Modern Software Meets Legacy Hardware

August 24, 2022

Grantek was recently able to achieve the unthinkable – pairing modern-day state-of-the-art PID Loop Tuning software with older, legacy PLC controllers.

As a system integrator, we are at the forefront of consulting, designing, and delivering against the critical issues that plague the manufacturing world.

While our focus is on providing businesses with innovative Digital Solutions with Industry 4.0 technologies, we also proudly serve a portfolio of leading global brands that are still using controllers that passed the test of time, but for which PID Loop Tuning software are either nonexistent, or lacking modern features.

However, through the efforts of one of our talented Principal Engineers, Grantek was able to pair the advanced PID Loop Tuning software LOOP-PRO TUNER (from Control Station) with Legacy Siemens/TI 505 PLCs as well as its newest compatible 2500 series PLCs processors manufactured by CTI.

This breakthrough is important for our company, as well as our customers for several reasons. Firstly, it helps us demonstrate our core values of commitment and playing the long game. We try our hardest to look after our customers and be innovative with our problem-solving while not taking shortcuts. It is important for us to provide the best quality of work that we can, even if that means developing new ways of working. Secondly, our customers now benefit from the realized solution and value that enables their current equipment to do things it could never have done before. Grantek takes pride in being able to strengthen and improve the working conditions of our customers as they work towards revitalizing their systems when they are ready to do so.

Using LOOP-PRO TUNER is a valuable asset to our company vs. the lengthy manual trial-and-error approach. Concretely, this translates into shorter commissioning time, and more optimized Loop controllers resulting in cost savings (e.g. well tuned Industrial Boiler controllers will use less fuel). Our customers can also now push the limits of their equipment without heavy capital investment. In the current global economic state, we are proud to deliver financial savings to our customers so they can continue to do the work that they do.

Here is a glimpse of the capabilities LOOP-PRO TUNER offers when mapped with TI 505 / CTI 2500 Series PLC controllers:

• Automatic PID Loops detection in OPC Server Tags mapped to the PLC controller (deep scan):

• Control of the PID Loop directly from LOOP-PRO TUNER interface:
o Tune your Loops with a singular interface, making the process modeling exercise (‘bump-tests’) faster and easier.

• State-of-the-art Process modeling:
o Selection of 5 different process models: FOPDT, FOPDT integrating, SOPDT, etc.

• Loop Tuning / Optimization using Internal Model Control (IMC):
o Use of a slider to better specify the loop response (from very conservative to very aggressive) as well as detailed relevant response statistics (e.g. IAE, Percent Overshoot, Stability Factor, etc.)

• Reporting:
o Detailed reporting, highlighting the differences between the existing and the recommended/applied tuning parameters.

Manufacturers can also find relief in the fact that this new method allows them to preserve the information and knowledge that is contained in these older PLCs. By introducing our new solution, they will be able to provide themselves with more time and resources to make sure they secure this invaluable information for when they decide to make the leap.

PLCs processors manufactured by CTI.

PID Loop Tuning Software.

About Grantek:
For over 40 years, top manufacturers in Food & Beverage, CPG and Life Sciences/Pharmaceuticals have called upon Grantek to solve their most complex business and manufacturing challenges. Grantek automates Pharmaceutical and Food & Beverage manufacturing operations, including integration with business systems for seamless solutions. Grantek helps customers meet the stringent requirements and challenges of the 4th Industrial Revolution. Grantek is a system integrator and solution provider with a specialization in Smart Manufacturing solutions, Manufacturing Automation solutions, Industrial IT/Cybersecurity solutions and Manufacturing Consulting services.

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