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  1. High Pressure PID Control

    Hello everyone, Not sure if I have the right forum, so please forgive me; but... I have a control loop to tune, and it's the first one that I've ever been in charge of.  My question is about tuning PID.  The loop I have to tune is controlling a pressure reactor to setpoints ~3000psi with a safety valve that blows around 4500 psi.  My question is what procedure you might go through to tune it safely.  I'm quite honestly a bit afraid of the high pressures and I really don't want to make anything "pop".  What also makes it tricky is that the reactor has to heat up to get to full pressure.  Without heat, the reactor will reach ~1000 psi, then it sits there for a long time and eventually the heat kicks in and the pressure can rises up very quickly. I currently have a very small gain value, something like 0.009 and an integral time of ~7sec.  I'm getting pretty good results in that the PID controller will bring the reactor up to pressure without major overshoot, but it oscillates at ~ +-100psi, which seems excessive to me. [The situation is further complicated by the material in the reactor, a slurry, which has variable density often causing pressure spikes and drops as thicker sediments blob through.  Then, valves that we are using to control appear to be only opening ~10% to maintain setpoint, meaning I only get 1/10th the resolution I would be hoping for.  Also, the valve responds quite slowly to command signal changes.  The controller will be attempting to open the valve in 0.1% increments, but it only responds at minimum to 0.4% changes in the control signal, and when it reverses directions it seems to only respond after a ~5% change in control signal.  This alone appears to cause oscillations that I don't know if a PID loop could ever get ahold of.] Anyways, aside from the obvious valve issues, is there any tips for tuning a system with this high pressure?  I need fast response, but slow buildup... (Oh yeah, I'm also having to use connected components workbench for control software.  At least the newest version of CCW seems to have a nice iPID control block; but man, I have never had to ctrl-alt-delete a program more times due to freezing while building or downloading...so frustrating...).
  2. Hello,  I have two pressure transmitters connected to a tank. One at the top and one at the bottom. How can I calculate the level of the tank ? I know the height and Specific gravity of the materials.    Thank You  Pratik Jain
  3. Hello Everyone... I got a project of pumping station... Need your help to fulfill client requirements through PLC logic...   #System# There are 6 pumps, every pump is Controlled by Individual VFD, and all 6 VFDs are in Communication with PLC. Output header is common for all pumps, and a Pressure Transmitter is connected at output header...   #Logic Requirements# Now when we start sequence in auto, the least run hour vfd should start first and increase the frequency slowly to maintain the pressure setpoint, now if vfd1 at 50hz and pressure is lower then the SP next vfd according to run hour should start and and increase frequency slowly, afterwords 3rd vfd according to runhour and so on untill pressure match SP, then maintain the pressure of header... If pressure increases above the setpoint, last started vfd should reduce rpm and shut down first and then second last started to shutdown and so on... And client also need enable-disbale logic, if they mark a pump disable then that pump should not start... Can you help me out and suggest anything, or provide some sample backups or documents ?
  4. Hi Everyone, I have a small project where I need to detect temperature and smoke using Allen Bradley Micro820 PLC and send email when the temp is above or below a set limit. And since I'm new to PLC world I'm not quite sure which sensors would work with my plc model. It would be really helpful if anyone could guide me through and suggest any sensors appropriate for temperature (surrounding temp not liquid temp) and smoke. 
  5. I am using DVP-ES2 PLC with DVP04AD-E2. I connected the flowmeter to the analog input module (4-20mA). And I noticed something weird, when the flowmeter shows 4mA value (no water flow at all) the data in the PLC keeps coming like 20-30 (0-32000). And when I change to the other port of the analog input , it even reaches value like 100 although there is no water flow at all. Note: I have done proper scaling to Liter/second and do proper grounding. Do you know what is the cause of this?
  6. Has anyone used 2 Keyence PZ series or similar retroreflective sensors in parallel to detect on the closest distance of irregular shaped objects? It should work if my sensor-fu is correct, but in actual use, has anyone had experience with it, and are there any 'gotchas' to watch out for?
  7. Hello.  I'm trying to help someone with a sawmill find a way to input from a sensor to connect it to the PC.  Not sure where even to look to ask for help. but here's what I understand:   The sensor is a SIKO MSA-213C Magnetic Sensor, using EtherCAT.  This interfaces with     SSI, BiSS C, IO Link They just need to connect it to the PC to work with it.   It could just connect to a USB port somehow, or the etherCAT option.   I found this:  MB3U    BiSS (SSI)-to-PC Adapter (USB)  link to .de site   any suggestions or pointers would be very helpful!    These folks don't use the internet, so I help them. Jeff
  8. Hi new to the forum, and first post, however, I have found an abundance of great information here, so I was hoping someone might able to help me with an issue.   PLC is BRX BX-DME1-10ED13-D I am trying to read an analog output from a sensor that is capable of essentially outputting a mA signal proportional to where a printed line, or contrasting edge is at in its field of view. It is used for web guiding applications to make sure the web is tracking straight, so you can identify if the line or edge is moving to one direction or the other, and correct the web with an articulating web guide. I have attached the diagram for the sensor, but I cannot for the life of me figure out 2 things 1) The power supply to the sensor is listed as follows Supply current - From fife control +/- 12vdc 50ma (+)12vdc  AND   - 40ma (- )12vdc how do you provide both (+) and( -) 12VDC for the supply power to a sensor- 2 power supplies with the the opposite polarities grounded on each?   2) The outputs are listed as "Sum" and "Differential" so apparently there are two outputs, i dont know if anyone has come across these terms relative to sensors before, but I am trying to sort these out. According to the OEM  Sensor Output Range   -20 mA to +20 mA for line guiding     -20 mA to +10 mA for edge Guiding   I have attached the pin out diagram as well as the sensor spec sheet, but I am curious to see if anyone might have insight as to how I would get an analog input reading from this configuration? Thank you in advance for any help!     224615.pdf SE-26B Product Sheet.pdf
  9. Modbus Addressing in Weintek HMI

    Modbus addressing in Weintek HMI to poll data from Temperature sensor through RS485. In my system i have connected Temperature sensor to I/O Scanner has output in terms of RS-485 which directly connected to COM3 Port pin. No. 6 (as Negative) & 9 (as Positive) of HMI (Model No: MT8071iE) and HMI connected to PC via ETHERNET. I want to read temp on HMI screen via MODBUS protocol. So, can you please provide me instruction about addressing of MODBUS register in Easy-Builder Software so can read data of corresponding register. Because when i do compile i got an error like " Device no Response". I hope i will get reply from your side as Fast as possible to overcome this problem. Thank you.
  10. Hi All, I am doing an application that use servo motor to feed plastic film to a target length (set by operator), and it need to stop immediately if marker sensor is ON. This application is control by Omron CP1E PLC. It will feed plastic film in 500-1000mm/s depends on the target length set by operator. It is require to stop immediately if the servo feed length more than 90% of the target length and the marker sensor is ON. However, is there any possibility for the servo to stop immediately once the condition is meet? As I am using PLS2(887) to feed with target length, and INI(880) to stop immediately, however, it cannot get the desired result as servo not able to stop immediately after marker sensor is ON, I am not sure is because of the PLC scan time, or servo need time to deceleration (deceleration rate assigned to #FFFF). Appreciate anyone able to assist on this. Thank you.
  11. Hi Everyone..I'm having hard time to read Analog Sensor. I've try to read the manuals about expansion module, but still having hard time to understand it. My PLC is CP1E-N30DR-A connect with Expansion CP1W-MAD44 and I'm trying to connect with pressure sensor Omron E8F2-B10C that in a certain pressure will trigger to open a Digital Valve. is there something wrong with my setting for range? I do the setting in 4-20mA (0-5V) I attached my Program and Picture while running, the program is only for reading the pressure sensor. the result is  -600 to +600, is there a way to earn the actual result? I've tried Scaling and APR, But didn't understand, is there a guide/tutorial for it as well?   Cheers.. Albert TEST.cxp TEST.cxp
  12. Hi guys....first post here. It's been about 6 years since I worked heavily with PLC's and automation, but I'm getting back into it. I was hoping you might be able to help me with an issue I've noticed at work.  Problem:  The sensor we use just reads if there's something there, or not. A make or break if you will. When boxes are pushed together and there is no gap between them it thinks there's a jam (after 6 seconds) even when the boxes are moving past (as they should).  A jam stops the conveyor belt requiring someone to physically move the boxes to clear the sensor and restart the equipment.   I'm trying to find a sensor that will see the distance changes from box to box (mounted on the side of the conveyor). Only when there is a true jam and the distance isn't changing will it send a jam signal.  I've tried researching sensors and have been overwhelmed by the endless possibilities and combinations (not all of which I understand).  We are currently using an Allen-Bradley 42EF-P2RJB-A2H It would be ideal to have a similar style plug, but it isn't a deal breaker.  Here's an idea of what I'm dealing with. (The actual conveyor the jams are occurring on is a decline belt, not a roller accumulator.) There are varying box sixes, but they are all packed together. Creating a gap between boxes or using metering belt is not an option here. Thank you for any help/guidance you can offer! -Steve
  13. Hi,  I'm new to TwinCAT 2 and i'm upgrading a long time design (hence the TwinCAT 2 reference), to read a more sensitive torque signal.  I'm using a Beckhoff CX1030 as my PLC Controller.  I needed to add 'homing' to my motor sequence and confirmed with Maxon, im using the function blocks correctly and in the correct sequence to establish my 'absolute zero'/'home' position.  The motor has an output to write to:  ControlWord, which tells the motor that the position it is sitting in is '0.'  My program compiles, it runs, it writes each function block, but it's not seeming to get back to the test run opMode, even though i tell it to and the function block performs the 'Write' function.  it's stuck at zero and not reading an analog input signal from my torque sensor.  so im getting an artificial torque reading through every test.   i think this is related to my tare motion.  I start the program, home the motor, get into profile velocity mode, tare my sensor, enter profile position mode, go back to position 0, then back to profile velocity mode, run a test, sample data, go back to 'home' or '0.'  I wonder 1st, is my variable not linked properly through the system manager?  2nd, i set a boolean variable to set the 4th bit to 1 in my control word write (setting the 4th bit high will set my current position to absolute zero), but did i not connect the program to the main sequence properly?  looking to read a valid signal again and see that my motor moves back to 'home' each time.  Do i not need to home the motor after the tare, since the tare nulls out the torque value after the tare? after this i need to program my sample period, instead of it being fixed, as it is currently written and then use my home position as my trigger to start sampling.... Beckhoff applications department is overloaded, currently and can't help and this is all beyond the knowledge of the general support line.  I've gotten fairly far, on my own, but of course, the project is under a time crunch.   Does anyone know twincat well enough to help guide me?
  14. Hi! Allen bradley PLC RS Logix 5000 I have a problem with a SMC pressure sensor (ISE30A if I remember correctly). When I monitoring the raw data from the ananlog module, I get about -7710 value, when the smc display shows about 0. There are another SMC pressure sensors too, and if the sensors displays shows 0 then the values what I get form the analog module is about 0 too, so the others work properly. But this one don't.  I already check the wiring. I have no clue waths the problem. Any idea from anybody? Thank you for your help.
  15. PID regulation PT

    Hello   Does someone have a good way to control pressure using PID in cx-programmer? I got two pumps and one PT(4-20mA) Half the year only one pump need`s to run (about 3bar)  but in the season (i work in a fabric) two pumps need to be running (about 4bar needed) except in the night. I`m going to use HMI for adjusting the setpoint so there is no need for any clock/date for this to change itself. The question is how to get one of the pumps to shut down when the need for pressure is not so high. And get the pumps to change "main" pump sometimes so one pump is not running all the time.   Hope this was understandable    
  16. I first saw AS-i at a factory this week and am trying to figure out what Allen Bradley modules can interface it. I am not finding anything, does AS-I go under some different name?
  17. Hello! Does anyone have experience of using tooth gear pulse sensors. I am looking for this kind of sensor for the machine, we are building. My problem is that the sensor we are using is not suitable for North American markets (UL-standard is not aproved) and now I am searching sensor like this. I am not sure is inductive sensors good enough for measuring this, the one that we have been using is magnetic field pulse sensor.
  18. I'm looking for some general information about different types of vibration/temperature sensors. What type, brand, model number, etc. will best fit my application.  Scenario: I want to monitor the vibration and temperature of multiple motors and gearboxes for a large overhead conveyor system. If an oil leak occurs and temperature increases, I want to see a temp. alert via a HMI. If a something mechanical fails, I want to see a vibration alert via a HMI.  I've looked into sensors that stick to the outside housing of the motors or gearboxes via a magnet. My concern is justifying the temperature readings. How accurate would a sensor that reads an "ambient" temperature be (compared to a thermocouple on the motor coil itself or some sort of probe)? Also, would the location of the magnet  on the motor or gearbox drastically affect the temp. or vib. readings? Has anyone had success with a similar setup? If so, what devices did you utilize? Are these systems truly beneficial?  I'm currently considering Banner's wireless products...
  19. Hi, Recently, we replaced our old digital temperature transmitter with a Baumer Flextop 2201 digital temp transmitter. The application of the digital temp transmitter is for a hydraulic press and the output is fed to the Siemens S95-U plc. The Flextop was able to react properly promptly when there is increase in temperature but whenever there are sudden drops in temperature it is slow to react. The analog transmitter (dial) was already at 25 C when the hydraulic press was shut down while the Flextop was still at 35 C. We used a three wire configuration for this. Does this have to do with our wire configuration? I know there are 2 wire ,3 wire, and 4 wire configurations for 4-20 ma sensors but I'm not sure what are their differences among them. Please see attached configurations below.     Thanks,
  20. Version 1.0.0

    130 downloads

    Temperature measurement usind Arduino Nano, RTD PT100 sensor,  4-20 mA current loop transmiter, and a python app for visualization
  21. View File Temperature measurement using Arduino Nano, RTD PT100 temperature sensor and 4-20 mA transmitter Temperature measurement usind Arduino Nano, RTD PT100 sensor,  4-20 mA current loop transmiter, and a python app for visualization Submitter Absolutelyautomation Submitted 04/01/16 Category Other PLC Demo Software
  22. Hello, I am new to this forum and I am looking for some help. I have to create a block mover system using the controllogix , I know that I must use a SQO as I have done this process without a Flex I/O on a SLC 500 before. Currently I am getting a error while dealing with the array can anyone show me an example of a SQO in 5000?   Thanks
  23. CP1E-N40 + CP1W-TS102

    Hi ! I have a question regarding the handling of the signal from the TS102 connected to my PLC.   I downloaded a .pdf  LINKED from "my omron", read it and put together a small program just to test the expansion unit and sensors. But I cant get any readings from the sensors and can't figure out why. I have never used a TS102 expansion unit before and would be glad if someone have an idea of what I'm doing wrong. Everything is brand new, so I'm quite sure I am the problem here..... If someone have an answer and maybe even an programming example to upload I would really appreciate it. Best Regards!  PT100 sensor test 3.cxp