Version 4.4
Process Loop Monitoring, Tuning and Diagnostic Software

INTUNE version 5 is now available for new installations or upgrades from version 4.X.

Contact ControlSoft for technical support for version 4.X.

INTUNE helps you to:

• Reduce process fluctuation and product waste
• Increase product quality and consistency
• Reduce field engineering time
• Save energy costs
• Reduce startup time
• Reduce wear and tear on the control valves

	See customized solutions for users of: Bailey INFI 90    ABB-Symphony™ (DCI Compatible) and DCI System Six®    Honeywell    Emerson Ovation™

INTUNE (version 4) is offered as an auto-tuning tool or as the complete toolkit. Contact ControlSoft for a complete list of all INTUNE variations available.

INTUNE is a unique software tool that:

• Automatically generates PID parameters
• Re-tunes loops for optimal performance
• Monitors multiple PID loops to determine how complete systems are being controlled

Log data, view multiple loop event logs, analyze error distribution curves, model and simulate process loops, and switch loops to INTUNE's advanced adaptive tuning--all without disturbing your process.

You choose the INTUNE features you need:

• Loop Diagnostics detect and rectify abnormal behavior
• Auto-Tuning provides optimal tuning parameters during loop commissioning
• Simulation graphical interface answers the "what-ifs?"

INTUNE is a process engineer's dream come true:

• Simultaneous tuning, monitoring, and diagnostics of multiple PID loops
• Elaborate reports of error analyses, event logs, tuning results
• PID loop and display configuration schemes allow dynamic configuration updates

Connecting to Allen-Bradley's ControlLogix ,PLC-5 or SLC 500, GE Fanuc Series 90, Modicon 984, Siemens TI, or any DCS/PLC, INTUNE works on most applications with complicated configurations (long lags, cascaded loops, interactive systems).

• PID Auto-Tuning
• Control Loop Diagnostics
• Modeling & Simulation
• Off Line Data Interface
• Configuration
• Connectivity

PID Auto-Tuning

Powerful Tools

Better PID loop control results in tighter tolerances in quality, reduced scrap, and reduced downtime. Thus, the ability to maintain all your process PID loops at their optimal operating conditions translates immediately to huge savings in manufacturing cost and higher productivity. As a process control engineer you have often wished for tools which would make your job of commissioning, tuning, and maintaining PID loops less time-consuming.

INTUNE (version 4) is a collection of software tools required by control engineers and process operators alike to start up, diagnose, and maintain the health of PID loops in a plant. Easy to use and designed specifically for the control systems in your plant operation, INTUNE boasts features which are unmatched by any other tuning, monitoring, or simulation software.

Auto-Tuning

Possibly the most useful tool for control system commissioning and process startup, the auto-tuning tool from ControlSoft has been in use on different control systems for the past decade, under license with several prestigious system manufacturers. INTUNE's auto-tuning tool can be applied to generate PID parameter values for your process loops, in a single or multi-loop mode.

Auto-tuning involves conducting a step tuning test on your PID loops in either manual or automatic mode. The software collects process data, analyzes the same, and identifies a model representing the true process dynamics. It then uses advanced Internal Model Control (IMC) based algorithms to calculate robust tuning parameters for the PID loop under test.

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Control Loop Diagnostics

Diagnostics

INTUNE loop diagnostics software is unique in its ability to detect and rectify poor control loop performance. Monitoring multiple loops simultaneously, INTUNE logs and reports many abnormal process events like control value saturations and persistent process oscillations. A real-time error distribution analyzer provides a graphical indication of the quality of control while intelligent self-tune adapts the control loop tuning parameters to changing process conditions.

Intelligent Self-Tune

The intelligent tuner is the heart of INTUNE's diagnostics module, and is designed for continuous background operation. When activated, it can perform self-tuning in either of the following modes:

1. Advisory mode - recommended PID changes are flashed on a pop-up window for operator acknowledgment and download.
2. Automatic mode - recommended PID changes are automatically downloaded to the controller, with a message to the event logger.

Error Distribution Analysis

The error distribution analyzer provides statistical analysis of the quality of control on your PID loop. It calculates time-based percentile for several process events which directly reflect the loop control quality, for example, Manual Control, Alarm Limits, and Output Saturation.

Event Logger

The Event Logger uses sophisticated pattern recognition techniques to analyze and interpret process data in real time. It detects abnormal process characteristics (e.g., controller output saturation or sluggish response to process load changes or persistent oscillations), validates the same, and logs the activity with a time and date stamp.

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Modeling & Simulation

Simulation

INTUNE simulation software is an off-line tool to predict the performance of your PID control loops in either a single or cascade configuration. It automatically uploads process models generated by INTUNE, and performs "what-if?" type analysis, allowing you to avoid expensive trials on your real process.

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Off-Line Data Interface

Off-Line Tune

The collection of tools in this module allows you to import any ascii data file which contains your valuable process information. Typically INTUNE expects you to provide a data file with columns of data containing process variables (temperature, pressure, flow), setpoints, and controller output data. Process data may be archived by a proprietary control system that does not offer PC connectivity, by using data logging tools provided within your system, or external analog signal interface cards.

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Configuration

INTUNE allows you to configure an unlimited number of PID loops and group them in pre-designed display templates, up to a maximum of 8 PID loops per display. This enables you to view trends, error distribution charts, and event logs, which belong to a process sub-system. A powerful collection of tools has been designed to navigate INTUNE efficiently and maintain maximum productivity while on-line.

Loop & Display Configuration

Loops are configured using a fill-in-the blanks form, and saved as loop configuration files. User enters the tuning and diagnostic priorities, selects trend colors, configures alarm values, etc. INTUNE simply saves all the PID loop configuration information in a file.

Displays consist of an unlimited number of trend, error distribution, diagnostic, and other windows, which are configured using a display configuration tool. Grouping loops functionally (e.g., all PID loops controlling a boiler) in a particular trend configuration allows you to analyze a total system as opposed to an individual PID loop.

Tools

INTUNE provides over a dozen unique tools to navigate INTUNE efficiently when on-line.
The status tool provides a summary of the current mode status of each loop (monitor/diagnostics/tuning test on/time left, etc.).

The X-Y Coordinates tool displays trend values at cursor locations, automatically switching to relevant loop parameters when moved from one trend box to another.

The Change Model tool allows massaging of process models generated by INTUNE to better fit the loop dynamics.

The Compare PID tool allows overlays of predicted loop responses in simulation mode to understand the subtle effects of changing inputs.

Numerous functions like tuning start/stop, mode change (auto/manual), download PID, and select loop are controlled from two unique toolbars – giving you instant access to the commonly used procedures within INTUNE.

Multiple Loops

INTUNE allows you to view trends, event logs, and error distributions in groups from two to eight loops at a time. Error distributions give you the overall view of how the loops have been doing over your time frame of interest, while event logs are a brief summary of your loop health.
You retain individual control on each loop by selecting the active loop button from the toolbar. The tools which allow for changing setpoint or modifying mode are relevant to the active loop selected at any point of time.

Multiple display windows can be viewed together tiled or cascaded, or the user may scroll through the windows using the scrolling tool. This feature efficiently presents all the important process information on a particular system.

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Connectivity

INTUNE connects to most process control systems using INTUNE direct drivers or third-party DDE or OPC Servers. The direct drivers either connect through serial ports or allow you to connect as a node on a data network. The DDE and OPC drivers allow easy access to any control system through DDE and OPC connections with a server.

Either way, INTUNE maintains real-time connections with your process PID loops, and updates all process parameters at every sampling interval specified within.

Optional direct drivers are available for RSLinx (OEM or Professional), Modbus (serial), and Siemens-TI (serial).

Some of the vendors whose control systems are supported on INTUNE are as follows:

• ABB (Bailey)
• Allen-Bradley
• AEG Schneider
• Fisher Controls
• GE Fanuc
• Honeywell
• Moore Controls
• Omron
• Siemens
• Emerson Ovation™

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INTUNE version 5 is now available for new installations or upgrades from version 4.X.

Contact ControlSoft for technical support for version 4.X.