Basic Control

Loop

Basic Loop
Transmitter

SV
PV

4-20 mA

I/P
I/P
Convertor

Controller

MV

4-20 mA

Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)

Final Control Element

Process Control Systems

Process control systems are classified

into

Analog Control Systems

Digital Control Systems

Analog Control System

Analog Control System

Operational Amplifier

Transmitter
Signal
Conversion

1 to 5V DC

4-20 mA DC

I/P
Set Point

Final Control Element

Digital Control
System

Digital Control System

Memory
Unit
1 to 5V DC
A/ D
4-20 mA DC
D/A

I/P

Digital

Input
Unit
Output
Unit

Processor

Control
Unit
Arithmetic
Unit

Set
Point

THE SEVENTIES

THE SIXTIES
* First control
computers
Ge.Tr Sl. Tr
Rapid growth of
process Industries

* First DDC

* First mini
computers

DTL SSI
TTL.SSI

* First distributed
DDC using
microprocessors

LSI uP
Demand for
Energy crisis
conservation
(Transition to
of resources
steady growth)

THE EIGHTIES
* First one-loop
DDC controllers

* Integrated systems

* Use of factory
management
computers
V LSI
Appearance of
OA, LA and FA
(Improved manmachine interface

BEYOND
2000

THE NINETIES

32bit UP
* Multi produce batch
applications
* Integrated FA system
* CIM

* multimedia
* windows NT gaining prominence
* Internet
* Pentium Processor
* Revolution in info tech
* Object linking
* ODBC
* RDBMS

THE SIXTIES

THE SEVENTIES

BEYOND
2000

THE NINETIES

THE EIGHTIES

Factory Management Computer System

YEWCOM
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 V
CENTUM II
YEWPACK

CENTUM-XL

YEWPACK
uXL
Mark II

YEWSERIES 80

YS 100

CS
CS1000
CS3000

Analog Control System

EBS
ECS

I SERIES

Digital Control System

Digital Control Systems are further

classified into

Centralized Control Systems

Distributed Control Systems

Centralized Control System

Centralized Control System

Centralized Control , Centralized Monitoring
PV1

Input
Signals
from
Field

PV2
PV3

MV1

Centralized
Processing

MV2
MV3

Unit
PVn

CPU

SV1 SV2 SV3

Set Points

MVn

SVn

Output
Signals
to
Field

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
would be active and the other would be
standby. If the active controller fails,
standby controller takes over.

the

Distributed Control System

Distributed Control System

Distributed Control
PV1

Input
Signals
from
Field

Centralized Monitoring

MV1

FCS

PV8

MV8
SV8

SV1
PV9

MV9

Output
Signals
to Field

FCS

PV16

OPS

OPS
MV16
SV16

SV9
PV17

MV17

FCS

PVn

MVn

SV17

SVn

Set Points

Communication
Bus

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

CENTUM VP2008

CENTUM-XL

CENTUM CS3000
1998
2nd CENTUM

1993 CENTUM CS
1988

World First DCS

1975
1st CENTUM

1981

1984 CENTUM V

CENTUM has developed as a true open system

CS3000-System Configuration

Ethernet
HI
S

HIS / ENG

Remote Domain System

CGW
V net
BCV
CS, CS 1000
CENTUM-XL, -V
MXL

PFCS
ooo

LFCS

FFCS

KFCS

CENTUM CS 3000 - Major Components

FCS (Field Control Station)

HIS (Human Interface Station)

The operator station based on Windows XP or Windows2000.

(Both are selectable.)
HIS provides easy & flexible operation.

ENG (Engineering Station)

Reliable controller.
Cost-effective and capable I/O subsystem.

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 Vnet.

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

Ethernet

V net

GSGW
Subsyste
m
Gateway

Ethernet

OPC
Serve
r

ooo

PROFIBUS-DPV1

FFC
S

DeviceNet
Discrete I/O

FCJ/FCN
Photoelectric
device

Drive

Safety
Syste
m
Other
Syste
PLC
m

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 nextgeneration.
FIO includes the latest network
technologies and field experience.

FFCS Hardware View

Eight FIO slots

Detachable
bottom unit
EC401 ESB bus coupler
Power supply unit
(Note)
CP401 CPU module
AIP504 Vnet coupler (10BASE2 Vnet cable is used.)

Note: Two I/O slots are to be used for NIU extensi

Hardware Configuration- Local Node

Up to 6
Modules

ESB bus
X
PW48
X

SB40
1
SB40
1
PW48

FIO: Max. 8

EC40
1
EC40
1
CP40
1
CP40
1
PW48
X
PW48
X

FFC
S

CP40
1
CP40
1
PW48
X
PW48
X

FFC
S

V net

Minimum
Up to 8
Modules

Configuration

X
PW48
X

Maximum

SB40
1
SB40
1
PW48

X
PW48
X

SB40
1
SB40
1
PW48

Configuration

Local
node
Max. 3

Hardware ConfigurationRemote Node

EB40
1
EB40
1
EB40
1
EB40
1
EB40
1
EB40
1
CP40
1
CP40
1
PW48
X
PW48
X

V net

FFC
S

Optical Repeater can be used

Expanded Remote node up

to 3

ER bus
X
PW48
X

EB50
1
EB50
1
PW48

X
PW48
X

X
PW48
X

Remote node
EB50
1
EB50
1
PW48

Remote node
EB50
1
EB50
1
PW48

Remote node

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
total 4 including CPU
node

No. of I/O 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
AI/AO

480

DI/DO

1920

Communication data
Global SW

AP capacity

4000 words
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)
Realtime trend

2500
256

Input Output Modules

Analog Modules
Analog Modules

<Non-isolated type>

AAI141
AAV141
AAV142
AAI841
AAB841
AAV542
AAP149

16Ch Current input

4-20mA (Transmitter power supply)
16Ch Voltage input
1-5V
16Ch Voltage input
-10V to +10V
8Ch Current input/8Ch Current output 4-20mA (Transmitter power supply)
8Ch Voltage input/8Ch Current output 1-5V input/4-20mA output
16Ch Voltage output -10V to +10V
16CH Pulse Count 0 to 6kHz (Pulse Input Module Pm1 Compatible)

AAI143
AAI543
AAV144
AAV544
AAT141
AAR181

16Ch
16Ch
16Ch
16Ch
16Ch
12Ch

AAI135
AAI835
AAT145
AAR145
AAP135

8Ch Current input 4-20mA (Transmitter power supply)

4Ch Current input/4Ch Current output 4-20mA (Transmitter power supply)
16Ch mV,TC input JIS R,J,K,E,T,B,S,N / -100 to +150mV
16Ch RTD/POT input RTD JIS Pt100ohum / POT 10kohum
8Ch 0-10kHz Pulse input Transmitter power supply 12V/24VDC,
(Shunt resistance can be selected)

<Isolated (between system and field)>

Current input 4-20mA (Transmitter power supply)

Current output 4-20mA
Voltage Input -10V to +10V
Voltage Output -10V to +10V
mV,TC input
JIS R,J,K,E,T,B,S,N / -100 to +150mV
RTD
JIS Pt100ohum

<Channel Isolated>

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

2 ports, 1200bps to 115.2k bps

ALR121

RS232C
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)

0x14 0x15

Field Devices

PSU

PSU

Com. Card

Com. Card

IOM

IOM

IOM

External
Power
Supply

IOM

IOM

ALF111

IOM

Image of Redundant Card

HIS (Human Interface Station)

The Station for Real time Plant Monitoring/Operation

Plant Operation by thousands of Graphics

Real time display of Plant Abnormalities.

Easy Operation by a mouse, a keyboard etc.

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
HIS

V net

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 : Extension Details

HIS

HIS

HIS

Optical
Fibre

Optical
Fibre

V net

Max. 500m

Max.
15 km

Max. 500m

Max.
15 km

Overall Max. 20 km

Co-axial Cable

Max. 500m

Bus Convertor
ETHERNET

EOPS

HF BUS

HIS
Domain
connection

V-NET

BCV
EFCD

FCS

ooo

ooo

ooo

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

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

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 Area

SYSTEM MESSAGE AREA ICONS

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

Operation Keyboard
OPERATIONKeyboard
KEYBOARD
Operation

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 Windows

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

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

Control Drawing Display

Select this icon to
call the 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

Select this icon to call the Process

Alarm Window

PROCESS ALARM WINDOW displays the

latest 200 process alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.

Process Alarm Window

This icon displays the current PV

Values of the instruments that are
in alarm

This icon is used to acknowledge

the process alarms.

This icon displays the important

tags (High Priority Alarms) that
are in alarm.

PROCESS ALARM WINDOW displays the

latest 200 process alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.

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

Virtual test Function

TEST

SYSTEM GENERATION

FUNCTION

FUNCTION
OPERATION
&
MONITORING
FUNCTION

CONTROL FUNCTION

SFCS
HUMAN INTERFACE STATION

Thank you
Page 77