted as "pHConverting" to convert pH values

pHConverting CV New interconnection to the link block

(from_CV.ReStru1)

pHConverting DV New interconnection to the link block

(from_DV1.ReStru1)

pHConverting SP New interconnection to the IF_SFC block

(IF_SFC.SP1Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 79

Equipment Modules
Block Connection Value Use

pHConverting MV New interconnection from controller block

(MPC.MV1)

pHConverting Feed_PV_Out New interconnection from throughflow display of the input

material
(FI_Feed\PV_In.PV_Out)

pHConverting Feed_Scale New interconnection from throughflow display of the input

material
(FI_Feed\PV_In.ScaleOut)

TitrConverting CV_Out Interconnection to the controller block

(MPC.CV1)

TitrConverting DV_Out Interconnection to the controller block

(MPC.DV1)

TitrConverting SP_Out Interconnection to the controller block

(MPC.SP1)

TitrConverting MVHiLim Interconnection to the controller block

(MPC.MV1HiLim)

TitrConverting MV_Valve Interconnection to the communication block

(to_Valve.ReStru1)

IF_SFC SP1 Interconnection of OpAnL block for setpoint specification

(Sim_pH_MPC\pH_SP.SP_Out)

to_Actor Out Interconnection to the valve

(YC_Neutralizer\from_Ctrl.In)

from_Actor In Interconnection to the valve

(YC_Neutralizer\from_Ctrl.Out)

NOTE The multivariable controller was optimized using the MPC configurator for an operating range from
7.5 to 6.5 pH and stored in DB 50. The relevant influencing variables were an inflow amount of the
input material of 3000 L/s with pH 4 and a neutralizing agent with a pH of 12.
For trend recording, the manipulated variable was excited using the "AutoExci" block and the
disturbance variable was changed (±10 %).

YC_Neutralizer
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_pH_MPC\pH_MPC.Neutr_MV)

from_Ctrl In Interconnection to the controller

(QIC_pH_Control_MPC\to_Actor.Out)

to_Ctrl Out Interconnection to the controller

(QIC_pH_Control_MPC\from_Actor.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 80

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "QIC_pH_Control_MPC" and change the controller's operating mode to "Automatic".

4. Wait for about 1 minute until the process value reaches its specified operating range.
5. Switch to operator control block "pH_Feed" and specify a new setpoint of 4.5 pH.

6. Close the faceplate and observe the plotter for about one minute until the new setpoint has been reached.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 81

Equipment Modules
Evaluation

1
2

1. The controller is optimized to reach the setpoint exactly and consequently, slowly. The controller detects the change
in the disturbance variable and it modifies the manipulated variable before the process responds to influencing of the
disturbance variable (set deadtime in the simulation block). The disturbance variable acts on the actual value without
delay (time delay elements).
2. In the example, the pH value of the input material was increased by 0.5 pH; however, it had an effect of about 1 pH
on the product.
Despite detecting the disturbance variable in good time, the controller needs about 90 seconds for compensation and
regulation. This time is also needed for control with bigger changes in the pH value of the input material.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 82

Equipment Modules

5.7. "Temperature-Flow-Cascade"
Temperature control via flow controller for a service medium (e.g. heating steam, cooling water, or fuel) in cascade
structure is used for applications in which fluctuations within the auxiliary control loop (of the flow controller) have to be
compensated quickly, or the slave controller can compensate other unpleasant properties of the actuator (e.g. a non-
linear valve characteristic curve) which are therefore invisible for the master controller. Temperature flow cascades are
used for heat exchangers, reactors or burners, for example.
In the heat exchanger, the system continuously pumps the contents of the container through the heat exchanger via
piping. This heats up or cools the product material to a defined temperature by means of thermal transfer from the
service medium.
The same control concept is used with a burner, i.e. the amount of fuel flow regulates the temperature.

NOTE The "temperature flow cascade" equipment module can be used for any process applications where
temperature control is carried out via flow.

In the following example, we will consider temperature control on a heat exchanger that is heated by means of a heating
medium. It is also possible to use heat exchangers to cool a material flow. In this case, the flow of cooling medium is
manipulated instead of heating medium. The usual generic term for a heating or cooling medium is "service medium”.
The controller structure of heat exchangers does not depend on whether they are used for heating or cooling. The only
change is the sign of the master controller's controlled system.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 83

Equipment Modules
Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as units and containers, etc. relevant to operation.

TIC
Temperature

FIC YC
ServMedium ServMedium

Inflow
Service medium
Outflow
Service medium
Inflow
Product

CM and variants
The "temperature flow cascade" equipment module consists of three interconnected CMs and one simulation chart. The
simulation chart simulates the effect of the heat exchanger on the input material temperature.
The following table provides an overview of the CMs of the equipment module including the associated CMTs.
CM CMT Selected variants Description

TIC_Temperature PIDCon • PV Master controller for temperature control

• PV_Scale#

FFIC_ServMedium PIDCon • IF_Ctrl# Slave controller for the flow control

• PV
• PV_Scale#

YC_ServMedium VlvAn • IF_Ctrl# Control valve for the heating medium

• MV_Scale#
• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

TIC_Temperature

PV
SimPV_In

to_Actor_Slave
Out

from_Actor_Slave
In

Sim_Temperature FIC_ServMedium
YC_ServMedium
to_Master
Lag_Heat_Slave
Out V
In
MV
from_Master
Noise_Master
In from_Ctrl
Out
In
PV
Gain_Slave
SimPV_In to_Ctrl
Out
Out
to_Actor_Slave
Out

from_Actor_Slave
In

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 84

Equipment Modules
Controller "TIC_Temperature" uses the temperature of a material to be regulated from the "Sim_Temperature" simulation
chart and generates the setpoint specification for the slave controller. This means that the desired temperature curve is
configured in process tag "TIC_Temperature". Slave controller "FIC_ServMedium" regulates the flow rate of the heating
medium by means of control valve "YC_ServMedium" based on the setpoint specification of the master controller.

Structure and parameterization

"Sim_Temperature" simulation
In CFC "Sim_Temperature", the system simulates a temperature change of a material by a heat exchanger. The figure
below shows the sequence of the simulation.

2 4

5
3

1. If a valve is 100 % open, with a 3-second delay, a flow of 5 t/h (factor 0.05) is sent to the slave controller as the flow
rate actual value.
2. With a 10-second delay (as a simulation for heating up of the thermal capacity of the heat exchanger), ten times the
value of the heating steam flow rate is sent to the reference junction as the actual value of the hot air temperature.
3. Alternating input material temperature that changes every 90 seconds between 20 °C and 21 °C to simulate a
disturbance.
4. Input material temperature for the master controller that changes in dependence on the heat exchanger. The output
signal can be given slight signal noise.
5. Material temperature before being heated by the heat exchanger.

NOTE Simulation behavior does not correspond to a real process and it is only used to demonstrate the
functionality and mode of operation of the "temperature flow cascade" equipment module.

TIC_Temperature
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 200.0 Scaling of the process value upper limit

PV_Unit In 1001 Unit of the process value in degrees Celsius

C TI 7.3 Controller lag

C SP_InHiLim 200.0 Maximum value of the internal setpoint

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 85

Equipment Modules
Block Connection Value Use

to_Actor_Slave Out Interconnection to the slave controller

(FIC_ServMedium\from_Ctrl.In)

from_Actor_Slave In Interconnection to the slave controller

(FIC_ServMedium\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_Temperature\Noise_Master.Out)

FIC_ServMedium
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 10.0 Scaling of the process value upper limit

PV_Unit In 1328 Unit of the process value in t/h (tons per hour)

C Gain.Value 2.8 Controller gain

C TI 1.7 Controller lag

C SP_InHiLim 10.0 Maximum value of the internal setpoint

to_Actor_Slave Out Interconnection to the control valve

(YC_ServMedium\from_Ctrl.In)

from_Actor_Slave In Interconnection to the control valve

(YC_ServMedium\to_Ctrl.Out)

to_Master Out Interconnection to the master controller

(TIC_Temperature\from_Actor_Slave.In)

from_Slave In Interconnection to the master controller

(TIC_Temperature\to_Actor_Slave.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_Temperature\Gain_Slave.Out)

NOTE The "PID Tuner" program is available for commissioning the controller. Please remind that you optimize
the slave controller (service medium flow) first, and then the master temperature controller.

YC_ServMedium
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_Temperature\Lag_Slave.In)

from_Ctrl In Interconnection to the controller

(FIC_ServMedium\to_Actor_Slave.Out)

to_Ctrl Out Interconnection to the controller

(FIC_ServMedium\from_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 86

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to slave controller "FIC_ServMedium”, change its operating mode to "Automatic" and the setpoint specification
to "External".
4. Switch to master controller "TIC_Temperature" and change the operating mode of the controller to "Automatic".
5. Enter a new setpoint of 21 °C in master controller "TIC_Temperature".
6. Wait for about 2 minutes and then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Evaluation

TIC_Temp TIC_Serv

1. The temperature of the product medium changes every 90 seconds. The master controller responds to this change
and regulates towards the temperature setpoint of 21 °C.
2. On detecting a temperature change, the master controller transfers a new setpoint to the slave controller. The slave
controller responds directly to this change with a new setpoint (brown trend display) and tracks the process value
(gray trend display) to the setpoint (orange trend display).
The slave controller (flow of the heating medium in t/h) is configured for exact control without overshooting.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 87

Equipment Modules

5.8. Coarse-/Finestream-Control "Stream-

Control”
In some process operating modes (start-up, production operation, load changes, etc.), it is necessary to control large flow
rates very precisely. In these situations, two valves are used, since the control ratio of continuous valves for flow rates in
pipelines is limited. Typically, the maximum flow rate cannot be more than 50 times greater than the minimum
controllable flow rate.
A large valve in a pipeline of great diameter controls the larger percentage of the material flow. However, the large valve
cannot dose very precisely and also reacts relatively slowly. A thinner pipe with a smaller valve acts in parallel; it can dose
more exactly and can control faster. Downstream of the valves, the two pipes are joined again to maintain the desired
overall flow.
The task of a coarse/fine flow control scheme is to control the two valves in such a way that the requirements regarding
the control range, precision, and dynamics of the total flow are met.
Typical fields of application are:

• Quality control in chemical processes, such as pH control with flow control of the neutralizing agent.
• Temperature controls on distillation towers or reactors with flow control of the heating/cooling medium.
• Provision of auxiliary energy (heating steam, compressed air) for process plants, e.g. with a large and a small steam
generator or a large and a small compressor.
The fine flow controller uses the overall flow as controlled variable. The coarse flow controller uses as its controlled
variable the position of the control valve for the fine flow, with a setpoint of 50 % and a relatively broad deadband. The
aim of the coarse flow controller is to roughly adjust the main mass flow so that the fine flow controller remains in the
middle of its working range and can perform the fine regulation.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 88

Equipment Modules
Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and pipes. relevant to operation.

YC
FineStream

Fine inflow
FIC
TotalStream

FIC
CoarseStream

YC
CoarseStream

Coarse inflow

CM and variants
The "Stream Control" equipment module consists of four connected CMs and one simulation chart. On the simulation
chart, the system forms the total from the two inflows (fine and coarse inflow).
The following table provides an overview of the CMs of the equipment module, including the associated CMTs.
CM CMT Selected variants Description

FIC_TotalStream PIDCon • PV_Scale# Throughflow control of fine stream

YC_FineStream VlvAn • IF_Ctrl# Control valve for the fine stream

• MV_Scale#
• RbkReturn
• YC

FIC_CoarseStream PIDCon • PV_Scale# Throughflow control of coarse stream with

acquisition of the manipulated value from the fine
stream valve

YC_CoarseStream VlvAn • IF_Ctrl# Control valve for the coarse stream

• MV_Scale#
• RbkReturn
• YC

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 89

Equipment Modules
In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_Stream FIC_TotalStream YC_FineStream

PV V
Scale_FineStream
SimPV_In MV
In1

Scale_CoarseStre to_Actor_Slave from_Ctrl

In1 Out In

SumOfFlow from_Actor_Slave to_Ctrl

Out In Out

FIC_CoarseStream YC_CoarseStream

C V

PV MV

to_Actor_Slave from_Ctrl
Out In

from_Actor_Slave to_Ctrl
In Out

Control "FIC_TotalStream" acquires the flow of the total stream and regulates the fine stream with control valve
"YC_FineStream".
The "FIC_CoarseStream" controller acquires the manipulated value of the "YC_FineStream" control valve and regulates the
coarse flow with the "YC_CoarseStream" control valve. The setpoint for the "FIC_CoarseStream" controller is 50%. With it
the "FIC_CoarseStream" controller works to keep the "YC_FineStream" control valve in the optimum working range of
50%.

Structure and parameterization

"Sim_Stream" simulation
The flow of both the fine stream and the coarse stream are simulated in the "Sim_Stream" CFC and the overall flow rate is
calculated as well. Apart from this, the system displays the total flow rate based on process tag type "MonAn".

1 2 6

3 4

1. Calculation of the flow for the fine stream (valve 100 % open corresponds to inflow of 200 l/h)
2. Delay in change of flow (PT1 response with 8-second delay)
3. Calculation of the flow for the coarse stream (valve 100 % open corresponds to inflow of 2000 l/h)
4. Delay in change of flow (PT1 response with 24-second delay)
5. Determination of the complete flow quantity (addition)
6. Creation of measurement noise

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 90

Equipment Modules
FIC_TotalStream
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 2200.0 Scaling of the process value upper limit

PV_Unit In 1353 Unit of the process value l/h (liters per hour)

C Gain.Value 5 Controller gain

C TI.Value 5 Controller lag

C SP_InHiLim 2200.0 Maximum value of the internal setpoint

to_Actor_Slave Out Interconnection to the valve

(YC_FineStream\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_FineStream\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_Stream\SumOfStream.Out)

NOTE Procedure for controller tuning:

1. Take coarse stream controller in manual mode, go to typical operating point.
2. Optimized fine stream controller by PID-Tuner and take it to automatic mode.
3. Adjust deadband of fine stream controller with respect to measurement noise, such that the
movements of the manipulated variable are sufficiently smooth.
4. Optimize coarse flow controller by PID-Tuner in manual mode, with a small step of manual value.
The controlled process has negative gain: if the coarse flow controller opens its valve, the fine
stream controller will compensate this by closing its valve. Process gain can be estimated from the
ratio of maximal flows of both valves. Typical is a factor of about 10 between coarse flow and fine
flow.
5. Specify the deadband of coarse flow controller with respect to the precision, that can be achieved
realistically by the coarse flow controller, such that the coarse flow valve does not move at all in
steady state operation.

FIC_CoarseStream
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 100.0 Scaling of the process value upper limit

PV_Unit In 1342 Process value unit %

C NegGain 1 Negative gain of PID controller

C Gain.Value 5 Controller gain

C TI.Value 24 Controller lag

C DeadBand 10.0 Deadband

C PV_In Interconnection for the simulated process value

(Sim_FineStream\V.MV)

to_Actor_Slave Out Interconnection to the valve

(YC_CoarseStream\from_Ctrl.In)

from_Actor_Slave In Interconnection to the valve

(YC_CoarseStream\to_Ctrl.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 91

Equipment Modules
YC_FineStream
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_Stream\Scale_FineStream.In1)
Interconnection to the controller
(YC_CoarseStream\C.PV)

from_Ctrl In Interconnection to the controller

(FIC_TotalStream\to_Actor_Slave.Out)

to_Ctrl Out Interconnection to the controller

(FIC_Totalstream\to_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

YC_CoarseStream
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_Stream\Scale_CoarseStream.In1)

from_Ctrl In Interconnection to the controller

(FIC_CoarseStream\to_Actor_Slave.Out)

to_Ctrl Out Interconnection to the controller

(FIC_Coarsestream\to_Actor_Slave.In)

MV_Out SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 92

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "FIC_TotalStream" and change the controller's operating mode to "Automatic".
4. Enter a setpoint of "800 l/h".

5. Switch to "YC_CoarseStream" valve and change the operating mode to "Automatic".

6. Switch to "FIC_CoarseStream" valve and change the operating mode to "Automatic" and the setpoint to "External".

NOTE The controller uses the preset setpoint "50" % as external setpoint to keep the valve "YC_FineStream" in
the middle of the working range.

7. Then wait about 1 minute until both controllers have reached their setpoints and change the main controller setpoint
to "1200 l/h”.
8. Wait for about 30 seconds and then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 93

Equipment Modules
Evaluation

PV_Total- SP_Total- PV_-

stream stream YC_Coarse

The setpoint step from 800 l/h to 1200 l/h opens the valve for the fine stream completely. The coarse stream controller
registers the change of the fine stream control valve and regulates the coarse stream valve accordingly. This leads to a
significant change of the total flow so that the controller for the total flow closes the fine stream valve again until the
total flow has reached the new setpoint value.

NOTE Typical a large disturbance moves the overall flow away from its setpoint. The fine stream controller is
supposed to react quickly and compensate the disturbance, but will reach one of its manipulated
variable limits. The coarse flow controller slowly adapts to the situation and allows the fine stream
controller to return to the center of its manipulated variable range.

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 94

Equipment Modules

5.9. Gradient limits in actuators

"Gradient-Limit"
Numerous mechanical actuators in process plants, such as control valves, pumps with variable speed or thermostatic
baths, react only with limited speed to a change in the manipulated variable. As a result, the valve position, the pump
speed or the bath temperature cannot be changed as quickly as required and the achievable gradient of the controller’s
manipulated variables is limited. Even with a linear controller and an otherwise linear system, the behavior of the closed
control loop in this case is not independent of the amplitude, it depends on the signal form of the manipulated variable.
There is no effect of gradient limitation for slow manipulated variable changes. The steeper the signal edge, the stronger
the delaying effect. This alters the visible dynamics of the controlled system from the controller’s point of view. Since the
behavior is not known to the controller, integrator windup may occur in PID controllers leading to strong overshoots.
If the speed of the actuator is sufficiently fast compared to the other time constants of the controlled system, the control
dynamics are hardly distorted. If the dynamics are more strongly distorted, the controller is usually designed according to
the worst-case scenario, i.e. according to the largest occurring setpoint steps. In all other scenarios, such as disturbance
behavior, significant limitations of control performance are imposed.
In the following, the problem is presented using a simple flow control loop, consisting of PID controller and valve, and
four methods for improving control dynamics are explained.

Overview
Below, the structure in the P&ID is shown and all CMs and the simulation of the equipment module are described. The
structure is described in general for all methods. The modifications of the respective method are explained in the
corresponding subchapter.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field devices and containers relevant to operation.

FIC YC
GradLimit GradLimit

Feed

Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 95

Equipment Modules

CM and variants
The technical function "GradientLimit" consists of two interconnected CMs and a simulation plan. The behavior of the
controlled system is simulated in the simulation plan.
The following table provides an overview of the CMs of the equipment module, including the associated CMTs.
CM CMT Variant Description

FIC_GradLimit PIDCon • PV Flow controller

• PV_Scale#

YC_GradLimit VlvAn • IF_Ctrl# Control valve

• MV_Scale#
• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in simplified form.

Sim_GradLimit FIC_GradLimit YC_GradLimit

PV_In V
ValveGradSim
SimPV_In MV
In

PT1_2s to_Actor_Slave from_Ctrl

Out Out In

from_Actor_Slave to_Ctrl
In Out

The "FIC_GradLimit" controller detects the flow and controls it using the "YC_GradLimit" control valve. In the CFC chart
"SimGradLimit", the flow rate is calculated from the control value for the valve and the gradient limitation.

Structure and parameterization

Simulation "Sim_GradLimit"
The CFC "Sim_GradLimit" simulates the gradient limitation of the control valve and the flow rate.

2 3

1. Calculation of the valve feedback (valve position in the range 0...100 % and a maximum travel speed of 3 %/s in both
directions)
2. Calculation of the flow rate (100 % valve opening corresponds to an inlet of 2000 l/h)
3. Flow change delay (PT2 behavior with 15 seconds and 2 seconds delay)
4. Visualization of the position feedback in the WinCC Runtime

CFC "Method_GradLimit"
In the CFC "Method_GradLimit" the different methods for considering the gradient limitation of the actuator are selected
and activated.
The respective methods are activated in sub-sheets 1 to 4, the description of the individual methods can be found in the
following sub-sheets. The methods are selected in Subsheet 6.
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 96
Equipment Modules
1 2 3

1. Selection of the method from WinCC Runtime

2. Checking the input
3. Activation of the respective method for consideration of gradient limitation

FIC_GradLimit
The instance has the following parameterization.
Block Connection Value Use

PV_Scale HiScale 2000.0 Scaling of the process value upper limit

PV_Unit In 1353 Unit of the process value l/h (liters per hour)

C Gain.Value 5 Controller gain

C TI.Value 28 Controller lag

C SP_InHiLim 2000.0 Maximum value of the internal setpoint

to_Actor_Slave Out Connection to valve (YC_GradLimit\from_Ctrl.In)

from_Actor_Slave In Interconnection for the valve

(YC_GradLimit\to_Ctrl.Out)

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

PV SimPV_In Interconnection for the simulated process value

(Sim_GradLimit\PT1_2s.Out)

YC_GradLimit
The instance has the following parameterization.
Block Connection Value Use

V MV Interconnection for the simulation

(Sim_GradLimit\ValveGradLim.In)

from_Ctrl In Interconnection for the controller

(FIC_GradLimit\to_Actor_Slave.Out)

to_Ctrl Out Interconnection for the controller

(FIC_GradLimit\to_Actor_Slave.In)

YC SimOn Activation of simulation on the channel block

(Equipment_Modules\\Activate_Simulation\Sim_Act.Out)

Equipment Modules

5.9.1. Control behavior without active method

Commissioning and operation
For commissioning and operation, it is assumed that the user program has been loaded in the automation system (AS) or
the S7-PLCSIM and that the OS (WinCC Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Click on the block symbol of the valve "YC_GradLimit1".
The system opens the corresponding faceplate.

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to the controller "FIC_GradLimit1" and change the operating mode of the controller to "Automatic".
4. Enter a setpoint value of "300" L/h.

The new setpoint will be reached after approximately two minutes.

5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend curve for about two minutes until the new setpoint has been reached.

Equipment Modules
Evaluation

During the positive setpoint step, a significant difference between the manipulated variable for the valve and the actual
valve position (position readback signal, green) is visible. The actual valve position cannot follow the commands of the
controller (red) fast enough due to the gradient limitation. Since the difference between the manipulated variable for the
valve and the actual valve position is not known to the controller, an overshoot of more than 30 % of the step height
occurs, which would not be acceptable in many applications.

Equipment Modules

5.9.2. Method 1 "External Reset"

For controllers with an incremental algorithm that have an input variable for external reset, setting the manipulated
variable from the last sampling step (e.g. PIDConR.ExtReset), the actual actuator position is connected to this reset input.
This prevents the controller manipulated variable from drifting too far away from the position feedback signal.

Setup

Instead of the PIDConL controller, method 1 "External Reset" uses the PIDConR controller from the
NOTE
Advanced Process Library.

The following parameterization is required for the "External reset" method:

Block Connection Value Use
C ExtRstOn 1 Activate external reset

The following wiring is used in addition to the standard wiring:

Block Connection Target Description
C ExtReset Circuit for position feedback of the Reset value for ExtRstOn = 1
valve

Commissioning and operation

2. In the "YC_GradLimit1" valve faceplate, change the operating mode to "Automatic".

3. Switch to the controller "FIC_GradLimit1" and change the operating mode to "Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.

The new setpoint will be reached after approximately two minutes.

5. Specify a new setpoint of "800" L/h for the controller.

6. Close the faceplate and observe the trend window for about two minutes until the new setpoint has been reached.

Equipment Modules
Evaluation

With the "External reset" method activated, a significantly better control response is achieved for the same setpoint step,
the overshoot is significantly smaller, and the settling time is also shorter.

Equipment Modules

5.9.3. Method 2 "Tracking output value in case of

excessive deviation"
With the method "Tracking output value in case of excessive deviation", the controller output is adjusted to the current
position feedback signal as soon as the difference between the controller output and the position feedback signal exceeds
a limit (e.g. 25 % of the positioning range).

Setup
Three additional blocks ("Sub02", "AbsR" and "CopmAn02") from the Advanced Process Library are required for the method
"Adjust control value if deviation is too large".
The following parameterization is required:
Block Connection Value Use

CompAn02 In2 25 Difference between output value and position

feedback signal at which the output value is to be
reset

The following wiring is used in addition to the standard wiring:

Block Connection Target Description

Sub02 In1 Connection to the manipulated Form difference between manipulated

variable of the valve variable and position feedback signal

Sub02 In2 Circuit for position feedback of

the valve

Sub02 Out AbsR.In Output of the difference between

manipulated variable and position feedback
signal

AbsR In Sub02.Out Form absolute value

AbsR Out CompAn02.In1 Output of the absolute difference

CompAn02 In1 AbsR.Out Compare difference independent of direction

CompAn02 GT C.MV_TrkOn If the difference between the output value

and the position feedback signal is large,
adjust the output value of the controller.

C MV_TrkOn CompAn02.GT Activating the output value

C MV_Trk Circuit for position feedback of Tracking value for manipulated variable MV
the valve

Commissioning and operation

For commissioning and operation, it is assumed that the user program has been loaded in the automation system (AS) or
the S7-PLCSIM and that the OS (WinCC Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "2" at the faceplate "GradientLimit".
2. In the "YC_GradLimit2" valve faceplate, change the operating mode to "Automatic".
3. Switch to the controller "FIC_GradLimit2" and change the operating mode to "Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until the new setpoint has been reached.

Equipment Modules
Evaluation

After the difference between the manipulated variable and the position feedback signal exceeds the parameterized limit
value, the controller output (red) is set to the position feedback signal (green). This limits the manipulated variable curve
and completely avoids overshoot. The method is not effective for smaller setpoint steps because the difference between
the controller output and the position feedback signal does not exceed the limit value.

5.9.4. Method 3 "Blocking integrator"

Another method of handling actuator gradient limitation is the method of blocking the integrator. For this purpose,
signals showing if manipulated variable limits are reached, are read from the underlying valve positioner (e.g. Sipart PS) in
order to block the integrator in a direction-dependent manner. This method acts very specifically against integrator
windup and corresponds to what is proposed for cascade control within the distributed control system (interconnection of
the function blocks for master and slave controllers, see templates of the PCS 7 Advanced Process Library). This assumes
that binary feedback signals from the actuator are available as soon as the actuator reaches its internal manipulated
variable limitation and the gradient limitation thus takes effect.
Setup
The following wiring is used in addition to the standard wiring:
Block Connection Target Description

C IntHoldPos Limitation of the manipulated Block integrator in positive direction

variable in positive traverse
direction from the downstream
valve positioner

C IntHoldNeg Limitation of the manipulated Block integrator in negative direction

variable in negative traverse
direction from the lower-level
valve positioner

Equipment Modules
Commissioning and operation
For commissioning and operation, it is assumed that the user program has been loaded in the automation system (AS) or
the S7-PLCSIM and that the OS (WinCC Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "3" at the faceplate "GradientLimit".
2. In the "YC_GradLimit3" valve faceplate, change the operating mode to "Automatic".
3. Switch to the controller "FIC_GradLimit3" and change the operating mode to "Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until the new setpoint has been reached.

Evaluation

With the "Blocking integrator" method activated, the integrator windup can be suppressed such that the overshoot is
reduced during the setpoint step. The lower part of the trend shows when the gradient limitation is active.
Direction-dependent blocking has the advantage that it works independently of the step height, such that tracking
behavior is less slowed down, and no parameterization is required. However, the binary signals required for this are only
available for a few installations in the distributed control system.
One example is an electro-pneumatic valve positioner, which often operates internally as a 5-point positioner. The so-
called slow gear zone, in which an approximately proportional control behavior is visible, covers only 1...10 % of the valve
position range. As soon as the control deviation leaves this range, the positioner opens the maximum air supply to the
valve actuator, i.e. it operates at its manipulated variable limit. This happens frequently during operation with large
setpoint steps. The corresponding binary signals are usually only available for internal use within the field device and are
not made available to the outside world via a communication interface.

Equipment Modules

5.9.5. Method 4 "Blocking integrator with gradient

calculation"
The "Blocking integrator with gradient calculation" method allows directional blocking of the integrator even in cases
where no feedback can be received from the actuator showing that the actuator is moving at maximum speed. For this
purpose, this information is reconstructed inside the process control system by calculating the current gradient of the
valve position and comparing it to the known limit value of the maximum travel speed.
Typically position feedback is superimposed by measuring noise, therefore a low-pass filtering with meaningful time
constant must be performed in front of the differentiator.

Setup
For the "Blocking integrator with gradient calculation" method, three additional blocks ("Derivative" and twice
"CopmAn02") from the Advanced Process Library are required.
The following parameterization is required:

Block Connection Value Use

Derivative OutHiLim -100.0 Maximum gradient in negative direction

Derivative LagTime 1.0 Low pass delay time

CompAn02_pos In2 2.9 Comparison gradient in positive direction

CompAn02_neg In2 -2.9 Maximum gradient in negative direction

The maximum gradient must be parameterized so that it is just below the real gradient limit. Otherwise the limitation
would not be detected.

The following wiring is used in addition to the standard wiring:

Block Connection Target Description

Derivative In Connection to the manipulated Calculation of the travel gradient
variable of the valve

Derivative Out CompAn02_pos.In Output of the calculation of the travel

CompAn02_neg.In gradient

CompAn02_pos In1 Derivative.Out Comparison of maximum travel speed

in positive direction

CompAn02_pos Out C.IntHoldPos Maximum travel speed reached in

positive direction

CompAn02_neg In1 Derivative.Out Comparison of maximum travel speed

in negative direction

CompAn02_neg Out C.IntHoldPos Maximum travel speed reached in

negative direction

C IntHoldPos CompAn02_pos.Out Block integrator in positive direction

C IntHoldNeg CompAn02_neg.Out Block integrator in negative direction

Equipment Modules
Commissioning and operation
For commissioning and operation, it is assumed that the user program has been loaded in the automation system (AS) or
the S7-PLCSIM and that the OS (WinCC Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "4" at the faceplate "GradientLimit".
2. In the "YC_GradLimit4" valve faceplate, change the operating mode to "Automatic".
3. Switch to the controller "FIC_GradLimit4" and change the operating mode to "Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until the new setpoint has been reached.

Evaluation

With the activated method "Blocking integrator with gradient calculation", the integrator windup can also be suppressed
such that the overshoot is reduced during the setpoint step. Due to the delay caused by the low-pass filter, the effect of
the method is not quite as good as if the original binary signals are available.

Equipment Modules

5.9.6. Methods comparison

In control loops with mechanical actuators whose moving speed is so strongly limited that the delaying effect of the
gradient limitation cannot be neglected compared to the other time constants of the controlled system, a windup of the
integrator can be avoided by applying one of the four methods. This allows to reduce the overshoot, especially with large
setpoint steps, without generally tuning the controller very sluggish and thus also impairing the disturbance
compensation of the control loop.
The following table compares the methods for suppressing integrator windup in case of gradient limitations of the
manipulated variable.

Method Requirements Parameters Effect

External reset Controller block PIDConR None reduces divergence of
setpoint and feedback of
Analog position feedback
the actuator in case of
from actuator
large setpoint steps,
reduces overshoot

Tracking output value in Analog position feedback Switching threshold for Proportional step is
case of excessive deviation maximum deviation truncated, tracking
e.g. 25 %. behavior is slowed down,
slow settling times

Blocking integrator Controller block PIDConL None Avoids windup in case of

binary feedback from active gradient limitation,
actuator when internal reduces overshoots
manipulated variable
limitation is active
(i.e. gradient is limited)

Integrator blocking with Controller block PIDConL maximum travel gradient Avoids windup in case of
gradient calculation Analog position feedback active gradient limitation,
Low pass filtering with
from actuator reduces overshoots
meaningful time constant

The "External Reset" method has the advantage that it can be used for controllers with incremental algorithms without
further parameterization and without special requirements on the feedback signals from the final control element.
The method "Tracking the output value in case of excessive deviation" has the widest range of application. It does not
require a special control algorithm, binary feedback signals or high signal quality of the analog feedback signal. Only
application-specific limit values must be parameterized. The method slows down the tracking behavior for large setpoint
steps and remains completely ineffective for small setpoint steps.
The "Blocking integrator" method achieves the highest overall control performance for setpoint steps of different heights,
but requires binary feedback signals from the actuator when its internal manipulated variable signal limitation is active.
The "Blocking Integrator with gradient calculation" method allows the use of directional integrator blocking with reduced
precision even when there are no binary feedback signals from the actuator. For this the maximum actuator gradient and
a meaningful filter time constant must be determined.

Selecting the method

When selecting the method for considering gradient limits in final control elements, the following sequence of criteria
can be used:
1. If an incremental control algorithm is used, the "External Reset" method is preferred.
2. If no incremental control algorithm is used, but the binary feedback signals of the actuator are available when the
internal manipulated variable limitation is active, the "Blocking integrator" method should be selected.
3. If the binary feedback signals are not available, the method "Blocking integrator with gradient calculation" must be
selected as an alternative.
4. If sufficient smoothing of the position readback signal is not possible or the filter time constant is not negligible small
compared to the time constants of the controlled system, use the method "Tracking output value in case of excessive
deviation".

Equipment Modules

5.10. Instance-specific adaptations

NOTE No alarm, warning or tolerance limits are pre-parameterized in the equipment modules. If you
parameterize a limit value, you must also activate the corresponding notification.
For example, parameter "PV_AH_En" for upper alarm limit "PV_AH_Lim".

NOTE Interconnection of the process variables depends on the selected variant of a CM. In the configuration
below, the control, process, and manipulated variables are acquired via the "Pcs7AnIn" and "Pcs7AnOu"
analog channel blocks.

The tables below contain the relevant parameters that you must either set or interconnect.

Controller
Block Connection Use

C Gain Proportional gain

C TD Differential action time in s

C TI Integral action time in [s]

C SP_InHiLim (Upper) limit value of the internal setpoint

C SP_InLoLim Limit (lower) of internal setpoint

C PV_AH_En Alarm in case of upper limit value violation if PV ≥ PV_AH_Lim

C PV_WH_En Alarm in case of upper limit value violation if PV ≥ PV_WH_Lim

C PV_TH_En Tolerance in case of upper limit value violation if PV ≥ PV_TH_Lim

C PV_TL_En Tolerance in case of lower limit value violation if PV ≤ PV_TL_Lim

C PV_WL_En Alarm in case of lower limit value violation if PV ≤ PV_WL_Lim

C PV_AL_En Alarm in case of lower limit value violation if PV ≤ PV_AL_Lim

C ER_AH_En Alarm in case of upper control difference violation if ER ≥ ER_AH_Lim

(hidden)

C ER_AL_En Alarm in case of lower control difference violation if ER ≤ ER_AL_Lim

(hidden)

PV_Scale HiScale Scaling of the measured value (e.g. maximum container fill level of 10000)
LoScale

PV_Unit IN Unit of the scaled measured value (e.g. 1038 fill level in liters)

PV PV_In Acquisition of the controlled variable, e.g. fill level

Display
Block Connection Use

I PV_AH_En Alarm in case of upper limit value violation if PV ≥ PV_AH_Lim

I PV_WH_En Alarm in case of upper limit value violation if PV ≥ PV_WH_Lim

I PV_TH_En Tolerance in case of upper limit value violation if PV ≥ PV_TH_Lim

I PV_TL_En Tolerance in case of lower limit value violation if PV ≤ PV_TL_Lim

Equipment Modules
Block Connection Use

I PV_WL_En Alarm in case of lower limit value violation if PV ≤ PV_WL_Lim

I PV_AL_En Alarm in case of lower limit value violation if PV ≤ PV_AL_Lim

PV_Scale HiScale Scaling of the measured value (e.g. maximum container fill level of 10000)
LoScale

PV_Unit IN Unit of the scaled measured value (e.g. 1038 fill level in liters)

PV PV_In Acquisition of the process variable, e.g. fill level

Valve
Block Connection Use

V MV_HiLim Upper and lower limit of the manipulated value

MV_LoLim

MV_Scale HiScale Scaling of the manipulated variable (manipulated value of the valve block)
LoScale

MV_Unit IN Unit of the scaled manipulated variable

MV_Out PV_Out or Channel blocks for linking a control valve

PV_ChnST Output of the manipulated variable or
Output of the manipulated variable including the signal status

NOTE In the object properties of the message-type blocks, you can configure instance-specific messages. You
can find a guide to the procedure in the "SIMATIC PCS 7 Process Control System; Operator Station
(V9.1)" configuration manual under https://support.industry.siemens.com/cs/ww/de/view/109794374.

Additional information

6. Additional information
6.1. General Information
Automation technology
Industrial processes in the chemicals or pharmaceuticals sectors, for example, are controlled and regulated using
automation technology.
The degree of automation of systems varies considerably and depends on the system type and the process.
In general, an automation solution includes the following aspects:

• Measurement and control

• Possibly, control of higher quality control strategies
• Transferring, processing and representing information
• Complying with defined steps and procedures
• Observing complex contexts
• Guaranteeing constant product quality
• Strategies in the case of deviations from or exceeding of process parameters or of component failures

Process control
The operator’s main task is to carry out operative process control based on process and plant information with respect to
production process and its logistics and auxiliary processes.
The task of process control is to guarantee that operating conditions are are kept in, compliance with defined tolerance
ranges for process safety and product quality, in a selective and reproducible way. In case of disturbances, the process has
to be driven back to the desired operating state. In addition, the production sequence should be continuously optimized
regarding costs, quality, and safety.
Using SIMATIC PCS 7 Advanced Process Graphics (APG), it is possible to make process visualization more efficient for
operators. When doing this, the system shows the information in the plant overview that is relevant for orientation and
navigation. The information that is necessary for operator control and monitoring of a plant unit, e.g. a reactor, is made
available in a lower-level process picture. This procedure provides the great advantage of dispensing information in a task-
oriented way that is optimized for process operation.

NOTE You can find detailed information and the procedure for configuring APG in the Siemens Industry
Online Support in the entry entitled "Integration of Advanced Process Graphics in SIMATIC PCS 7"
under https://support.industry.siemens.com/cs/ww/en/view/89332241.

Additional information

6.2. Standardized plant units

Partial automation solution
The figure below shows the components of an automation solution for a process plant. The production process is divided
into several steps, e.g. fermentation and distillation. In this connection, one process step corresponds to one plant unit,
which, for its part, can consist of different equipment modules, e.g. addition of starting material or agitation.

Unit
The term plant unit represents an apparatus (device) in process plants (e.g. stirred tank reactor, fermenter) which
includes sensor technology, actuators and automation (hardware and software).
There are structured units for both continuous and discontinuous processes.
Package units are variants of a plant units. Examples of package units include refrigeration systems, vacuum systems and
packaging machines. In this case, the manufacturer of the mechanical or technical device includes automation
technology, specially tailored for this device, which is mounted locally on the device on a separate hardware platform.
The package unit is integrated as a whole into a higher-level process control system.

Equipment module
An equipment module forms part of a unit and contains sensors, actuators and the automation system (hardware and
software). Equipment modules are designed and configured for use in concrete applications, such as process technology
(dosing device, level or temperature control).
The automation solution of an equipment module is structured as follows:

• Connected and parameterized process tags

• Elementary simulation to demonstrate the mode of operation for virtual commissioning, not necessary for plant
operation
Each equipment module is combined in a hierarchy folder and can be integrated into existing projects.

Control module
Actuators and sensors are used at the control module level as control modules.
In PCS 7, the control module is implemented with software typicals
(control module types) such as a valve, motor, or controller, for example.
The implementation in the CFC contains all the relevant building blocks, interconnections, and basic parameters. A
control module type is produced from the CFC, which is then stored in the PCS 7 master data library. You can create as
many instances as you like from this control module type using the Automation Interface, for example. There can be
major differences between the instances, e.g. you can select options for functions as well as for the process link.
Each designation of a control module follows a uniform naming convention. This means that the name provides
information about the function and the job of the control module.

Additional information
Unit Template
A Unit Template is composed of several equipment modules. In a Unit Template, equipment modules are grouped into a
partial automation solution.
In addition, it is possible to display other information in a Unit Template, such as economic or process engineering
parameters (KPIs) or the operating times of equipment.
A Unit Template is grouped in a hierarchy folder and you can easily integrate it into existing projects and adapt it.
In contrast to package units, no local isolated control systems with their own hardware are set up; rather, in the Unit
Template concept, pre-assembled software solutions are created in a central process control system for frequently
occurring unit types. Partial automation solutions for process plants are provided on a uniform pre-assembled basis and
can be edited by users. This means that it is sufficient to adapt the templates to the existing process plant and automation
hardware. This significantly reduces the engineering effort required for several similar automation tasks.

Configuration with templates

You can carry out configuration using templates at the equipment module or control module level.
At the control module level, you use control module types in PCS 7 to create a template for creating instances. It is
possible to compare and match the instances of the control module types with the PCS 7 Automation Interface.
Equipment modules or plant units are duplicated as a unit and adapted to the corresponding process engineering.
The equipment modules and the Unit Template contain all functions that are needed for automation in form of:

• CFCs (instances of control module types)

• SFCs
• OS pictures

Additional information

6.3. Design and structure

6.3.1. CFC naming convention
A uniform naming convention was used to identify the control modules with the function being named according to
European standard EN 62424 or to ISO 3511. The figure below shows how a label is composed:
FIC_Reflux
Function Designation
F = Flow (First letter)
I = Indication (Next letter)
C = Control (Next letter)

The table below contains all the letters that are used in the Application Example and their meanings:

First letter Meaning

F Flow

J Power

L Level

M Moisture

N Motor

P Pressure

Q Amount, quantity or quality

S Speed

T Temperature

W Weight

X Freely selectable first letter

Y Control valve

Subsequent letter Meaning

A Alarming/Messages

C Control

F Fraction

I Indication

R Recording/Storage

S Binary control function or switching function (not safety-oriented) ("switching")

T Monitoring (transmitter, analog value processing)

H High

L Low

Additional information

6.3.2. Plant view

In the plant view, the equipment modules are implemented on two hierarchy levels.
In the "EquipmentModules_AS_Prj" AS project, the first hierarchy level is empty and on the lower hierarchy level there is
one hierarchy folder for each equipment module that contains the necessary CFC.
On the first hierarchy level of the "EquipmentModules_OS_Prj" OS project, there is the overview picture of all the
equipment modules "EquipmentModules.pdl”. On the lower hierarchy level there is one hierarchy folder for each
equipment module that contains a process picture. The illustration below shows the folder structure on a schematic basis,
i.e. the designations of the sub-folders differ from the folder designations of the PCS 7 project.

EquipmentModules OS Project

PDL
Overview picture

EquipmentModule 1

PDL
EquipmentModule 1

EquipmentModule 2

PDL
EquipmentModule 2

EquipmentModules AS Project

EquipmentModule 1

User program Simulation

CFC CFC CFC

LIC_RefluxDrum LIC_Level Simulation

EquipmentModule 2
User program Simulation

CFC CFC CFC

PI_Tank PIC_Split Simulation

Additional information

6.4. Controllers and control response

The aim of this chapter is to give you an understanding of controller response and the principle of operation in the case of
faults or maintenance. To do this, we describe tracking of the manipulated variable in picture form and display the
messages or displays on the faceplates in the case of faults.

6.4.1. Tracking standard and cascade controllers

Tracking of the manipulated variable is explained using the temperature flow cascade as an example by changing the
(internal/external) setpoint specification from the control valve to the master controller and the (manual/automatic)
operating mode.
The following applies, in general: A controller must always be set to tracking mode if it does not have access to the
following block (follower controller or actuator), because otherwise windup problems occur with controllers with an I
component. A controller always has no access to the following block if the following block is not in automatic mode and
uses the external setpoint. The tracking value is always selected in such a way that the cascade can be closed again later
without jolts.

Master controller

Slave controller

Control valve

No. Master controller Slave controller Control valve Comment

1. Manual/Internal Manual/Internal Manual/Internal

(Forcing active) (Forcing active)
2. Manual/Internal Manual/Internal Manual/Internal Manipulated value
(Forcing active) (Forcing active) specification 20 % in control
Manipulated value 1t/h Manipulated value Manipulated value valve
20 % 20 % The manipulated values are
tracked automatically
3. Manual/Internal Manual/Internal Automatic/External Operating mode changed in
(Forcing active) (Forcing canceled) control valve. The control
Manipulated value 1t/h Manipulated value Manipulated value valve applies the tracked
20 % 20 % (external) manipulated
variable on a bumpless basis
from the slave controller
4. Manual/Internal Automatic/Internal Automatic/External Operating mode changed in
(Forcing active) slave controller. No change
Manipulated value 1t/h Manipulated value Manipulated value in behavior.
20 % 20 %
5. Manual/Internal Automatic/External Automatic/External Setpoint specification
(Forcing canceled) changed in slave controller.
Manipulated value 1t/h Manipulated value Manipulated value The slave controller applies
20 % 20 % the tracked (external)
manipulated variable on a
bumpless basis from the
master controller

Additional information

6.4.2. Tracking ratio controllers

Tracking of the manipulated variable is explained using the "Ratio control” equipment module as an example by changing
the (internal/external) setpoint specification from the control valve to the master controller and the (manual/automatic)
operating mode.

Master controller Control valve

Master controller

Slave controller Control valve

Slave controller 1

Slave controller Control valve

Slave controller 2

No. Master controller Slave controller Control valve Control valve Comment
master controller slave controller

1. Manual/Internal Manual/Internal Manual/Internal Manual/Internal

(Forcing active) (Forcing active)
2. Manual/Internal Manual/Internal Manual/Internal Manual/Internal Manipulated value
(Forcing active) (Forcing active) specification 20 % in
Manipulated value Manipulated value Manipulated value Manipulated control valve2
0.00 l/h 100 l/h 0% value 20 % The manipulated
variable is tracked
automatically
3. Manual/Internal Manual/Internal Manual/ Manual/ Manipulated value
(Forcing active) (Forcing canceled) Internal Internal specification 30 % in
Manipulated Manipulated value control valve1
value 600 l/h 100 l/h Manipulated Manipulated value The manipulated
value 30 % 20 % variable is tracked
automatically
4. Manual/Internal Manual/Internal Manual/ Automatic/ Operating mode
(Forcing active) (Forcing canceled) External External changed in control
Manipulated value Manipulated value valve2.
600 l/h 100 l/h Manipulated value Manipulated value
30 % 20 %
5. Manual/Internal Manual/Internal Automatic/ Automatic/ Operating mode
(Forcing (Forcing canceled) External External changed in control
canceled) Manipulated value valve1.
Manipulated value 100 l/h Manipulated value Manipulated value
600 l/h 30 % 20 %
6. Manual/Internal Automatic/ Automatic/ Automatic/ Operating mode
(Forcing canceled) External (forcing External External changed in slave
Manipulated value canceled) controller. The
600 l/h Manipulated value Manipulated value Manipulated manipulated variable
150 l/h 30 % value 30 % is tracked
automatically

Additional information

6.4.3. Tracking split range temperature

Tracking of the manipulated variable is explained using the split range temperature as an example by changing the
(internal/external) setpoint specification from the control valve to the master controller and the (manual/automatic)
operating mode. The front part of the cascade with the interaction of master and slave controller works exactly like the
normal cascade control in section 6.4.1. In tracking operation, the split-range controller uses the neutral position as the
tracking value, because in manual operation or with an internal setpoint of both actuators, combinations of output values
can be set that cannot be mapped via the split-range.

When using a split-range rule structure, it is not ensured that bumpless return to normal operation is
NOTE
possible.

Master controller

Slave controller
Control valve 1

Control valve 2

No. Master controller Slave controller Control valve1 Control valve2 Comment

1. Manual/Internal Manual/Internal Manual/ Manual/

(Forcing active) (Forcing active) Internal Internal
2. Manual/Internal Manual/Internal Automatic/ Automatic/ Operating mode
(Forcing active) (Forcing External External changed for control
canceled) valves. No change in
behavior.
3. Manual/Internal Automatic/ Automatic/ Automatic/ Operating mode
(Forcing External External External changed with slave
canceled) (Forcing canceled) controller. No change in
behavior.
4. Automatic/ Automatic/ Automatic/ Automatic/ Operating mode
Internal External External External changed with master
(Forcing canceled) controller. Manipulated
Manipulated variable specification
variable 30 °C 30 °C in master
controller. The slave
controller applies the
tracked (external)
manipulated variable on
a bumpless basis from
the master controller.
5. Manual/Internal Automatic/ Automatic/ Automatic/ Setpoint specification
(Forcing canceled) External External External changed in slave
Manipulated controller. The slave
variable 30 °C Manipulated Manipulated Manipulated controller applies the
variable 50 °C variable >= 0 % variable >= 0 % tracked (external)
manipulated variable on
a bumpless basis from
the master controller.

Additional information

6.4.4. Faults and maintenance for temperature

throughflow cascade
In general, a controller cannot work if it does not receive correct actual value of the measured values due to wire break,
loose contact, short circuit, bus error, sensor failure or similar. The error case is signaled at the channel block by the
output "Bad = true".
The controller is then put into the fault state (CSF: Control System Fault) by means of an interconnection and allows the
operator to set manually the manipulated variable in order to be able to influence at least the process. In case of a fault in
the channel to the actuator even this possibility of intervention is no longer available. For the tracking of the master
controller, the general rules also valid here: as soon as the slave controller is no longer able to follow commands of the
master controller (no matter why, even with CSF in slave controller), the master controller must be taken in tracking to
enable later bumpless switching to normal operation.
The tables below describe the way of functioning and generated messages of the individual process tags using the
temperature throughflow cascade in case of errors as an example.
The error on the channel block (the Bad output is active) occurs if there is a short-circuit or a wire break on the device, for
example.
Maintenance status OoSAct (lies: "Out of Service") occurs if maintenance is being carried out on the device. From the
controller's point of view, the sensor state "Out of service" has the same consequences as the measurement loss.

Faulty slave controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

Control or manipulated variable CSF puts the controller into No change in operating mode. The
specification is not possible since the disturbance status (external error). manipulated variable of the slave
CSF with the slave controller is forced Controller switches to manual mode. controller still matches the
The manipulated variable for the manipulated variable, MV.
control valve can be changed

NOTE As soon as the CSF on the slave controller is no longer active, it can be switched back to the original
operating status (automatic/external).

Additional information
Faulty master controller
Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

CSF puts the controller into The slave controller continues to The control valve continues to receive
disturbance status (external error). receive the MV from the master the MV from the slave controller
The manipulated variable (MV) can controller
be changed.

NOTE As soon as the CSF on the master controller is no longer active, it can be switched back to the original
operating status (automatic/external).

Faulty control valve

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

The controller receives the MV in the The controller receives the MV in the CSF puts the valve into disturbance
case of a manual change on the case of a manual change on the status (external error)
control valve control valve The manipulated variable (MV) can
be changed (manual)

NOTE As soon as the CSF on the control valve is no longer active, it can be switched back to the original
operating status (automatic/external).

Maintenance status on slave controller

Master controller

Slave controller
Control valve

Additional information
Master controller Slave controller Control valve

The controller maintains the old MV The controller cannot be operated The control valve retains the old
until normal operation is re- due to maintenance. value while there is no new MV from
established or the operator specifies a The user can switch to manual the slave controller
different MV on the slave controller mode and specify the MV for the
manually. control valve.

NOTE As soon as the maintenance status is no longer active, the slave controller can be switched back to the
original operating status (automatic/external).

Maintenance status on master controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

The controller cannot be operated The controller retains the old value The control valve retains the old
due to maintenance. while there is no new MV from the value while there is no new MV from
The user can switch to manual mode master controller. the slave controller.
and specify the MV for the slave
controller.

NOTE As soon as the maintenance status is no longer active, the master controller can be switched back to
the original operating status (automatic/external).

Maintenance status on control valve

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

Normal operation is possible Normal operation is possible Normal operation is still possible.
The maintenance status is
displayed.

Additional information

6.4.5. Faults and maintenance for ratio controllers

The tables below describe the way of functioning and generated messages of the individual process tags using the ratio
controllers in case of errors as an example.
The error on the channel block (the Bad output is active) occurs if there is a short-circuit or a wire break on the device, for
example.
Maintenance status OoSAct occurs if maintenance is being carried out on the device.

NOTE In the chapter below, we will not consider the second slave controller with control valve, since the
behavior matches that of the first slave controller with control valve.

Faulty slave controller

Master controller Control valve

Master controller

Slave controller 1
Control valve
Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Master controller Control valve master Slave controller 1 Control valve slave
controller controller 1

The controller functions The control valve functions CSF puts the controller The control valve retains
without limitations. without limitations. into malfunction status. the old MV until the slave
The MV can be changed. controller specifies a new
value.

NOTE As soon as the CSF on the slave controller is no longer active, it can be switched back to the original
operating status (automatic/external).

Additional information
Faulty master controller

Master controller Control valve

Master controller

Slave controller 1
Control valve
Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Master controller Control valve master Slave controller 1 Control valve slave
controller controller 1

CSF puts the controller into The control valve functions The controller functions The control valve functions
malfunction status. without limitations. without limitations. without limitations.
The manipulated variable
can be changed.

NOTE As soon as the CSF on the master controller is no longer active, the master controller is back in
operating condition

Faulty control valve of master controller

Master controller Control valve

Master controller

Slave controller 1
Control valve
Slave controller 1

Slave controller 2 Control valve

Slave controller2

Additional information
Master controller Control valve master Slave controller Control valve slave
controller controller

The controller functions CSF puts the control valve The controller functions The valve functions
without limitations. of the master controller without limitations. without limitations.
into malfunction status.
The valve functions
without limitations.

NOTE As soon as the CSF on the master controller's control valve is no longer active, it is back in
Automatic/External mode.

Faulty control valve of slave controller

Master controller Control valve

Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Slave controller 2

Faulty control valve of slave controller

Master controller Control valve master Slave controller Control valve slave
controller controller

The controller functions The valve functions The controller functions CSF puts the control valve
without limitations. without limitations. without limitations. of the slavce controller
into malfunction status.
The valve functions
without limitations.

NOTE As soon as the CSF on the slave controller's control valve is no longer active, it is back in
Automatic/External mode.

Additional information
Maintenance status on slave controller

Führungsregler
Master controller Control
Stellventil
valve
Master
Führungsregler
controller

SlaveFolgeregler
controller 11 Stellventil
Control valve
Slave controller 11
Folgeregler

SlaveFolgeregler
controller 22 Control
Stellventil
valve
SlaveFolgeregler
controller 2

Master controller Control valve master Slave controller Control valve slave
controller controller

The controller functions The valve functions The controller cannot be The control valve retains
without limitations. without limitations. operated due to the old value until the slave
maintenance. controller specifies a new
The user can switch to MV.
manual mode and change
the MV.

NOTE As soon as the maintenance status is no longer active, the slave controller can be switched back to the
original operating status (automatic/external).

Maintenance status on master controller

Master controller Control valve

Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Additional information
Master controller Control valve master Slave controller Control valve slave
controller controller

The controller cannot be The control valve retains The controller functions The valve functions
operated due to the old value until the slave without limitations. without limitations.
maintenance. controller specifies a new
The user can switch to MV.
manual mode and change
the MV.

NOTE As soon as the maintenance status is no longer active, the master controller can be switched back to
the original operating status (automatic).

Maintenance status on control valve of master controller

Control valve
Master controller
Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Slave controller 2

Master controller Control valve master Slave controller Control valve slave
controller controller

The controller functions The valve displays the The controller functions The valve functions
without limitations. maintenance status and without limitations. without limitations.
functions without
limitations.

Additional information
Maintenance status on control valve of slave controller

Control valve
Master controller
Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Slave controller 2

Master controller Control valve master Slave controller Control valve slave
controller controller

The controller functions The valve functions The controller functions The valve displays the
without limitations. without limitations. without limitations. maintenance status and
functions without
limitations.

Additional information

6.4.6. Faults and maintenance of split range

temperature
The tables below describe the way of functioning and generated messages of the individual process tags using the split
range temperature controller in case of errors as an example.
The error on the channel block (the Bad output is active) occurs if a short-circuit or a wire break occurs on the device, for
example.
Maintenance status OoSAct occurs if maintenance is being carried out on the device.

Faulty slave controller

Master controller

Slave controller
Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller functions CSF puts the controller The valve functions The valve functions
without limitations. into malfunction status. without limitations. without limitations.
The MV can be changed.

NOTE As soon as the CSF on the slave controller is no longer active, it can be switched back to the original
operating status (automatic/external).

Faulty master controller

Master controller

Slave controller Control valve 1

Control valve 2

Additional information
Master controller Slave controller Control valve1 Control valve2

CSF puts the controller into The controller retains the The valve functions The valve functions
malfunction status. last manipulated variable without limitations. without limitations.
The MV can be changed. that was present until the
master controller specifies
a new value.

NOTE As soon as the CSF on the master controller is no longer active, it can be switched back to the original
operating status (automatic).

Faulty control valve 1

Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller functions The controller functions CSF puts the valve into The valve functions
without limitations. without limitations. malfunction status. without limitations.
Operation and the MV
can be changed.

Faulty control valve 2

Master controller

Slave controller Control valve 1

Control valve
2

Master controller Slave controller Control valve1 Control valve2

The controller functions The controller functions The valve functions CSF puts the valve into
without limitations. without limitations. without limitations. malfunction status.
The operating mode and
the MV can be changed.

Additional information
Maintenance status on slave controller
Master controller

Slave controller
Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller cannot affect The controller cannot be The valve functions The valve functions
the process while the slave operated due to without limitations. without limitations.
controller is being maintenance.
maintained. The user can switch to
manual mode and specify
the MV for the control
valve.

NOTE As soon as the maintenance status is no longer active, the slave controller can be switched back to the
original operating status (automatic/external).

Maintenance on master controller

Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller cannot be The controller retains the The valve functions The valve functions
operated due to old value while there is no without limitations. without limitations.
maintenance. new MV from the master
The user can switch to controller.
manual mode and specify
the MV.

NOTE As soon as the maintenance status is no longer active, the master controller can be switched back to
the original operating status (automatic).

Additional information
Maintenance on control valve 1
Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller functions The controller functions The valve displays the The valve functions
without limitations. without limitations. maintenance status and without limitations.
functions without
limitations.

Maintenance on control valve 2

Master controller

Slave controller
Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller functions The controller functions The valve functions The valve displays the
without limitations. without limitations. without limitations. maintenance status and
functions without
limitations.

Additional information

6.5. Block description of "pHTitrBlock"

Function description
The block is used to convert pH values to concentration differences. To do this, you must enter process-specific
characteristics of the titration curve in the form of parameters for the pH amplitude and buffer effect (α). The titration
curve describes the relationship between the pH value and the concentration difference between H + (or H3O+) ions
(acidic) and OH- ions (alkaline) in the solution. For a given combination of chemicals, you can determine them in an
experiment by adding an acid or an alkali (neutralizer) in small steps. After each small dose, you mix the solution well,
wait for the neutralization reaction, and make a note of the new pH value.

For the equipment modules for pH value control, you use the trigonometric function below as an approximation of the
titration curve for conversion:
2𝑝𝐻𝑎𝑚𝑝𝑙 ∆𝑐
𝑝𝐻 = 7 + ∙ arctan (𝛼 ∙ 6 )
𝜋 10
This characteristic curve is inverted to convert pH values to concentration differences.

1 𝜋
∆𝑐 = ∙ tan ( ∙ (𝑝𝐻 − 7)) ∙ 106
𝛼 2𝑝𝐻𝑎𝑚𝑝𝑙

NOTE Conversion is carried out in the two blocks below that are a component of the "pHTitrBlock" and are
included in the master data library:

• FB1025 "Titr_pH" for converting the concentration difference to the →pH value
• FB1026 "TitrDeltaC" for converting the pH value to the →concentration difference

Titration curve for various highly buffered solutions; pHampl=5

pH
12

11 alpha=3500
alpha=12000
10

2
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
delta c 4
x 10

In the titration curve illustration, the neutral zone is at 7 pH with the maximum excursion (amplitude) of 5. Typical values
of between 3500 and 12000 are present for the steepness of the characteristic curve in the neutral point (parameter α).
Entry ID: 53843373 V5.2 09/2023 © Siemens 2023 131
Additional information

NOTICE Use in a productive environment is conditional upon knowing the titration curve that must be
entered in the block.
The parameters include:

• the amplitude area pHampl to be passed through on the pH value scale

• the buffer parameter α (alpha) as a measure of the steepness of the characteristic curve in the
neutral point

Inputs
Input Data type Description

CV STRUCT pH actual value

->Real
->Byte

DV STRUCT pH value of the disturbance variable

->Real
->Byte

SP STRUCT pH setpoint (specified by OpAnL operator control block oper SFC, for
->Real example)
->Byte

Alpha STRUCT Measure of the steepness of the characteristic curve in the neutral point
->Real
->Byte

Ampl_pH STRUCT The amplitude range that is to be crossed

->Real
->Byte

MV STRUCT Manipulated variable of the controller

->Real
->Byte

Feed_PV_Out STRUCT Inflow of the input material (disturbance variable)

->Real
->Byte

Feed_Scale STRUCT Scaling of the inflow (ScaleOut)

->Real
->Real

Conversion of the concentration differences for inputs "CV", "DV", and "SP" is carried out based on parameters "Alpha" and
"Ampl_pH".

Outputs
Output Data type Description

CV_Out STRUCT Concentration difference of the pH actual value

->Real
->Byte

DV STRUCT Concentration difference of the pH value of the disturbance variable

->Real
->Byte

SP STRUCT Concentration difference of the pH setpoint

->Real
->Byte

Additional information
Output Data type Description

MVHiLim STRUCT Variable upper limit value of manipulated variable MV depending on the feed
->Real amount of input material
->Byte (MVHiLim = 100/Feed_PV_Out/Feed_Scale.Max)

MV_Valve STRUCT Variable manipulated variable (to the valve process tag) depending on the
->Real feed amount of input material
->Byte (MV_Valve = Feed_PV_Out/Feed_Scale.Max * MV)

Interconnection of the inputs and outputs of the manipulated variables/disturbance variables ("MV", "Feed_PV_Out",
"Feed_Scale", "MVHiLim", "MV_Valve") is carried out if it is intended to compensate the feed amount as a disturbance
variable.

NOTE The output variable of the controller (what you can think of as a "concentration") is multiplied by the
(standardized) feed amount of the waste water (input material) to calculate a measure of the required
amount of neutralizer. If manipulated variable limitation in the controller itself were to be constant,
this would result in it only being possible to use the dosing valve for complete control at maximum
waste water flow through. One remedy is to interconnect MV1HiLim dynamically in dependence on
the feed amount.

Additional information

6.6. Block description of "SimpHTitr"

Function description
The block is used to calculate a pH value based on process-specific characteristics like the titration curve of the process,
the inflow amounts, and the pH values of the input material and the neutralizer, for example. The titration curve
describes the relationship between the pH value and the concentration difference of the supplied neutralizer.

Inputs
Input Data type Description

Feed_pH STRUCT pH value of the input material

->Real
->Byte

Alpha STRUCT Measure of the steepness of the characteristic curve in the neutral point
->Real
->Byte

Ampl_pH STRUCT The amplitude range that is to be crossed

->Real
->Byte

Neutr_MV STRUCT Manipulated variable of the controller for the neutralizer

->Real
->Byte

Neutr_Lag Real Delay of the manipulated variable (neutralizer)

Neutr_Factor Real Factor value for inflow of the neutralizer

Feed_PV STRUCT inflow amount of the input material

->Real
->Byte

pH_DeadTime Real Time-delayed signal output in seconds (deadtime)

NOTICE When using the deadtime (pH_DeadTime > 0), you must use a multi-variable controller
(ModPreCon block) for compensation and feedforward injection of disturbance variable.

Outputs
Output Data type Description

pH STRUCT pH simulation value

->Real
->Byte

To calculate the pH value, you carry out the following calculation steps:
1. Determine the products (multiplication) from the concentration differences and inflow amounts of the input material
and the neutralizer
2. Determine the overall inflow amount
3. Calculate the factor (proportional concentration difference) from the products and the overall inflow amount
4. Convert the concentration difference to the pH actual value
In the simulation, you can adapt both the process-specific characteristics of the titration curve and the effect of the values
of feedforward injection of disturbance variable (change the pH values of the input material by ± 1) and the variable
throughflow amounts (change the inflow amount by ±500 mol/L).

Additional information

6.7. Block description of "ComStruIn" and

"ComStruOut"
Function description
The blocks are used for standardized interconnection of process tags (controllers with a valve process tag) or for setting
up cascade controllers. All relevant signals from a process tag are grouped into one structure, so that only a single
interconnection (of the structure) is required, instead of numerous individual cross-system interconnections.
Connections from the valves or controllers are present at the inputs of the blocks, which are then connected via the cross-
chart interconnections outputs structure to the target process tag (i.E. slave controller or valve).

Inputs "ComStruIn"
Input Data type Description

ReStru1 bis STRUCT e.g. transmission von process-, parameter- or limit values
ReStru6 ->Real
->Byte

BoStru1 bis STRUCT e.g. setpoint, out of service and interlock

BoStru6 ->Bool
->Byte

Int1 and Int2 INT e.g. process value unit

Scale1 and STRUCT e.g. process value scale

Scale2 ->Real
->Real

Outputs "ComStruIn"
Output Data type Description

Out. STRUCT Structure for connection to Control module

BoStru1-6 ->Real
Int1-2 ->INT
ReStru1-6 ->Real
Scale1-2 ->Real

The ComStuOut block is the opposite to ComStruIn. It deconstructs the cross-chart interconnections input structure from
the signal source into the original individual variables, which can be used individually in the target process tags.

Inputs "ComStruOut"
Input Data type Description

In. STRUCT Structure for connection to Control module

BoStru1-6 ->Real
Int1-2 ->INT
ReStru1-6 ->Real
Scale1-2 ->Real

Outputs "ComStruOut"
Output Data type Description

ReStru1 bis STRUCT e.g. transmission von process-, parameter- or limit values
ReStru6 ->Real
->Byte

Additional information
Output Data type Description

BoStru1 bis STRUCT Condition of MV output drive/channel block

BoStru6 ->Bool
->Byte

Int1 and Int2 INT e.g. process value unit

Scale1 and STRUCT e.g. process value scale

Scale2 ->Real
->Real

Appendix

7. Appendix
7.1. Service and support
SiePortal
The integrated platform for product selection, purchasing and support - and connection of Industry Mall and Online
support. The SiePortal home page replaces the previous home pages of the Industry Mall and the Online Support Portal
(SIOS) and combines them.

• Products & Services

In Products & Services, you can find all our offerings as previously available in Mall Catalog.
• Support
In Support, you can find all information helpful for resolving technical issues with our products.
• mySieportal
mySiePortal collects all your personal data and processes, from your account to current orders, service requests and
more. You can only see the full range of functions here after you have logged in.
You can access SiePortal via this address: sieportal.siemens.com

Industry Online Support

Industry Online Support is the previous address for information on our products, solutions and services.
Product information, manuals, downloads, FAQs and application examples - all information is available with just a few
mouse clicks: support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent support regarding all technical queries with
numerous tailor-made offers – ranging from basic support to individual support contracts.
Please send queries to Technical Support via Web form: support.industry.siemens.com/cs/my/src

SITRAIN – Digital Industry Academy

We support you with our globally available training courses for industry with practical experience, innovative learning
methods and a concept that’s tailored to the customer’s specific needs.
For more information on our offered trainings and courses, as well as their locations and dates, refer to our web page:
siemens.com/sitrain

Industry Online Support app

You will receive optimum support wherever you are with the "Industry Online Support" app. The app is available for iOS
and Android:

Appendix

7.2. Links and literature

No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/53843373
\3\ SIMATIC PCS 7 overview (collection of links for FAQ, manuals, compendium, forum, application examples and
multimedia)
https://support.industry.siemens.com/cs/ww/en/view/63481413
\4\ Controller optimization with the PID Tuner
https://support.industry.siemens.com/cs/ww/en/view/8031495
\5\ Model Predictive Control including integral transfer functions
https://support.industry.siemens.com/cs/ww/en/view/42200753
\6\ Configuration of Cascade Control
https://support.industry.siemens.com/cs/ww/en/view/43033319
\7\ PCS 7 Unit Template "Stirred Tank Reactor" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/60546560
\8\ PCS 7 Unit Template "Fermenter" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/68098270
\9\ PCS 7 Unit Template "Distillation Column" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/48418663
\10\ PCS 7 Unit Template "Dryer" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/74747848
\11\ PCS 7 Unit Template "Polymerization Reactor" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/84061788
\12\ How do you procure documentation for PCS 7 (including the PCS 7 Manual Collection)?
https://support.industry.siemens.com/cs/ww/en/view/59538371

Appendix

7.3. Change documentation

Version Date Modifications
V1.0 12/2011 First version
V1.1 04/2012 Valid for PCS 7 V7.1.3 and PCS 7 V8.0
V1.2 06/2012 Corrections and comments from suggestions
V2.0 06/2013 Expansion of the Val process tag type, new CTRL process tag types, additional
equipment modules for pH value control
V2.1 10/2013 New process tag types (CTRL; AMon and MOT) for multi-variable control and drives
inserted. Additional Links.
V2.2 04/2014 Equipment module "Temperature-Flow-Cascade" added.
V3.0 09/2016 Update for PCS 7 V8.2
V4.0 11/2017 Update for PCS 7 V9.0
Modification of the "Level control" equipment module
New equipment modules added:
• Buffer level control by means of "Buffer-Control" feedforward control
• "Stream-Control" coarse/fine flow control
V5.0 05/2019 Update for PCS 7 V9.0 SP1, cross reference for the CMT on the BCM Library, new
equipment module Gradient limits in actuators "Gradient-Limit"
V5.1 10/2021 Update for PCS 7 V9.1
V5.2 09/2023 Update to new template

Ihs PC 2dadv
100% (1)
Ihs PC 2dadv
686 pages
Sap Ewm Outbound Process
100% (2)
Sap Ewm Outbound Process
19 pages
DigiTitans 2
No ratings yet
DigiTitans 2
74 pages
Application Example TIA PFL Silo V18 en
No ratings yet
Application Example TIA PFL Silo V18 en
61 pages
KA0040-Weligalle Airtel - Proposed Tower Layout
No ratings yet
KA0040-Weligalle Airtel - Proposed Tower Layout
1 page
LIOLink DOC V7 2 en
No ratings yet
LIOLink DOC V7 2 en
78 pages
Ice Cream Demo DOC PCS7V91 SP2 En-1
No ratings yet
Ice Cream Demo DOC PCS7V91 SP2 En-1
202 pages
DistillColumn DOC PCS7V90 en
No ratings yet
DistillColumn DOC PCS7V90 en
72 pages
LibraryOfBasicControls LBC V3 1 0 en
No ratings yet
LibraryOfBasicControls LBC V3 1 0 en
429 pages
PumpMonitoring PCS 7 V9 1 DOC en
No ratings yet
PumpMonitoring PCS 7 V9 1 DOC en
30 pages
Oxford Phonics World Readers L2 03
No ratings yet
Oxford Phonics World Readers L2 03
18 pages
WinCC Unified Engineering Guideline DOC V3 en
No ratings yet
WinCC Unified Engineering Guideline DOC V3 en
106 pages
Application Example HMI Wincc Unified
No ratings yet
Application Example HMI Wincc Unified
74 pages
CAD-150-1 CAD-150-1 Mini CAD-150-2: One and Two Loop Control Panels
No ratings yet
CAD-150-1 CAD-150-1 Mini CAD-150-2: One and Two Loop Control Panels
2 pages
SIMATIC NET OPC UA S7server DOC V2 0 en
No ratings yet
SIMATIC NET OPC UA S7server DOC V2 0 en
120 pages
WinCC Unified Engineering Guideline DOC V2 en OS
No ratings yet
WinCC Unified Engineering Guideline DOC V2 en OS
102 pages
E Book Iot Made Simple
No ratings yet
E Book Iot Made Simple
23 pages
SIMIT FrequencyConverter PROFIdrive V111 en
No ratings yet
SIMIT FrequencyConverter PROFIdrive V111 en
39 pages
Config and End User Guide To Sap Fi Ar
100% (1)
Config and End User Guide To Sap Fi Ar
59 pages
Windows Server 2016-2019
No ratings yet
Windows Server 2016-2019
5 pages
TwoHandControlPanel DOKU v40 en
No ratings yet
TwoHandControlPanel DOKU v40 en
49 pages
EngineeringGuideLine V1 Preliminaryversion
No ratings yet
EngineeringGuideLine V1 Preliminaryversion
79 pages
Recipe Development Manual
No ratings yet
Recipe Development Manual
177 pages
KalFilReactor DOC en
No ratings yet
KalFilReactor DOC en
71 pages
PCS7 OpenOS PU Integration S71500 V9.0 en
No ratings yet
PCS7 OpenOS PU Integration S71500 V9.0 en
64 pages
PCS7
No ratings yet
PCS7
162 pages
PCS 7 Control Performance Monitoring PCS 7 V100 DOC V3 0 en
No ratings yet
PCS 7 Control Performance Monitoring PCS 7 V100 DOC V3 0 en
31 pages
SIMATIC PCS 7 Remote IO Upgrade Guideline
No ratings yet
SIMATIC PCS 7 Remote IO Upgrade Guideline
41 pages
KD100
No ratings yet
KD100
20 pages
Plotly Cheatsheet
No ratings yet
Plotly Cheatsheet
3 pages
Gainsched Pid-Tun en v2
No ratings yet
Gainsched Pid-Tun en v2
34 pages
003 109823905 - Replace - ET200M - With - ET200SP - HA - Via - PAA - en - Pdf#page 14
No ratings yet
003 109823905 - Replace - ET200M - With - ET200SP - HA - Via - PAA - en - Pdf#page 14
19 pages
SIMATIC PCS 7 Remote IO Upgrade Guideline Sic - Original
No ratings yet
SIMATIC PCS 7 Remote IO Upgrade Guideline Sic - Original
41 pages
PCS 7 TeleControl Engineering Type Configuration Limits en
No ratings yet
PCS 7 TeleControl Engineering Type Configuration Limits en
42 pages
BatchEPH PCS 7 V91 DOC V2 0 en
No ratings yet
BatchEPH PCS 7 V91 DOC V2 0 en
104 pages
ABBYY Lingvo - All About User Dictionaries
No ratings yet
ABBYY Lingvo - All About User Dictionaries
3 pages
Ad0 E117 Demo
No ratings yet
Ad0 E117 Demo
6 pages
WinCC Unified Engineering Guideline DOC V1 en
No ratings yet
WinCC Unified Engineering Guideline DOC V1 en
80 pages
MM Tech Bpo
No ratings yet
MM Tech Bpo
18 pages
(4) Инжиниринг и Автоматизация Пакетных Процессов с Помощью Pcs 7 По Моделям Isa-88
No ratings yet
(4) Инжиниринг и Автоматизация Пакетных Процессов с Помощью Pcs 7 По Моделям Isa-88
51 pages
Aastha IP Employee Project
No ratings yet
Aastha IP Employee Project
32 pages
Rosas CV
No ratings yet
Rosas CV
1 page
Wiring Voting F-DI F-DO V20 en
No ratings yet
Wiring Voting F-DI F-DO V20 en
98 pages
PCS7 CMT Engineering
100% (1)
PCS7 CMT Engineering
62 pages
CS - Summary of Graduation thesis (Trần Dương Quang - 18IT3 - 18IT168)
No ratings yet
CS - Summary of Graduation thesis (Trần Dương Quang - 18IT3 - 18IT168)
30 pages
Ms Excel
No ratings yet
Ms Excel
61 pages
Ohori 2020
No ratings yet
Ohori 2020
31 pages
Plant Wide Automation Water Industry V30 en
No ratings yet
Plant Wide Automation Water Industry V30 en
89 pages
Graphics Design Course Brochure - CDR
No ratings yet
Graphics Design Course Brochure - CDR
3 pages
PCS7 Mini V91 en
No ratings yet
PCS7 Mini V91 en
132 pages
12th Gen Intel Mobile Product Brief PDF
No ratings yet
12th Gen Intel Mobile Product Brief PDF
16 pages
Redundant PNPN Coupler With PCS 7 en
No ratings yet
Redundant PNPN Coupler With PCS 7 en
36 pages
SIMATIC NET OPC UA S7variable DOC V2 0 en
100% (1)
SIMATIC NET OPC UA S7variable DOC V2 0 en
115 pages
ET200SPHA PCS7V100 DOC V1 4 en
No ratings yet
ET200SPHA PCS7V100 DOC V1 4 en
37 pages
Pulse Width Modulation PCS 7 V100 DOC V3 0 en
No ratings yet
Pulse Width Modulation PCS 7 V100 DOC V3 0 en
20 pages
Tulip Devhandbook
No ratings yet
Tulip Devhandbook
103 pages
PCS 7 Water Templates V9122 en
No ratings yet
PCS 7 Water Templates V9122 en
153 pages
080 236 LAH - dum.900.BE SW Integrity Protection V1.1
No ratings yet
080 236 LAH - dum.900.BE SW Integrity Protection V1.1
21 pages
Guide-Introduction To Batch Processing With S88-Hallam-ICS
No ratings yet
Guide-Introduction To Batch Processing With S88-Hallam-ICS
21 pages
Tulip Training Guide
No ratings yet
Tulip Training Guide
156 pages
Govpub C13
No ratings yet
Govpub C13
86 pages
SimaticHmiOptionPlus IPC V12 Advanced DOC en
No ratings yet
SimaticHmiOptionPlus IPC V12 Advanced DOC en
71 pages
Mateus Santos Mendonça
No ratings yet
Mateus Santos Mendonça
1 page
PCS 7 Water Templates V902 en
No ratings yet
PCS 7 Water Templates V902 en
115 pages
Wincc Upgrade v6.2 v7.5 en
No ratings yet
Wincc Upgrade v6.2 v7.5 en
32 pages
Integration of An Abb Protection Device in Pcs 7 Powercontrol Station Gateway V9.0
No ratings yet
Integration of An Abb Protection Device in Pcs 7 Powercontrol Station Gateway V9.0
45 pages
En Modbus TCP Client v1.6 122022
No ratings yet
En Modbus TCP Client v1.6 122022
78 pages
EquipmentModules DOC PCS7V90 en
No ratings yet
EquipmentModules DOC PCS7V90 en
156 pages
Tulip Quickstart
No ratings yet
Tulip Quickstart
16 pages
Pansare 2018
No ratings yet
Pansare 2018
11 pages
Using JACK On Windows - JACK Audio Connection Kit
No ratings yet
Using JACK On Windows - JACK Audio Connection Kit
1 page
PCS7 OpenOS 3rdparty Integration ABB V9.0 en
No ratings yet
PCS7 OpenOS 3rdparty Integration ABB V9.0 en
57 pages
Batcheph Doc Pcs7v90 en
No ratings yet
Batcheph Doc Pcs7v90 en
107 pages
Iso 32000 2 2020
No ratings yet
Iso 32000 2 2020
15 pages
Stitch Labs
No ratings yet
Stitch Labs
19 pages
How To Learn Angular
No ratings yet
How To Learn Angular
12 pages
Modbus TCP Client V90 en
100% (1)
Modbus TCP Client V90 en
74 pages
DataSplice COTS Inventory UsersGuideOverview
No ratings yet
DataSplice COTS Inventory UsersGuideOverview
12 pages
Sugiyama 1990
No ratings yet
Sugiyama 1990
7 pages
1 s2.0 S1474667015331943 Main
No ratings yet
1 s2.0 S1474667015331943 Main
6 pages
DOCU MP MU PCS7 V91 en
No ratings yet
DOCU MP MU PCS7 V91 en
66 pages
002 49740087 - PCS7 - OpenOS - Application - Guide - V9.0 - en
No ratings yet
002 49740087 - PCS7 - OpenOS - Application - Guide - V9.0 - en
24 pages
Simatic Comm Doku v23 e
No ratings yet
Simatic Comm Doku v23 e
318 pages
Hephestos 2 Technical Specifications
No ratings yet
Hephestos 2 Technical Specifications
1 page
TCP IP Networks Panel DOC V2.0.en
No ratings yet
TCP IP Networks Panel DOC V2.0.en
93 pages
V20 at ET200SP USS V101 en
No ratings yet
V20 at ET200SP USS V101 en
54 pages
PidTemp MultiZone DOC V11 en
No ratings yet
PidTemp MultiZone DOC V11 en
62 pages
Override Control PCS 7 V91 DOC V2 0 en
No ratings yet
Override Control PCS 7 V91 DOC V2 0 en
23 pages
Loadmanagement DOC PCS7 V90 SP1 en
No ratings yet
Loadmanagement DOC PCS7 V90 SP1 en
43 pages
AnISA-95-based Manufacturing Intelligence System in Support of Lean Initiatives
No ratings yet
AnISA-95-based Manufacturing Intelligence System in Support of Lean Initiatives
15 pages
MRP and Erp
No ratings yet
MRP and Erp
25 pages
SimaticHmiOptionPlus IPC V12 Base DOC en
No ratings yet
SimaticHmiOptionPlus IPC V12 Base DOC en
57 pages
DS
No ratings yet
DS
3 pages
Line Integration WCCV75 en
No ratings yet
Line Integration WCCV75 en
57 pages
Application pcs7 Panel Integration en
No ratings yet
Application pcs7 Panel Integration en
72 pages
TIA AddIn Code2Docu DOC V1 3 0 en
No ratings yet
TIA AddIn Code2Docu DOC V1 3 0 en
76 pages
Dating Format PDF Romance (Love) Passion (Emotion)
No ratings yet
Dating Format PDF Romance (Love) Passion (Emotion)
1 page
SiOME MAN V27 en
No ratings yet
SiOME MAN V27 en
148 pages
OSModule II
No ratings yet
OSModule II
26 pages
LPD Library of PLC Datatypes DOCU v14 en
No ratings yet
LPD Library of PLC Datatypes DOCU v14 en
58 pages
Geerhardus Vos - O Reino de Deus e A Igreja
No ratings yet
Geerhardus Vos - O Reino de Deus e A Igreja
72 pages
ARTlink 9 Ebook 012822
No ratings yet
ARTlink 9 Ebook 012822
8 pages
Unified Custom Web Control V30 DOC en
No ratings yet
Unified Custom Web Control V30 DOC en
37 pages
21A35X401 - TN - MyLab15-20 - Video Printer Problems
No ratings yet
21A35X401 - TN - MyLab15-20 - Video Printer Problems
2 pages
DIGITAL The Digital in Architecture and
No ratings yet
DIGITAL The Digital in Architecture and
13 pages
PI Controller For Simple Applications - Optimum Motor Speed Control
No ratings yet
PI Controller For Simple Applications - Optimum Motor Speed Control
39 pages
Multistage Interconnection Network Design for Engineers
From Everand
Multistage Interconnection Network Design for Engineers
Shilpa Gupta
No ratings yet