Basic Loop

Controller
I/P
Transmitter
I/P
Convertor
PV MV
SV
4-20 mA
4-20 mA
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)
Final Control Element
Basic Control Loop
Process Control Systems
Process control systems are classified
into

Analog Control Systems

Digital Control Systems


Analog Control System
Signal
Conversion
I/P
4-20 mA DC
1 to 5V DC
Operational Amplifier
Set Point
Final Control Element
Transmitter
Analog Control System
Digital Control System
I/P
4-20 mA DC
A / D
1 to 5V DC
D / A
Digital
Output
Unit
Input
Unit
Memory
Unit
Control
Unit
Arithmetic
Unit
Set
Point
Processor
Digital Control System
* First control
computers
* First DDC * First mini
computers
* First distributed
DDC using
microprocessors
* First one-loop
DDC controllers

* Integrated systems

Ge.Tr Sl. Tr
Rapid growth of
process Industries
DTL SSI
TTL.SSI
LSI uP
Energy crisis
(Transition to
steady growth)
Demand for
conservation
of resources
Appearance of
OA, LA and FA
(Improved man-
machine interface
V LSI 32bit UP
* Multi produce batch
applications
* Integrated FA system
* CIM

* multimedia
* Pentium Processor
* Revolution in info tech
* Internet
* windows NT gaining prominence
* Object linking
* ODBC
* RDBMS
THE EIGHTIES
THE NINETIES THE SEVENTIES THE SIXTIES
BEYOND
2000
* Use of factory
management
computers
YEWCOM
Factory Management Computer System
HP9000
Computer Control System
CCS
YODIC 100 YODIC 1000
Manufacturing Line Control System
YEWMAC
Centralized DDC System
YODIC 500 YODIC 600
Distributed Control System
CENTUM II
CENTUM V CENTUM-XL
YEWPACK
YEWPACK
Mark II
uXL
YEWSERIES 80
YS 100
ECS EBS I SERIES
Analog Control System
CS1000
CS3000
CS
THE EIGHTIES
THE NINETIES THE SEVENTIES THE SIXTIES
BEYOND
2000
Digital Control System
Digital Control Systems are further
classified into

Centralized Control Systems

Distributed Control Systems
Centralized
Processing
Unit
CPU
Centralized Control System
Input
Signals
from
Field
Set Points
Output
Signals
to
Field
Centralized Control , Centralized Monitoring
PV1
PV2
PVn
PV3
MV1
MV2
MVn
MV3
SV1 SV2 SV3 SVn
Centralized Control System
Centralized Control System
Drawbacks Of CCS:
If the CPU fails the entire plant
gets affected.
Redundancy concept is not
available.
Redundancy is having two controllers. One
woul d be acti ve and the other woul d be
st andby. If t he act i ve cont rol l er f ai l s,
t h e s t a n d b y c o n t r o l l e r t a k e s o v e r .

Distributed Control System
Input
Signals
from
Field
Distributed Control Centralized Monitoring
Set Points
Communication
Bus
Output
Signals
to Field
MV1
MV8

FCS
PV1
PV8
SV1
SV8
MV9
MV16

FCS
PV9
PV16
SV9
SV16
MV17
MVn

FCS
PV17
PVn
SV17
SVn

OPS

OPS
Distributed Control System
Basic Components of DCS
FCS (Field Control Station):
Used to control the process. All the
instruments and interlocks created by
software reside in the memory of the FCS.
All the field instruments like transmitters
and control valves are wired to the FCS.
OPS (Operator Station):
Used to monitor the process and to operate
various instruments.
Communication Bus:
Used to communicate between the FCS and
the OPS

Advantages of DCS
Control function is distributed among multiple CPUs
(Field Control Stations). Hence failure of one FCS
does not affect the entire plant.
Redundancy is available at various levels.
Instruments and interlocks are created by
software.
Generation and modifications of the interlocks are
very flexible and simple.
Information regarding the process is presented to
the user in various formats.
Field wiring is considerably less.
Maintenance and trouble shooting becomes very
easy.
Cost effective in the long run.
CENTUM Series (DCS) Evolution
1st CENTUM
2nd CENTUM
CENTUM V
CENTUM-XL
CENTUM CS
CENTUM CS3000
1975
1981
1984
1988
1993
1998
CENTUM has developed as a true open system.
World First DCS
2008 CENTUM VP
CS3000-System Configuration
CS, CS 1000
CENTUM-XL, -V
MXL
BCV
CGW
Remote Domain System
V net
HIS
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PFCS
LFCS
Ethernet
HIS / ENG
FFCS
KFCS
CENTUM CS 3000 - Major Components
FCS (Field Control Station)
Reliable controller.
Cost-effective and capable I/O subsystem.
HIS (Human Interface Station)
The operator station based on Windows XP or Windows2000.
(Both are selectable.)
HIS provides easy & flexible operation.
ENG (Engineering Station)
Engineering Station is used to do the engineering builder for
all the stations like HIS, FCS, CGW, BCV etc. ENG is a PC
loaded with Engineering software.
The HIS can be loaded with engineering software so that it
can be used as HIS as well as ENG.
CGW: Communication Gateway Unit used to communicate
with supervisory computers.
BCV: Bus Converter is used to link two domains.
CENTUM CS 3000 - Networks
V-Net (Communication Bus)
Real-time control bus.
V-NET is a used for
communication between HIS, FCS,
BCV & CGW.
Maximum 64 Stations can be connected
on the V-net.
ETHERNET (Communication Bus)
Ethernet is a standard network in
CS3000 to connect HIS, ENG and
supervisory computers .
Transmission speed: 10 MBPS

CS3000 FIO System Configuration-Overview
ooo
GSGW
V net
PLC
FCJ/FCN
Ethernet
PROFIBUS-DPV1
Discrete I/O Drive
DeviceNet
Photoelectric
device
OPC
Server
FFCS
Ethernet
Safety
System
Other
System
Subsystem
Gateway
FIO
FIO means Field network I/O.
FIO is Process I/O modules.
A kind of compact, cost-effective,
reliable I/O devices, targeted as the
industrial standard I/O of next-
generation.
FIO includes the latest network
technologies and field experience.
Power supply unit
CP401 CPU module
Eight FIO slots
EC401 ESB bus coupler
(Note)
Note: Two I/O slots are to be used for NIU extension.
AIP504 Vnet coupler (10BASE2 Vnet cable is used.)
Detachable
bottom unit
FFCS Hardware View
Hardware Configuration- Local Node
FIO: Max. 8
Local node
Max. 3
ESB bus
Up to 6
Modules
Up to 8
Modules
C
P
4
0
1

C
P
4
0
1

P
W
4
8
X

P
W
4
8
X

V net
FFCS
C
P
4
0
1

C
P
4
0
1

P
W
4
8
X

P
W
4
8
X

E
C
4
0
1

E
C
4
0
1

S
B
4
0
1

P
W
4
8
X

P
W
4
8
X

S
B
4
0
1

S
B
4
0
1

P
W
4
8
X

P
W
4
8
X

S
B
4
0
1

S
B
4
0
1

P
W
4
8
X

P
W
4
8
X

S
B
4
0
1

FFCS
Minimum Configuration
Maximum Configuration
Hardware ConfigurationRemote Node
V net
FFCS
Remote node
Expanded Remote node up to 3
ER bus
E
B
4
0
1

E
B
4
0
1

E
B
4
0
1

E
B
4
0
1

E
B
4
0
1

E
B
4
0
1

E
B
4
0
1

C
P
4
0
1

C
P
4
0
1

P
W
4
8
X

P
W
4
8
X

E
B
5
0
1

P
W
4
8
X

P
W
4
8
X

E
B
5
0
1

Remote node
E
B
5
0
1

P
W
4
8
X

P
W
4
8
X

E
B
5
0
1

E
B
5
0
1

P
W
4
8
X

P
W
4
8
X

E
B
5
0
1

Remote node
Optical Repeater can be used
FIO System Specification for FFCS
The bus among FFCS and local nodes. (ESB bus)
Dedicated Internal Bus
Speed : 128 Mbps
Distance in Total : Max. 10m
Remote I/O bus (ER bus)
Based on Ethernet
Speed : 10 Mbps
Distance in total :
10base2 -> max. 185m / 10base5 -> max. 500m
max. 2 km with repeater (Standard of Ethernet)
Up to 3 remote nodes can be installed on a FFCS.
Pair & Spare CPU Concept
FFCS Specification
CPU R5432 (RISC)
Memory Size 32MB
Power supply 100/220V AC, 24V DC
No. of I/O slot 8
No. of I/O node
total 4 including CPU
node
ESB bus I/F EC401/SB401
Local node for ESB bus Up to 4
Remote node for ER bus Up to 3
ER bus I/F EB401/EB501
AP capacity
AI/AO 480
DI/DO 1920
Communication data 4000 words
Global SW 256
Common SW 4000
%ANN 1000
%PR 1000
%OP 500
%RQ 200
No. of control drawing sheet 200
No. of function block (total
with %ANN)
2500
Realtime trend 256
Input Output Modules
Analog Modules
Analog Modules <Non-isolated type>
AAI141 16Ch Current input 4-20mA (Transmitter power supply)
AAV141 16Ch Voltage input 1-5V
AAV142 16Ch Voltage input -10V to +10V
AAI841 8Ch Current input/8Ch Current output 4-20mA (Transmitter power supply)
AAB841 8Ch Voltage input/8Ch Current output 1-5V input/4-20mA output
AAV542 16Ch Voltage output -10V to +10V
AAP149 16CH Pulse Count 0 to 6kHz (Pulse Input Module Pm1 Compatible)
<Isolated (between system and field)>
AAI143 16Ch Current input 4-20mA (Transmitter power supply)
AAI543 16Ch Current output 4-20mA
AAV144 16Ch Voltage Input -10V to +10V
AAV544 16Ch Voltage Output -10V to +10V
AAT141 16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mV
AAR181 12Ch RTD JIS Pt100ohum
<Channel Isolated>
AAI135 8Ch Current input 4-20mA (Transmitter power supply)
AAI835 4Ch Current input/4Ch Current output 4-20mA (Transmitter power supply)
AAT145 16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mV
AAR145 16Ch RTD/POT input RTD JIS Pt100ohum / POT 10kohum
AAP135 8Ch 0-10kHz Pulse input Transmitter power supply 12V/24VDC,
(Shunt resistance can be selected)
Analog Modules with HART
FIO HART Module Lineups
AAI135-H:8 input, channel isolated
AAI835-H:4 input/4 output, channel
isolated
AAI141-H:16 input, non-isolated
AAI841-H:8 input / 8 output, non-isolated
AAI143-H:16 input, Isolated
AAI543-H:16 output, Isolated
ASI133-H:8 input, IS module
ASI533-H:8 output, IS module
HART Module data
Analog Data
4 to 20 mA from Device

HART Variable Data
HART device supports Max 4 HART Variable
PV Primary Value
SV Secondary Value
TV Third Value
FV(4V) Fourth Value
HART Module supports Max 32 HART Variable
data
Digital I/O Modules
<Generic type>
ADV151 32Ch24VDC input, Common minus side every 16-channel
ADV157 32Ch24VDC input, Common minus side every 16-channel, Single and Weidmueller only
ADV161 64Ch24VDC input, Common minus side every 16-channel, MIL type only
ADV551 32Ch24VDC,0.1A, Common minus side every 16-channel
ADV557 32Ch24VDC,0.1A, Common minus side every 16-channel, Single and Weidmueller only
ADV561 64Ch24VDC,0.1A, Common minus side every 16-channel, MIL type only
ADV851 16ch Input/16ch Output, 24VDC
<AC input modules>
ADV141 16Ch100VAC input, Common minus side every 8-channel
ADV142 16Ch220VAC input, Common minus side every 8-channel
<Relay output module>
ADR541 16Ch Relay output, Common minus side every 8-channel, 24-100VDC,100-200VAC,
2A/point, Maximum 8A is allowed per common, A type contact, exchange by a module.
<CENTUM-ST compatible type>
ADV859 ST2 compatible -16Ch input,16Ch output
ADV159 ST3 compatible - 32Ch input
ADV559 ST4 compatible - 32Ch output
ADV869 ST5 compatible - 32Ch input, 32Ch output
ADV169 ST6 compatible - 64Ch input
ADV569 ST7 compatible - 64Ch output
Communication Modules
Serial Communication Module
ALR111 RS232C
2 ports, 1200bps to 115.2k bps
ALR121 RS422/RS485
2 ports, 1200bps to 115.2k bps

Ethernet Communication Module
ALE111 Ethernet Communication
Installable both on Local and Remote Node
Subsystem Packages List
RS Communication (ALR111/ALR121)
YS Communication
YS Directly Communication
FA-M3
Modbus
SLC500/PLC5
MELSEC

Ethernet Communication (ALE111)
FA-M3
Modbus
SLC500/PLC5
Control Logix
MELSEC
Foundation Fieldbus Module (ALF111)
FF-H1 interface card
Redundancy
Installable both on Local and Remote nodes
VCR (Virtual Communications Relationship):
105 per port (one segment)
Both pressure clamp and terminal board are
available.
Link Master
Redundant Fieldbus Module (ALF111)
I
O
M

I
O
M

I
O
M

I
O
M

I
O
M

I
O
M

C
o
m
.

C
a
r
d

C
o
m
.

C
a
r
d

P
S
U

P
S
U

Field Devices
ALF111
Image of Redundant Card
0x14 0x15
External
Power
Supply
The Station for Real time Plant Monitoring/Operation
HIS (Human Interface Station)
Easy Operation by a mouse, a keyboard etc.
Real time display of Plant Abnormalities.
Plant Operation by thousands of Graphics
Types of HIS
DESKTOP HIS:
A IBM PC/AT compatible machine is generally used. Apart from the general PC, the
Yokogawa PC is also supported. Specifications of the PC HIS Desktop are as
follows:
CPU : Pentium IV Processor
Main Memory : 256 MB (Minimum)
Hard Disk : 20 GB or more
Video Display : 1024 x 768 or more, 256 colours
CRT Monitor : Multi Scan 17 monitor or larger
Serial Port : RS232C one port or more
Parallel Port : One port or more
Extension Slot : PCI slot for V/VL net card, ISA slot for Ethernet card
Power Supply : 200-240V AC
Basic Software : Windows NT with Service Pack ,Windows 2000 or
Windows XP

CONSOLE HIS
The floor mounted console type HIS comes with 21 monitor which has a touch panel
operation. It has an operation keyboard and an engineering keyboard.
Application Capacity of HIS
Maximum number of tags that can
be monitored from HIS : One
Million.

Maximum number of windows
that can be created per HIS :
4000.

Maximum number of Trend
Recording Points per HIS : 3328.

V net Communication
Protocol : IEEE 802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance : 500m to 20km
Media : Coaxial/Optical Fibre
Std. max. length : 185 m
Max. length : 20 Km (with optical repeater) 1.6
Km (with coax. repeater)



V net
HIS
V net : Extension Details
Optical
Fibre
R
R R
R T
T
Optical
Fibre
R
R R
R T
T
Max. 500m Max. 500m Max. 500m
Max.
15 km
Max.
15 km
Overall Max. 20 km
Co-axial Cable V net
HIS
HIS HIS


Domains are group of stations connected on the V-net.
Bus Convertor is used to link two domains.
BCV is used to connect CS, CS 1000, CENTUM-XL,CENTUM-V AND MXL to CS3000
system


Bus Convertor
HF BUS
EFCD FCS
HIS
ooo
BCV
ooo ooo
Domain
connection
EOPS
V-NET
ETHERNET
Operation Windows
Information regarding the process is gathered
as well as monitored by the following Standard
Operation windows on the HIS.
Tuning Window
Control Group Window
Trend Window
Process Alarm Window
Operator guide Message Window
Graphic Window
Overview Window
Process Report Window
Historical Report Window
System Message Window
These buttons are provided for
calling various functional windows
on the HIS
Type the TAGNAME to call the
instrument faceplate window
System Message Window
Various windows can be
accessed by selecting
the respective icons in the
System Message Area
These windows can also be accessed by the keys
on the Operator Keyboard

SYSTEM MESSAGE AREA ICONS
System Message Area
Operation Keyboard
Operation Keyboard
OPERATION KEYBOARD
All the operations can be performed with the help
of the Operation Keyboard. The same
operations can also
be performed by touch functions available
on the System Message Area Icons.
Operation Keyboard
From this window, you can open the
following windows.
1. Overview Window
2. Control Window
3. Tuning Window
4. Trend Window
5. Graphic Window
6. Alerm Window
7. Operator Guide message
Window
Operation Windows
Instrument Faceplate Window
Tuning Window

Select this icon to display
the Tool box
Select this icon to display
the Tuning Window
Tuning Window
TUNING WINDOW displays all the
Tuning parameters of the instrument.

The Tuning Window is used to set up the
alarm setting as well as the loop tuning
parameters.

Only the items indicated with a = can
be changed.

Displaying a Tuning Window
1.Double click on a Tags name on a
Control Window and a faceplate window
will appear. Select the Tuning
window icon from the toll box.

2. Select NAME icon in the System Message
Area then enter the TAGNAME.
Tuning Window
Control Drawing Display
Select this icon to
call the Control
Drawing display
Control drawing display
Control Drawing Display
Control Group Window
Select this icon to display
the Tool box
Select this icon to display
the Control Group Window
Control Group Window8 Instruments
Control group windows are used to
display multiple instrument faceplates.

Maximum 8 or 16 instrument faceplates
can be displayed in one Control Group
Window

Normally the instruments are monitored and
operated from this window.

Double click on the instrument TAGNAME to
display the Tuning Window of the instrument.
Select the Upper Window Key to come back to
Control Group Window

.
Control Group Window 16 Instruments
Trend Window
Select this icon to display the
Tool box
Select this icon to display
the Trend Window
Trend Window
TREND WINDOW records the PV, SV and
MV of various instruments.

Trend can be displayed in Trend Group
Format or in Trend Point Format.

Maximum 8 pens can be assigned in one
Trend Group Window
Trend Group Window
Trend Point Window
Double click here
to call the Trend
Point Window
Trend Point
Window
Calling Instrument from Trend Window
Double click here
to call the
Instrument
faceplate
Window
Instrument
Faceplate
Window.
Instrument can
be operated from
this window.
Process Alarm Window
PROCESS ALARM WINDOW displays the
latest 200 process alarms.

Alarms can be acknowledged either as a
Group or as Individual alarm.
Select this icon to call the Process
Alarm Window
Process Alarm Window
PROCESS ALARM WINDOW displays the
latest 200 process alarms.

Alarms can be acknowledged either as a
Group or as Individual alarm.
This icon displays the current PV
Values of the instruments that are
in alarm
This icon displays the important
tags (High Priority Alarms) that
are in alarm.
This icon is used to acknowledge
the process alarms.
Operator Guide Message Window
Select this icon to call the
Operator Guide Message Window
OPERATOR GUIDE MESSAGE WINDOW
displays the predefined messages to guide
the operator regarding the current process
status and /or the actions to be taken.

OG messages can be acknowledged either
as a Group or as Individual message.
Graphic Window
Overview Window
Select this icon to display the
Tool box
Select this icon to display
the Overview Window
Overview Window
Overview Window displays the overview of the
current process status.

Information regarding the process is distributed
among the various display blocks.

32 Display Block s per Overview Window.

Each block gives dynamic information regarding the
process.

Double click on the display block to more details.

3 Types of Display Blocks

Single Tag Block
Window Display Block
Comment Block

Overview Window
Process Report Window
Historical Message Report Window
Sequence Tables
Sequence Tables
Logic Charts
Logic Charts
System Status Window
System Alarm Window
SYSTEM ALARM WINDOW displays the
latest 200 system alarms.

Alarms can be acknowledged either as a
Group or as Individual alarm.
Navigator Window
HUMAN INTERFACE STATION
Virtual test Function
SYSTEM GENERATION
FUNCTION
OPERATION
&
MONITORING
FUNCTION
CONTROL FUNCTION
TEST
FUNCTION
SFCS
Page 77
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