NetSol Business Unit Yokogawa Corporation of America Copyright © Yokogawa Corporation of America January 26, 2006 Yokogawa Green Series Controllers.

NetSol Business UnitYokogawa Corporation of America

Copyright © Yokogawa Corporation of AmericaJanuary 26, 2006

Yokogawa Green Series Controllers


Tier 3: Yokogawa Field Instrumentation Solutions

Page.2

What is a controller?

A device used to set or adjust the conditions in a desired environment.– Must be able to continually sense the conditions in

the environment.• Thermocouple• Flow meter• Level transmitter

– Must be able to have a desired condition set by a user.

• Setpoint

– Must have the ability to change the conditions in the environment.

• Turn on an electric heater• Open or close a gas or water valve



Page.3

Simple Temperature Controller



Page.4

Simple Control System

Thermocouple

Electric Heating Element

Setpoint Control

Load



Page.5

Typical Control Drawing



Page.6

Inputs and Outputs



Page.7

Unsurpassed Selection

YS170 Dual Loop Programmable Controllers– pH, boiler & other complicated control actions.– Maximum versatility with custom programming.

US1000 Digital Loop Controllers– Single loop or dual loop control.– Custom computation and expanded discrete I/O.

GREEN series Industrial Controllers– Primarily used in the heat treating industries.– Can be used in many process applications.– Most cost effective for many control applications.– 301, 400, 500 or 700 series: – Provide only the functions required.



Page.8

More Product Selections

UT100 Series Temperature Controllers– Focused on plastic and OEM markets– 1/16, 1/8 or 1/4 DIN size– High reliability and easy configuration

at a very low price

JUXTA Signal Conditioners– Large number of functions– Isolators, T/C, RTD, frequency

inputs– VJ series allows BRAIN &

PC configuration



Page.9

Industrial/Process Controllers

YS170 Series

Full Featured Process Control

US1000 Series

UT100 Series

GREEN SeriesHigh Performance Industrial Control

High LevelProcessControl

Full Featured Temperature Control



Page.10

Where Do You Find Control Applications?

Simple Controller ApplicationsTemperatureLevelpHFlowPressureRatioHeat/Cool

Programmable Controller Applications

Furnaces (Lab & Industrial)

Environmental

Chambers

Ovens

Refrigeration

Kilns

Just about anywhere you make sales calls!



Page.11

What about PID

Proportional Band– Set as (PB) Proportional Band– Proportional makes the controller output move in proportion to the error between

set point and controlled variable.– K (Gain) = measure of the sensitivity of the final control element position change to

a given error– K is the inverse of PB (K= 100/PB)– Two items to set: Proportional Band (PB) & Manual Reset (MR)

Integral– Integral - “automatic reset” of final control element– Integral changes output over time– Integral repeats proportional action in integral time.– Integral tuning parameter is time based: the smaller the number the stronger the

action.– Integral continues to act until error is zero.

Derivitive– Derivative has no effect when error is not changing– Gives anticipatory response - not effective in fast loops, i.e., flow, pressure,

pH, etc.... etc...…– Derivative acts on “rate of change”, performs breaking action



Page.12

UT 100 Series Dynamic Self Tune

Dynamic Self Tuning is initialized when applying power or changing set point.– Parameter CTL must be in

SLF mode (Default).– Does not use open loop

response like Auto Tuning, uses PV wave form analysis.

– Calculates new P, I & D parameters.

SP

0%

100%PV

PV

Time

100%

0%

Output

Time

Self Tune STARTSSP change or Power ON



Page.13

Auto Tune

The standard GREEN series Auto Tune can be implemented in the Operating menu if the CTL parameter is placed in the PID mode. This bypasses the Self Tuning operation.

PV

SV

MV

100%

0%

100%

Being Auto-tuning Auto-tuning ends at 3rd peak.

PID control according to PID parameterobtained by auto-tuning.



Page.14

Super Control



Page.15

SUPER 2 Function

Hunting occurs during:– Set point changes– Load changes

SameFurnace

CoilSheet

SUPER2=O

NHunting

PID parameters are set at this condition.

Temperature Change

SUPER2=ON

Hunting

Load Change



Page.16

UT130 1/16 DIN Controller

3 digit LED display (shared PV & SP)High performance at a very low costT/C or RTD input onlySpecify ON/OFF relay or voltage pulse outputDynamic Self tuneAuto Tune & Super ControlHeat/cool outputs*Two alarms relays*Heater break alarms*RS485 communication*

*Option



Page.17

UT150 1/16 DIN Controller

4 digit LED display of PV & SP (Red and Green)Universal input (T/C, RTD, mV or VDC)Specify relay, voltage pulse or DC current outputHeat/cool outputs*Two alarm contacts*Heater break alarms*Retransmission of PV*Two contact inputs for SP selection & timer function*RS485 communication*

*Option



Page.18

UT152 & UT155 Controllers

Universal input (T/C, RTD, mV or VDC)Specify relay, voltage pulse or DC current outputHeat/cool outputs*Two alarm contacts*Heater break alarms*Retransmission*Contact inputs for SP selection & timer function*RS485 communication*

*Option



Page.19

UP150 1/16 DIN Program Controller

1 Program pattern, 16 segments 4 digit LED display of PV & SP (Red and Green)Universal input (T/C, RTD, mV or VDC)Specify relay, voltage pulse or DC current outputHeat/cool outputs*Two Event contacts*Retransmission of PV*External contact input RS485 communication*

*Option



Page.20

Oven Temp Control with SSR

Simple control application to control temperature in an oven or electric furnace.Probably the simplest and one of the most common control applications.Points to note– SSR needs a time proportional,

voltage pulse output to operate properly.

– Cycle time setting can affect control if too large.

Applicable control units– All



Page.21

GREEN Series Standard Features

Universal inputs (T/C, RTD, mV or VDC)Universal outputs (Relay, voltage pulse or4-20mADC current)Retransmission of PV, SP, output OR15VDC loop power supplyMultiple contact inputs and outputsAuto Tune for easy start upSuper Control for SP overshoot suppressionUL, CSA & CE approvalsIP55 front panel assembly (Splash Proof)



Page.22

UT321/351 Industrial Controllers

Large 4 digit 20mm “active” LEDdisplay of PV (UT351)Single loop controlAuto/Manual switching2 contact inputs (SP, A/M)3 contact outputs (Alarms)Heat/cool output optionOptional 24VDC loop power supplyRS485 communication optionGeneral purpose temperature controlInexpensive alternative for level, flow & pressure control

UT351UT321



Page.23

UP351 Program Controller

2 patterns, 10 segments each2 contact inputs (Pattern select, HOLD)3 contact outputs– 1 time event alarm– 2 PV event alarms

NO local set point capabilityRS485 comm. optionSmall furnaces & environmental chambers



Page.24

Temperature Programs

Ramp & SoakSelect Program bypressing PRG keyRESET key to stopprogramTime event to startauxiliary heater,fan, etc.Up to 4 PID Sets fortighter control

SP

PRG2PRG1

PRG2

PRG1

PRG2

KEYS

RESET

PV MVControl

PRG1Time Event

PID 3

PID 2

PID 1

PID 4

2nd Reference point

1st Reference point

Reference Deviation



Page.25

Active Color PV Display

PV Display LED color changes between Green-color and Red-color

It can be explained as "the function to actively change a display color according to conditions."

•Active Color PV Display:



Page.26

Industrial Ethernet

Industrial Ethernet Protocol allows a variety of industrial control devices to be integrated into the same application.Modbus TCP/IPGateway function



Page.27

Single Loop Control

Universal input4-20mADC output for gas controlRetransmission of PV toa recorderRoasted hot dog??

AnalogOutput

UT450/420

PV Input

4-20 mAOutput

Temperature

PIDRecorder

Air flow

Gas



Page.28

Furnace Temp Control with SCR

Simple control application to control temperature in an oven or electric furnace.One of the simplest and one of the most common control applications.Points to note– SCR needs an analog 4 - 20 mA output from the

controller.Applicable control units– All



Page.29

UT420/450 Controllers

Large 5 digit 20mm LED display of PV (UT450)Single loop control strategyPosition proportional control option (motorized valve)Heat/cool output optionOptional 24VDC looppower supplyOptional remote set pointUp to 7 contact inputsUp to 4 contact outputsRS485 comm. option



Page.30

Steam

Control

CoolingWater

CoolingOutput

HeatingOutput

RawMaterial

TC

MVCo

olin

g O

utpu

t

MV

Heat

ing

Out

put

Heat & Cool Control

Heat output & cool outputcan be relay, voltage pulse,or DC current individually.Cool output 0 to 100%above set pointHeat output 0 to 100% belowset pointDeadband around set pointis adjustable



Page.31

Position Proportional Control

Uses two relay contactsto increase or decreasevalve positionSlide wire feedback forreading valve positionon the output display“Assuming” mode can beused with no slide wireDO NOT USE for standardPID control

ValvePosition

Direct/Reverserotation

M

UT450

PositionFeedback

Control



Page.32

UT520/550 Industrial Controllers

Large 5 digit 20mm LED display (UT550)Remote set point option (Ratio Control)Up to eight pre-defined control strategies– Cascade control– Analog backup for PLC’s– Input auto selector

Up to 7 contact inputsUp to 7 contact outputsHeat/cool control optionPosition proportional control option (motorized valve)Optional 24VDC loop power supply



Page.33

Single Station Cascade

Water

RawMaterials

JacketTemp.

ReactorTemp.

UT550

Steam

Ctrl1

Ctrl2

Heat&CoolUM330

Performs cascade loop control within a single controller.Two temperature measurement signals are available.– Universal PV input– Auxiliary analog

voltage input

Can be used for heat and cool control.



Page.34

Cascade Control for Jacketed Vessel

This application explains how cascade control can be used to control temperature in a vessel.Points to note– This application requires two

independent control loops– Loops can be referred to as inner &

outer, master & slave, or primary & secondary

– There must be a significant difference in the response times for the inner and outer loops for the process to function properly. The larger the better.

– The outer loop must be tuned first and then the inner loop.

Applicable control units– 500 Series and higher or– Any combination of controllers in a

Master Slave configuration. (minor differences)



Page.35

Automatic Analog Back Up

MV feed-backBack-upControl Mode

Fail4 - 20mA

UT550/UT520

Ctrl

Steam

RawMaterials

ControlSystem

Back-upAuto

Under normal conditions, the tracking input for UT520/550 from the supervisory control system is the control output. When the supervisory control system has failed, UT520/550 begins automatic backup control.



Page.36


5 digit 20 mm LED and backlit LCD displays– LCD display can show temperature pattern

30 Patterns, up to 300 SegmentsFive control strategiesSeven contact inputs & outputs– Time events & process events

Heat /cool control optionPosition proportional controloption (motorized valve)



Page.37

Temperature Programs

Pattern can be seen in LCD displayPattern numberSegment numberTime remaining in currentsegmentCan be used with UT controllers as a set pointgenerator for multi-zonefurnaces

ProgramControl

SP1 SP2

SP1SP2

SP1SP2

30ptn

99 seg./ptn (Total 300 seg.)

Retransmissonoutput

Loop1



Page.38

PV Auto-Selector

Selects maximum, minimumor average of 2 PV inputsTemperature sensors canbe located at differentlocations within thefurnaceOne universal inputOne analog voltageinput

Electric Furnace

CtrlSelector

Product

SCR

UM330

UP550



Page.39

PV Switching

Switches between twoinputs depending ontemperature rangeA contact input orUP550 temperatureset point flag switchesthe inputsOne universal inputOne analog voltageinput

TC for Low Temp.Universal PV input

TC for High Temp.Auxiliary analog input

CtrlSwitching

SCR

UP550

UM330



Page.40

UT750 Industrial Controller

Large 5 digit 20mm LED with backlit LCD display.

Up to 13 types of control functions including dual loop control, cascade control, temperature/humidity and more.

Custom Computation function for complex regulatory control and sequential logic.

7 contact inputs & 7 outputs Expandable to 23 each with

external modules using RS485 50ms scan time is available for

pressure/speed/flow control.



Page.41

Dual Loop Control

RawMaterial

Ctrl1 Ctrl2

CoolingMedium

Controls two loops in a single instrument.Example: Control two stages of a multi-stage heat exchanger.T/Cs or RTDs can be directly connected to UT750-5X. Both control loops have run/stop functions and set point selection by an external contact input.



Page.42

PV Auto-Select

Heater

Contact Input

CtrlSwitching

SCR

Raw Materials

Switches and controls from one of two measured inputs by using a contact input or input range.Controls either furnace or product temperature according to certain conditions.Two universal inputs allow T/C or RTD inputs



Page.43


Up to 300 patterns, 3000 segments (99 seg/pattern)Ten resident control strategies– Dual loop control with universal inputs– Single station cascade with universal inputs– Auto-selector & PV Switching

Custom computation capability7 event alarms std (Time & PV)Up to 23 contact inputs (7 Std)– Requires RS485 option &

expansion modules

Up to 23 contact outputs (7 Std)



Page.44

UT/UP750 Custom Computation Function

ControlFunction

TemperatureComp.

Flow Pressure

Square root

DI1 DI2 DI3

Man MV

A/MAM

Temp.

Pressure Comp.

OR

AND

Performs special computations that are not included in the standard pre-configured control strategies.Users can customize input/output computations by linking function modules.Math, logic & special function modulesExamples: Carbon potential, pressure/temperature compensated flow and other sophisticated applications.



Page.45

PC Configuration Using the Light Loader

With Model LL100 PC-Based Parameters Setting Tool, all parameters of GREEN series controllers can be set on a PC.– Parameter setting function– Write/read parameters to/from

controllers– Saves to a disk– Printout (Hard copy

documentation)– Tuning function

Custom computation in the UT/UP750 requires LL200



Page.46

LL100 Parameters Setting Tool

Use with 300E, 400E, 500E & 700E seriesCan be used with older UT520, UT/UP550, UT/UP750



Page.47

LL200 Custom Computation Tool

Use for creating special programs for UT/UP750Eand UT750-7X



Page.48

RS485 Communication Option

PC-Link Communication

RS485 2Wire or 4Wire

1 2 UT/UP Controllers 31

Up to 9600bpsYokogawa PC-Link or Modbus communication protocol are used.Number of units: 31 units/serial portCommunication distance: Up to 4000 Ft.Communication interface: RS485



Page.49

UM331/351 Digital Indicators

Large 4 digit 20mm displayFront panel configurationRetransmission of PVThree alarms standardOptional 4th alarmOptional 24VDC loop powersupplyIP55 front panelUL, CSA & CE approvalsRS485 comm. option

UM351

UM331



Page.50

UD310/320/350 Manual Setters

Large 4 digit 20mm display (UD350)Front panel configurationSetpoint loading via the arrow keysRetransmission of PV standardTwo alarms standardIP65 (UD310), IP55 (UD320/350),

front panel UL, CSA & CE approvals



Page.51

GREEN Series Selections

Simple applications

UT750

UT351/321

Smaller sizeUT150/130

UT520/550

Complex control applications

Most complex applicationsDual Loop

Custom ComputationMultiple contact I/O

Select UT420/450 First



Page.52

JUXTA Signal Conditioners

Lightening Arresters

Power Distributors

J Series Socket Mount

Programmable Mathusing BRAIN terminal

F Series (24VDC)

W Series (110VAC or 24VDC)



Page.53

Furnace Control Using Zone PID

Zone control is used when multiple setpoint are used in the furnace and the control characteristics of the process changes as temperature changes.Points to note– Reference points must be set to activate switching

action– RDV (Reference Deviation) is available if special PID

control is necessary if PV deviates from SP by a set amount.

Applicable control units– All units except; 100 series, US1000 & YS series



Page.54

Tank Level Control

Controller can be used to control the level in a tankPoints to note– Can be controlled in a variety of different methods

depending on the control elements.• Alarms can be used for control in very simple on/off

application• Controller can supply 15 or 24 VDC power for the

transmitter




Page.55

Air Conditioner Temperature Control

Controller can be used to control both the heat and cool control elements of a packaged AC systemPoints to note– Can be controlled in a variety of different methods

depending on the control elements.

• Alarms can be used for control in very simple on/off solenoid application

• Heat/cool units a recommended for control elements that are not on/off

Applicable control units– All - very simple applications– All heat/cool control units



Page.56

Heat Exchanger Temperature Control

Heat exchanger is a device that transfers heat from one medium to another without the two mediums physically touching.– Liquid to liquid– Steam to liquid– Steam to air

Points to note– If there is a pump on the secondary side of the H.E.,

you may want a DI for the pump to turn off the controller.




Page.57

Heat Exchanger Control & BTU Calculation

Allows for control of a heat exchanger as well as track the BTU transferred though the heat exchanger. The BTU (British Thermal Unit) is universally accepted as a unit of heat transfer measurement. The BTU is defined as the quantity of heat required to raise the temperature of one pound of water 1F.Can be used for billing purposes or maintenance of the heat exchangerPoints to note– Feed forward input is necessary for application to work– Custom programming is required

Applicable control units– US1000– YS170



Page.58

Carbon Potential Control

Controlling Carbon PotentialPoints to note– CP is not a direct measurement but an estimated

value based upon some assumptions. The only true way of determining if the CP is effective is a shim stock test.

– The Carbon Master does not supply the carbon content to the furnace, It trims the CP by adding small amounts of gas & air to maintain the desired CP.

Applicable units– CX, UT750 & UP750



Page.59

Neutralization Control for Wastewater

Used to balance the PH of wastewaterPoints to note– This method does not use feed forward

control, so simpler controllers can be used.– Is tricky to control properly due to changing

gain as PH approaches 7. Zone PID must be used.

– Use plenty of dead band to keep alkaline and acid from fighting one another

Applicable Controllers– US1000, YS170, UT750, UT550



Page.60

Neutralization control for acid wastewater

US1000

4 to 20mA

zone PID control:Acid zone (zone 1) PID gain largeNeutralization zone (zone 2) PID gain small

pH

Neutralization control range1.0

14.0

TICPID

neutralizingpool

Acid wastewater

alkalineneutralizer

zone PIDcontrol

zone 1

zone 2

zone 3

pH sensor

9.0

5.0



Page.61

Feed Forward Control

Used to allow the controller to anticipate upcoming upsets in the process and to react before they affect the processPoints to note– Used mostly in flow applications– The FF is added to the output signal directly, after

the PID computation is done. This signal may not be appropriate for the process. A FF ratio and bias signal must be set to ensure that the right amount of FF is added to the output. This is not easy.

Applicable Controllers– US1000, YS170



Page.62

Feed Forward Control

US1000 Add the Product flow to control theMV for fast control action, beforeProduct temperature change.Temp. input Tin : 0 to 200 deg CFlow input Fin : 0 to 100L/min.

Feed Forward Calculation FF =FGN * (Fin + FBI) + FBO FF:Signal which is added to MV FGN : Gain FBI : Input bias FBO : Output bias

Product Flow(Feed Forward input signal)

T CPID

F

+

Pt100

Steam

HeatExchanger SQRTBias &

Gain



Page.63

Boiler Combustion Control

Used to provide steam to a variety of applicationsPoints to note– This application requires many controllers working in

tandem to operate a boiler.• Boiler Master• Fuel Flow Controller• Air Flow Controller• Drum Level Controller

– Requires specialized knowledge to operate, so customer is usually quite familiar with application and configuration.




Page.64

Boiler Combustion Control Overview

Boiler Master Signal

Air Flow

AirFlow

Controller

FuelFlow

Controller

M

Boiler Master ControllerBoiler output Pressure control

Fuel Flow

Boiler outputPressure

Pressure

Flow

Cross LimitControl

Control ConditionSteam Pressure 50 to 150 kg/cm2Steam Flow 0 to 100 t/hFuel Flow 0 to 8.0 kl/hAir Flow 0 to 100.0 %

Air to Fuel ratio should bedecided from optimumcombustion dondition in eachboiler master zone.



Page.65

Boiler Master Pressure Controller

Used to control steam header pressure by adjusting the setpoint of the air and fuel controllersPoints to note– Feed forward input from header steam flow is used

to adjust boiler air & fuel flow setpoint. Predictive action for unexpected steam demand.

– Feed forward signal must be linearized for each particular boiler




Page.66

Boiler Master Pressure Control

MV

PC001

FX +

Output tracking signal

Linearizer

Boiler Steam Flow

Pressure

Flow

Fuel Flow setpoint

Fuel control statusAUTO mode

FX Linearizor

Boiler Steam

Fuel FlowRate

This charactaristic of lineariszershould be tuned from actualSteam to fuel flow data.



Page.67

Fuel Flow Control

Used to control the fuel flow to the boilerPoints to note– Controller looks at both the boiler master signal and

the air flow rate, select the lower of the two and this becomes the fuel flow setpoint. This configuration limits the fuel to keep it lagging behind the air.




Page.68

Fuel Flow Control with Cross Limit Method

LOW selector + K1

Fuel Flow RateControl

Fuel Flow

Air FlowRate

Boiler Master Signal



Page.69

Air Flow Controller

Used to control air flow to the boilerPoints to note– Controller looks at both the boiler master signal and

the fuel flow rates, select the higher of the two and this becomes the air flow setpoint. This configuration limits the fuel to keep it leading the fuel.

– A ratio is placed in this controller to achieve the proper mix of air to fuel. The RT parameter can be used or this signal can be linearized




Page.70

Air Flow Control with Cross Limit Method

--

M

HI selector Air to FuelRatio

Air Flow RateControl

Air Flow

- K2

Boiler Master SignalFuel Flow Rate

signal

Fx

Air Flow rate

Fuel FlowRate

Fx



Page.71

Drum Level Control

The Drum is the object of combustion. The drum provides steam to the header and associated equipment. The drum level controller ensures there is enough water in the drum to meet the steam demand. Points to note– There are three types of drum level configurations

• Single Element Control• Two Element Control• Three Element Control

– Applicable Controllers

– US1000, YS170

NetSol Business Unit Yokogawa Corporation of America Copyright © Yokogawa Corporation of America January 26, 2006 Yokogawa Green Series Controllers.

Documents

super control slide

control applications

typical control drawing

dual loop control

breaking action slide

integral time

series dynamic self

water valve slide