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th
International Scientific - Technical Conference - PROCESS CONTROL 2006
June 13 16, 2006, Kouty nad Desnou, Czech Republic

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PID CONTROLLERS OF INDUSTRY SYSTEM SIMATIC

ONDROVIOV MAGDALNA, BAKOOV MONIKA, VANEKOV KATARNA

Faculty of Chemical and Food Technology
Slovak Technical University in Bratislava
Institute of Information Engineering, Automation and Mathematics
Department of Information Engineering and Process Control
Radlinskho 9, 812 37 Bratislava, Slovak Republic
e-mail: magdalena.ondrovicova@stuba.sk, monika.bakosova@stuba.sk, vanek.katka@atlas.sk

Abstract: In this paper results of control of reboiler temperature by industry control system
Simatic are presented. In the Simatic library occur several controllers and two of them we have
chosen to temperature control: FB41 and FB58. The main aim of this paper is compare results of
control by two blocks of PID controllers.

Keywords: industry system Simatic, control of temperature, controller

1 SIMATIC S-7 300
The structure of the users program is given by organization block OB, witch represent main
program that is cyclic working. Organization block OB consists from function blocks (FB). They have
the memory and enable store variables in block by declaration table. For most often used routines are
used Functions (FC). To store user data are used data blocks (DB). To right work of the FB, FC and
DB blocks they have be called by organization block OB. Before blocks programming it is necessary
to made project, to configure network and define connected and used input and output modules.
Visualisation of the project is realised in v Graphics Designer.

2 PID CONTROLLERS IN STEP 7
A library of program Step 7 provides a package of function blocks (FB) that contains of the
PID controller blocks. To control of processes user may choose suitable PID controller and to set its
parameters. In this paper were chosen two controllers to control of temperature of the reboiler to
compare their effect to process control. Function block FB41 is continuous PID controller and block
FB58 is PID controller especially to temperature control used.

2.1 Function Block FB41
FB41 CONT_C is used on Simatic S7 to control processes with continuous input and output
variables. During parameter assignment, we can activate or deactivate sub functions of the PID
controller to adapt the controller to the process. The inputs and outputs of Function Block FB 41 are
shown on the Fig. 1.
The input parameters are:
MAN_ON - if this input is set TRUE, the control loop is interrupted and a manual value is set as
manipulated value.
P_SEL the PID actions can be activated or deactivated individually in the PID algorithm. The P
action is on when the input proportional action on is set TRUE.
I_SEL - the PID actions can be activated or deactivated individually in the PID algorithm. The I
D_SEL - the PID actions can be activated or deactivated individually in the PID algorithm. The D
SP_INT The internal setpoint input is used to specify a setpoint.
PV_IN an initialisation value of process variable
MAN manual value input is used to set manual value using the operator interface functions
GAIN proportional gain
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TI the reset time input determines the time response of the integrator
TD - the derivative time input determines the time response of the derivator unit
LMN_HLM manipulated value high limit
LMN_LLM - manipulated value low limit
Output parameters of controller
LMN - manipulated value output
LMN_P proportional component output of the manipulated variable
LMN_I integral component output of the manipulated variable
LMN_D derivative component output of the manipulated variable
PV process variable
ER error signal

Figure 1 - Inputs and outputs of FB41

The block scheme of the PID controller is shown in the Fig. 2.

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Figure 2 - Block scheme of PID controller FB41

From the block scheme in Fig. 2 we can determine simply form of the transfer function of the
controller
) .
.
1
1 ( ) ( s Td
s Ti
Zr s G
R
+ + =
To verify outputs of the Simatic controller we used Matlab and Simulink. In Simulink we
created scheme of the PID controller (Fig. 3) with as inputs and outputs as block FB41. This scheme
enables to us compare outputs of the Simulink and Simatic controllers.

Figure 3 - Simulation scheme of PID controller FB41 in Simulink

Parameters LMN_P, LMN_I, LMN_D in Fig. 3 have the same meaning as parameters of the
Simatic PID controller block FB41 (Fig. 1, Fig. 2). Simulink block Saturation enable to set high and
low limits for output of controller. Constant is initialisation value of the process value.

2.2 Function Block FB58
Function Block FB58 is used to control temperature processes with continuous or pulsed
control signals. We can set parameters to enable or disable subfunctions of the PID controller and
adapt it to the process. These settings can be made simply with the parameter assignment tool. FB58
can be used either purely for heating or purely for cooling. If we use the block for cooling, GAIN must
be assigned a negative value. The PID algorithm operates as a position algorithm. The proportional P,
integral (INT), and derivative (DIF) actions are connected in parallel and can be activated or
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deactivated individually. This allows P, PI, PD, and PID controllers to be configured. The controller
tuning supports PI and PID controllers.
In the Fig. 4 is scheme of block FB58. We can see variables on the input and output of the
block.

Figure 4 - Scheme of block FB58

From the scheme on the Fig. 4 we can obtain equation of controller
+ + =
F D TD
t
e F D t
TI
ER GAIN t sum LMN
_ /
* _ *
1
1 ) 0 ( * ) ( _

where
LMN_sum manipulated value
ER(0) error
GAIN controller gain
TI integrator time constant
TD derivative time constant
D_F derivative factor
Then the form of the controller transfer function is
) .
.
1
1 ( ) ( s Td
s Ti
Zr s G
R
+ + =

In the Fig. 5 we can find form of the function block FB58 that is used in organisation block
OB1. There we can see setting of the input and output parameters of the controller. The input
parameters of the FB58 may be set directly in OB1 or by data block. (Fig. 6)

Figure 5 Inputs and outputs of controller FB58
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Figure 6 - Data block of the FB58

Inputs and outputs parameters of the block FB58 are:
MAN_ON - on/off controller
SP_INT input of setpoint
PV_INT measured value
MAN manual value if MAN_ON is set TRUE
LMN - manipulated value
PV process value

Internal parameters of FB58:
LMN_P output of P part of controller
LMN_I - output of I part of controller
LMN_D - output of D part of controller
GAIN gain
TI integrator time constant
TD - integrator time constant
LMN_HLM - manipulated value high limit
LMN_LLM - manipulated value low limit
ER error
PID_ON activation of PI or PID controller

3 DESIGN OF CONTROLLER PARAMETERS
Four electric heaters heat a reboiler. The temperature inside of the reboiler depends on the
power consumption of the electric heaters. So, a controlled variable is a temperature and we can
describe model of the reboiler in the form

( )
( )
dt
t d
k t Q
=

where
Q - a power of electric heaters
k - constant depended on reboiler and liquid parameters
- temperature
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Controller design by Pole-Placement method is really generally well - known. We have
controlled system with 1
st
order transfer function. We can write characteristic equation of the close
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loop system with suitable controller structure. Than we can choose poles of the close loop system and
obtain constants of controller. By this way was obtained gain of P controller.

4 CONTROL OF THE REBOILER TEMPERATURE
Visualisation of the project is realised in Graphics Designer of WINCC. This environment
enables monitoring and control of process variables as well as setting of parameters of controller.
Design of the operators window is on the Fig. 7.

Figure 7 - Design of control display

To verify functionality of both controllers we have set the same P part of the controllers. After
to set the desired temperature we could see the control response of the temperature (Fig. 8). We
compared control of the reboiler by Simatic controller and control of the reboiler model by simulation
in Matlab. Outputs of the P part both controllers (without limits) are shown in Fig. 9. Step by step we
have set various desired values of the temperature. Values of setpoint, manipulated and measured
variables were archived in second intervals. Results of control of reboiler temperature by controller
blocks FB41 and FB58 are shown in Fig.10. Comparing of outputs of P parts of function blocks FB41
an FB 58 are in Fig. 11.
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Figure 8 - Control response of the temperature control by Simatic

Figure 9 - Comparison of P parts of Simatic and Matlab controllers.
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Figure 10 - Comparison of control responses of two Simatic controllers

Obr.11 Outputs of P parts of controllers FB41 and FB58

5 CONCLUSIONS
The main aim of this paper was to control of temperature of reboiler by control system
Simatic. Library of Simatic offers several types of controllers. Two of them were chosen and used in
control program Step7. We obtained and compared results of control by two blocks of Simatic
controllers. Control result were the same. To design parameters of the controller we used enthalpy
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model of the reboiler ansd generally well - known Pole-Placement method. Finally, we compared
control responses obtained in Simatic and Matlab.

REFERENCES
SIMATIC. Standard Software for S7-300 and S7-400 PID Control V5.1. Source: www.ad.siemens.de
MSZROS, A., DANKO, J., MIKLE, J., BAKOOV, M. 1997. Zklady automatizcie, STU,
Bratislava 1997
BAKOOV M., FIKAR M., IRKA ., 2003. Zklady automatizcie, STU, Bratislava 2003

Acknowledgement
The authors are pleased to acknowledge the financial support of the Scientific Grant Agency of the
Slovak Republic under grants No. 1/1046/04 and 1/3081/06.

The authors are pleased to acknowledge the financial support of the Cultural and Educational Grant
Agency of the Slovak Republic under the grant No. 3/3121/05.
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