PID rules allow the controller to continuously vary the speed or position of a controlled device in order to achieve a target condition. PID is a commonly used control scheme in industrial settings. The theory is beyong the scope of this document, but this is one of many good references available on the web.
Use of PID rules in the Vesta assumes that you have a motor, circulator, fan, blower, or other device that is connected to a VS-1108 Variable Speed Control Unit or some other device that can be controlled directly using the 4-20ma analog outputs on the Vesta.
Line 1 - Rule Setup
PID rules have three lines. The first line sets up the rule itself - what is to be controlled, what the goal is, and when the rule should operate. There are five fields in this line. All are required, and all must refer to Vesta data elements. This rule is from the included Demo application. It varies the current through a light bulb to keep the shade temperature at a target value:
Control Light Bulb to make Shade Temp close to Shade Target based on Room Temp when ~PID Enabled is true
The fields are as follows:
- Control Output - 'Light Bulb' in this example. This must refer to a Vesta analog output.
- Process Variable - 'Shade Temp' in this example. This is the parameter that you wish to affect and bring as close as possible to a desired target value. It almost certainly needs to be a sensor input, although it could be a variable whose value is calculated from sensor inputs. For example, you could calculate temperature rise through a heat exchanger as the difference between inlet and outlet temperatures. A PID rule could then vary fan or circulator speed to maintain a constant temperature rise.
- Target Value - 'Shade Target' in the example. This can be a variable or an analog input. In eiter case, the purpose of the PID rule is to vary the control output to drive the process variable as close as possible to this value.
- Bias Input - 'Room Temp' in the example. This is used to predict an initial value for control output. It is discussed in more detail below.
- Control Input - '~PID Enabled' in the example. If this data element is true, then the PID rule will be active. If it is not true, then the PID rule will not manage the control output, except that it will set the output to zero when the control input first becomes false.
Line 2 - Tuning Parameters
The second line contains tuning parameters. All are required, and all are directly entered numeric values:
gain = 5.0 damping = 20.0 lmin = 100.0 lmax = 40.0
Gain is the simplest tuning parameter. The technical term is proportional gain, and it's the 'P' in PID. It controls how strongly the PID rule responds to errors - that is, differences between the value of the process variable and the target value. The control output is in percent and has a maximum possible range of 0 to 100. The PID engine will compute an expected value for the control output and then add a correction that is the gain multiplied by the error as defined above.
For example, assume that the expected control output is 50%, but the shade temperature is 5 degrees cooler that the target temperature (an error of 5 degrees). With a gain of 5, that would result in a correction of 25 to be added to the expected output of 50, yielding an output of 75.
Start with a relatively low value for gain. Too high a value will cause large fluctuations as the system over-reacts to small errors.
Proportional gain alone is usually not enough to bring the process variable to the target value. PID controls also contain a factor that looks back to see whether there's been a persistent error over time. It calculates an additional correction based on how long an error has existed and how large that error has been. Mathematically, this technique is called integration, and contributes the 'I' in PID.
In the Vesta PID engine, the damping term controls the effect of the integral factor. A large damping value supresses the effect of the integral factor.
Start with a relatively high value for integral damping - 100 to 1000 or more, especially if there's a large time lag between changes in the control output and resulting changes in the process variable. Once a reasonable value for gain has been established, reduce damping in 50% steps until the system starts to over-react, then go back to the last stable value.
Bias - lmin and lmax
It is helpful to enable the system to make a reasonable estimate of the required control output. In many cases, there's some environmental value that can be used to make an approximate guess. For instance, outdoor temperature might allow an estimate of required radiant floor supply temperature - higher when it's colder outside. In the Vesta PID rule, the bias value is used with lmin and lmax to calculate the estimated control output. The bias value element would be outdoor temperature in the radiant floor example. In our light bulb example it's room temperature, since we expect that room temperature can predict how hot our bulb will need to be to achieve a given shade temperature. If our shade temperature target is 140 degrees and the room temperature is also 140, then the control output would be 0 - no additional heat would be needed. The lmin parameter is the bias value at which the control output would be expected to be at it's minimum.
By the same token, lmax is the bias value at which the system would need maximum control output. We don't really know what that is for our light bulb, but we'll guess that at a room temperature of 0 degrees, it would need 100% output.
Note that it's not critical to have an exact value. As long as the estimate is better than an arbitrary fixed value, it will improve performance.
If there is no value that can be used to predict the control output, set lmin and lmax to 0. In that case, the Vesta will use 50% as a starting value for control output.
Min and Max Output
In some cases, you may want to set a minimum and/or maximum value for the control output. In most cases, 0 and 100 are appropriate.
Line 3 - Purge Logic
Line 3 is used if there's a need for purge cycles. This is often the case when controlling the draft blower on a wood gasification boiler. When running at low speed, it's necessary to periodically flush the primary chamber by running the blower briefly at high speed. This technique can also be used if low speed allows air bubbles to accumulate, or if there's any other reason to have brief periodic high speed intervals.
Purge values are required. Set them to 0 if purge is not desired.
Min Output = 0.0 Max Output = 100.0 Purge Threshold = 0.0 Purge cycle interval = 0.0 Purge duration = 0.0
Purge Threshold sets the value for control output below which purges are required. A value of 50 means that the system will run purge cycles any time the output is below 50%.
Purge cycle interval is the time in seconds between purges.
Purge duration is the duration in seconds for the purge cycle. The output will be set to 'Max Output' value for this duration each purge cycle.