Working with Controllers

Table of Contents

Chapter 1: Introduction to Controls

Topics: Process dynamics; Current, position, and time proportioning; Controller modes, actions, terminology, and options; Loop accuracy

Learning Objectives:

• Describe the kinds of controllers most often used in industrial applications.
• Discuss six important problems of process dynamics that controllers must overcome.
• Compare the actions of current proportioning, position proportioning, and time proportioning.
• Name four kinds of controller alarms.
• Discuss the importance of safety in control loops.

Chapter 2: Controller Operations

Topics: Automatic/manual control; Range and span; Direct-, reverse-acting, on/off, and proportional controllers; Current, time, and position-proportioning control; Control strategies

Learning Objectives:

• Explain why automatic/manual control is necessary.
• Explain how on/off controllers work and discuss the difference between on/off and proportional controllers.
• Describe a basic controller tuning process.
• Describe current-, time-, and position-proportioning controllers and name possible uses for each.
• Explain how split control works.

Chapter 3: Controller Modes and Tuning

Topics: Proportional mode; Offset; Integral mode (reset); Derivative mode (rate); Single, two, and three mode controllers; Loop tuning; Step-change response

Learning Objectives:

• Describe the effect of the proportional, integral, and derivative modes on a controller's response to process changes.
• Discuss proper uses for the proportional, integral, and derivative modes.
• Explain how the proportional, integral, and derivative modes affect the tuning of a controller.
• Describe the procedure for tuning a controller by the step-change response method.

Chapter 4: Special Controller Applications and Options

Topics: Cascade, feedforward, ratio, and auctioneering control; Hardware options; Remote setpoint; Auxiliary outputs; Indicators; Limits and alarms

Learning Objectives:

• Compare cascade, feedforward, ratio, and auctioneering control strategies.
• Describe three optional features used with auto/manual controllers.
• Discuss the use of remote setpoint, auxiliary outputs, and several kinds of indicators as hardware options for controllers.
• Explain how input signal conditioning, anti-reset windup, adaptive gain, error-squared calculation, and setpoint/output ramp and clamp affect controller operation.
• Discuss the use of limit and alarm options available for controllers.

Chapter 5: Maintaining Controller Systems

Topics: Preventing problems; Electrical noise and suppression; Regulating power; Electrical coupling; Temperature variation; Troubleshooting

Learning Objectives:

• Describe five ways of suppressing electrical noise.
• Discuss the effects of an inadequate power supply and explain how to regulate it.
• Describe ways to avoid the harmful effects of electrical coupling.
• Explain how temperature variations affect controllers.
• Describe the kinds of equipment and proper connections needed to test controllers.
• Discuss elements of effective controller maintenance and troubleshooting.

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