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CENTUM CS3000
Cour se Evaluation
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CENTUM CS3000
TABLE OF CONTENTS 1 System Overview .................................................................................................................................................6 1.1 Hardware terminology .................................................................................................................................8 1.2 Human Interface Station (HIS) ..................................................................................................................12 1.3 CS3000 Field Control Station....................................................................................................................14 1.4 I/O Modules and Nodes .............................................................................................................................15 1.5 Used I/O Modules......................................................................................................................................18 System Operations .............................................................................................................................................21 2.1 Operator Keyboard ....................................................................................................................................22 2.2 System Message area .................................................................................................................................26 2.3 HIS Operation Displays .............................................................................................................................27 2.4 Control Window ........................................................................................................................................31 2.5 Overview Window.....................................................................................................................................34 2.6 Tuning Window .........................................................................................................................................36 2.7 Trend Window...........................................................................................................................................38 2.8 Graphic Window........................................................................................................................................41 2.9 Process Alarm Window .............................................................................................................................43 2.10 Operator Guide Message Window.............................................................................................................45 2.11 Navigation..................................................................................................................................................47 System Maintenance Windows ..........................................................................................................................48 3.1 System Overview Window.........................................................................................................................50 3.2 System Alarm Window ..............................................................................................................................52 3.3 CS3000 Control Station Status Display Window.......................................................................................54 3.4 HIS Setup Display .....................................................................................................................................56 Process and Historical Reports ..........................................................................................................................57 4.1 Process Report Window.............................................................................................................................59 4.2 I/O Searches...............................................................................................................................................61 4.3 Historical Report Window .........................................................................................................................63 Control System Design ......................................................................................................................................64 5.1 Architecture ...............................................................................................................................................64 5.2 I/O Module Arrangement...........................................................................................................................65 Control Concept.................................................................................................................................................66 6.1 Tag naming standards ................................................................................................................................66 6.2 Tag alarms standards .................................................................................................................................67 Process screens standards ..................................................................................................................................68 7.1 Colors of medium ......................................................................................................................................68 7.2 Colors of device states ...............................................................................................................................68 7.3 Colors of electrical failures........................................................................................................................68 7.4 Basic types of equipment (shapes).............................................................................................................69 7.4.1 Pump, fan ...........................................................................................................................................69 7.4.2 Solenoid Valve (ON/OFF) .................................................................................................................70 7.4.3 Regulation valve ................................................................................................................................71 7.4.4 Analog measurement..........................................................................................................................72 7.4.5 Regulator............................................................................................................................................72 7.4.6 Faceplates ..........................................................................................................................................72 Operator displays ...............................................................................................................................................73 Pro-Safe .............................................................................................................................................................74 9.1 SCS System................................................................................................................................................74 9.2 Communication..........................................................................................................................................74 9.3 Used I/O Modules......................................................................................................................................75
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CENTUM CS3000
CENTUM CS3000
1 System Overview
OBJ ECTIVES OF THIS CHAPTER 1. 2. 3. 4. 5. Learn the overall layout concept of CENTUM 3000. Learn the terminology of the CENTUM 3000 system. Show how to setup unit addressing. Learn the Field Control Station hardware. Identify the different types of I/O modules and how software addresses each point.
CENTUM CS3000
Ethernet
HIS
HIS
Vnet
FCS
FCS
CENTUM CS3000
Ethernet communication link for loading soft and transmission data from printers, amount of PC station
CENTUM CS3000
FCS HIS
FCS HIS
Domain 2
Vnet
CENTUM CS3000
Bus conver ter (BCV) The ABC bus converter is used to connect CENTUM 3000 to existing CENTUM-XL or Micro XL systems. The ABC is also used for splitting the CENTUM CS3000 into what are called Domains. Domain A Domain is a grouping of stations on a Vnet segment. CS3000 Domains can have up to 64 stations; the domain address range on the V net is 1-16. A maximum of 256 stations are allowed per CS3000 system. CS1000 is fixed as Domain 1 with a maximum of 24 station. When CS1000 is connected to a uXL, the uXL is assigned Domain 17.
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Minimum Requir ements: CPU Pentium 800MHz or higher. Memory 128 MB for operations and monitoring. 256 MB for operations and builder. Hard Disk Drive 1 GB (2 GB recommended for using builder functions). CRT 17 inch or larger; 1024 x 768 (16 bit color depth colors). Station Addr essing There is a card in the HIS that defines its station number on the Vnet by the physical switch settings. Vnet STATION ADDRESS Switches
ODD PARITY
ODD PARITY
DOMAIN NO.
0 0 16 8 4 2 1
STATION NO.
0 0 16 8 4 2 1
Domain 1
1 0 12345678
Station 24
1 0 12345678
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CENTUM CS3000
FCS Application Capacity Process I/O Analog I/O: Contact I/O: Internal Status Switch Common: Number of Control Drawings CS3000 Number of Function Blocks Depends upon database type
Addressing for both types of units is carried out through setting dip-switches on the unit. Vnet STATION ADDRESS Switches
ODD PARITY
ODD PARITY
DOMAIN NO.
0 0 16 8 4 2 1
STATION NO.
0 0 16 8 4 2 1
Domain 1
1 0 12345678
Station 1
1 0 12345678
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FCS Application Capacity Process I/O Analog I/O: Contact I/O: Internal Status Switch Global (future): Common: Function Blocks Control Drawings: Function blocks:
Max. 640 4096 256 (shared with other FCSs) 4000 (shared within that FCS) 200 Depends upon FCS type.
The Node Inter face Unit houses the I/O modules that are wired directly to the process.
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I/O connection:
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CONTROL DRAWING SOFTWARE MODULE ADDRESSING When a user creates an instrument (called a function block), it must be told which input point it will be using for reference or output point for control. This is accomplished in an engineering screen called a Control Drawing.
Using FIC100 (on the previous page) as an example, this is how the function blocks running in the processor know which I/O module to use.
%Z011107
%Z011108
%Z011109
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System Operations
OBJ ECTIVES OF THIS CHAPTER Upon completion of this chapter you should be able to: 1. 2. 3. Identify the standard display windows of the CENTUM CS3000. Operate the Overview, Control Group, Operator Guide, and Process Alarm window. Explain the function of the above windows.
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OFF
ON EN
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SYSTE
COPY
AUX
HELP
ES TA
2 Q A
3 W S
4 E D
5 R F
6 T G
7 Y H
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8 U J
9 I K
0 O L
_ P ; : ' /
AL
+ = [ { " ]
~ ` }
\ DE
BS
CAPS LOCK
RETUR
ITE NAM
SHIF
N
SPAC
<
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CTR
SHIF
CTR
AL
EX
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OPERATOR KEYS
Page forward and backward Display SYSTEM overview Screen hard copy AUX key Help message for the window Circulate Clear screen Process alarm display Manual Auto Cascade Fast ramp Ramp UP Ramp DOWN Target key
SYSTEM
COPY
AUX
HELP
Move cursor Trend panel Graphic panel Process report Navigator window call key Upper window Left Brother window Right Brother window Process overview panel Scroll keys Cancel . Confirm Acknowledge alarm Buzzer silence
ITEM
NAME
CL
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Process Alarm System Alarm OperationGuide messages Display Always System Ststus Display HELP Message Window Process Alarm Window Operator Guide Window Control Window Tuning Window Trend Window Graphic Window Message monitor User In Window Call Menu Operation Menu Preset Window Menu Tool Box Navigator Name Input Circulate Clear All Buzzer Reset Hard Copy Input Window Name Tool Box
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Process Report Historical Report Navigate Left Next Level Up Navigate right Overview Window Save Window Set Release Window Set Save Image Rotate Windows Larger Size Middle Size
CENTUM CS3000
CENTUM CS3000
Icons in the System Message Ar ea: Process alar m: Lights when an alarm condition occurs in an instrument. System Alar m: Lights when a system level occurrence happens, such as hardware failure or software file load. Oper ator Guide message: Lights when a message is generated by the system for the operator. Change user : Used to change security levels on the HIS, based upon the user who logs on. Window call menu: Allows access to display window without the use of the Tool box or the operator keyboard. Oper ation menu: Allows the user to manipulate windows related with the currently displayed operation window. Preset Window menu: Windows that the operator uses often can be shown here. They are defined under the HIS Setup icon on the System display. Tool Box: Gives access to different categories of displays. Navigator : Is used to display the plant window configuration. Icons under the Navigator can be selected to display their specific windows. Name: Used to enter the name of the window or function block to be displayed. Cir culate: Used to switch between an NT package and a HIS display. Clear all: Erases operation display screens Buzzer r eset: Silences alarm tones. Copy: Makes a screen copy of the current display. Tool Box Icons: These icons represent another way of accessing the operation displays without the use of the operator keyboard. The purpose of these icons is discussed in this chapter.
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Switch Instrument
Tag Number Tag Comment Tag mark Mode Alarm status Engineering Units Cascade Mark
Index Mark Scale Manipulated Variable Limits High High alarm setting High alarm setting Manipulated Variable Setpoint Process Variable
Index Mark
Manipulated Variable
Puts the loop into MANUAL Puts the loop into AUTO and Puts the loop into CASCADE . to confirm the change.
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INSTRUMENT FACEPLATE Instr ument mode examples: AUT: Control computation (PID) determines the instruments output. MAN: IMAN: CAS: O/S: No control computation and the instruments output is manually adjusted. Displayed on the primary instrument of a cascade loop when the secondary instrument isnt in CAS. Shows there is no control computation or output on this instrument. Setpoint control of this instrument comes from another (primary) instrument. Out of Service. All functions are non-operational.
The color of the pointers (SV and MV) on the tag faceplate also show the tags mode. The r ed pointer is in contr ol. If a tag is in AUT, the MV pointer will be yellow, and the SV pointer will be r ed. If a tag is in MAN, the MV pointer will be r ed, and the SV pointer will be yellow. If a tag is in CAS, the MV pointer and the SV pointer will be yellow.
MODE Changes Clicking on the text of the current mode makes the mode selection box appears. Click on the appropriate icon, then Confir m. If a tag is a cascade, then will be shown on the faceplate.
A box will appear under the selected tag; type in the new value. MV appears in the box if the loop is in MAN, SV appears if the loop is in AUT. Clicking on the data item on the faceplate also displays this box. Use the mouse and select the SV or MV pointer (depending on the mode of the instrument) and a ramping window appears. The item can be adjusted by selecting the up or down arrows. On the operator keyboard, the SV or MV can be changed with the ramping keys been selected. To ramp quickly, select a tag, press the Switch Instr uments Switch instruments are used to control ON/OFF devices like valves, motors, or pumps. A switch instrument has to be in MAN for the operator to make any changes in the output. To open or close a switch instrument, press the up or down ramping arrow click on the faceplate position you want. The left-hand box on the faceplate shows the current output. The right-hand box on the faceplate shows the answer back (digital confir mation) from the field instrument. for the selected tag or after the loop has
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CG0007
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Each control group window can show up to 16 tags. To bring up a specific window, select the NAME icon and type in the window name. The Faceplate window for that tag appears. Next, select the Contr ol window icon from the Tool Bar or on the Window Call Menu. Operation Marks used as flags for the operator. Click on the X in the upper corner of any window to close it. Alar m color s: Gr een: Red: Yellow: Blue: White:
Normal operations Process alarm (IOP, HH, LL, OOP) Alarm has occurred (Deviation, Velocity, or Output limits) Alarm output disabled Tag without alarms (i.e.: internal switch)
Security Levels: Eight different access levels can be selected to specify the instruments operation, the mode selection key affects the security level assigned to an instrument. The chart shown below contains a simplified version of the different security levels. Specific security information can be found in the Instruction Manuals.
Level 1 2 3 4 5 6 7 8
Operation S2 S3
x x x
x x
x x x x
x x x
Can be executed
x Cannot be executed
**1 Only the alarm settings, SV, MV, and block mode can be changed. **2 Only the SV, MV, and block mode can be changed.
Tag Impor tance Mar ks One of the four different tag importance marks can be assigned to a function block. Important: The users must acknowledge SV and MV changes, and tag marks remains flashing after alarm recovers. General: No acknowledge SV and MV changes, but tag marks remains flashing after alarm recovers. Auxiliary 1: No acknowledge SV and MV changes, and tag marks stops flashing after alarm recovers. Auxiliary 2: No acknowledge SV and MV changes, and tag mark doesnt flash before or after alarm.
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HELP WINDOWS Help messages can be assigned to any operation window, with specific text created to aid the operator.
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OV0001
Reactor
Boiler
Furnace
Sample Displays
CG0007
CG0002
CG0005
Logo
CG0008
CG0003
CG0006
Bit map
CG0004
3D type
TG0007
TG0001
TG0005
CUSTOM
01LIC-601 5% AUT NR
16 Loops
Trend Group
Help
Face Plate
System status
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{xe "**Empty**"} Scr een Hier ar chy Layout: The alarm statuses can be read from the lowest level window to the Overview window. Plant-A Overview Plant-B Overview Area-B Graphic Reactor-1 Reactor-2 Reactor-3 Reactor-4 Area-A Area-D Overview
Area-A
Overview
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Oper ation mar k assignment menu window Touching the Operation mar k icon displays the menu window, then select the desired text. To select items on this window: 1. Only items with a = mark next to them can be changed.
Tr end data that can be displayed: Process variables (PV, CPV, or FV). Setpoint values (SV). Manipulated output values (MV). Switch positions (SW) Tr end display. The Tuning Trend starts displaying when the window is displayed. 48 minutes of data maximum. Selecting the Reduce or Enlarge time or data axis icon allows the modified for optimum viewing. Moving the scroll bar under the tuning trend allows viewing of past trend data. Selecting the Reduce or Enlarge data axis changes the vertical scale. Move the up or down arrow at the right- hand side of the trend to see the expanded data. (1, 2, 5, 10x) Selecting the Stop/Resume icon will pause the updating of the trend data. Selecting it again releases the pause. Touching the Reser ve icon allows the trend data to be recorded even when the Tuning Window isnt being displayed. Up to 16 points can be reserved.
PG-L13 TUNING PANEL The PG-L13 is a 13 zone program set block. The user sets the time base in Zones, and the ramping to occur in during that time. Can be used to heat, cool, or cook products at a pre-defined rate. AUT allows the PG-L13 to run one time and then goes to MAN. CAS allows the PG-L13 to run continuously. MAN holds the output at the point it was put into that mode.
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Pen assignment Stop/Resume display Enlarge time axis Reduce time axis Reduce data axis Enlarge data axis Pen numbers Display/delete reference Display initialize Save data Read data Stop/resume collection Start collection
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TG0006
CENTUM CS3000
CENTUM CS3000
Trend blocks can have different sampling periods. (2880 samples each): 1 second, (48 minutes) 10 seconds (8 hours) 1 minute (2 day) 2 minutes (4 days) 5 minutes (10 days) 10 minutes (20 days) There is a maximum of 1024 trend pens, with 256 pens for 1 and 10 second sampling.
Tr end display. Trends are displayed by typing in TGbbgg (bb=block #, gg=group # i.e. TG0101) Selecting the Reduce or Enlar ge time axis icon changes the displayed time scale. Moving the scroll bar under the tuning trend allows viewing of past trend data. Selecting the Reduce or Enlar ge data axis changes the vertical scale. Move the up or down arrow at the right- hand side of the trend to see the expanded data. (1, 2, 5, 10x). Selecting the Stop/Resume icon pauses the updating of the trend data. Selecting it again releases the pause. There is a blue (cyan) pointer at the top of the trend, the data shown at the right-hand side of the screen is the result of where the pointer is on the trend. To move the pointer, click where you want it to be. Trend data can be saved (maximum of 100) and read from a Windows file. Trend data can also be read from other HIS.
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TREND POINT WINDOW Double clicking on the desired trend item displays a window that shows only that single items pen.
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Graphic items can be modified, depending upon the process state, to change color or blink. Each primitive (graphic item) can have up to 8 condition modifiers.
A graphic window can be a representation of a plant or a control system. Displaying the plant status graphically for intuitive operation and monitoring. The Over view and Contr ol windows ar e gr aphic windows also. The window can be built with: Process data displayed Touch targets assigned (so a loop can be controlled from this window) Links to other windows. Bit maps can be imported. Faceplate windows Overview primitives.
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Save window set Release window set Rotate windows M ake larger M ake smaller
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2.11 Navigation
The Navigator window displays a list of HIS window like Windows Explorer. Clicking on the panel name will display that panel. USER displays all of the operation windows in the HIS. Clicking on a graphic panel with a + in front displays the assigned panel hierarchy. SYSTEM displays all of the message and system level windows in the HIS.
SAVE / RELEASE WINDOW SET When multiple windows are displayed on the HIS, they can be saved and displayed again by calling up the window they were overlaying when the save was made. Up to 30 window sets can be defined.
MAKE LARGER / SMALLER A windows size can be changed by using these icons.
HELP WINDOWS Help windows can be created for special help situations. A help window (up to 70 characters and 21 lines) can be attached to any of the graphic operations windows and is displayed when the "HELP" button is pressed.
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Alar m conditions: Green: Red: Normal. Failure (Duplex stations will also show processor failures).
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SYSTEM ALARM MESSAGES The system alarm message window is used to display the system alarms in order of occurrence, beginning with the most recent. System alarms can be acknowledged by selecting the button.
The message marks will stop blinking when the alarms have been acknowledged.
HELP icon displays an on-line help message for the system message with the cursor positioned in front. Filter icon allows for custom system alarm searching either by FCS, HIS (current) or All stations.
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IOM Load reloads a selected I/O modules database. Save Tuning Parameter s icon saves the contents of the FCS setup file for control parameters like P, I and D.
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HIS Setting
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Selecting HIS Setting icon on the System Overview window will bring up this display. Station displays the setup information when the HIS was defined. Printer defines the Windows printer to use for specific message types. Buzzer allows the changing of alarm tones and volumes. Display defines the screen mode (full screen or window) and the length of the tag name to be displayed. Window switching allows the changing of the size or type of display when the process alarm window, system alarm window, Operator Guide, or process alarms are selected. Vnet shows the status of the Vnet. Alar m allows definition of the alarm types to be displayed on the HIS. Preset Menu is used to configure the Preset Window Menu which allows quick access to important or often used operation windows. Equalize used to equalize the database files. A message will appear when this is necessary. Function key shows the current definition of the programmable function keys on the operator keyboard. The keys can be re-assigned on this display by using drop down menus. Example Display pre-defined operation screens. Start and stop trends. Execute system function O CG0001 T TG0001 STOP K HDCP Most of these are existing Keyboard, Tool Box, or System Message Window functions. Light LED (FLASH, ON, or OFF) Run programs Run multimedia files E 10 F F C:\file\program X PLAY1 filename.avi
A function keys LED can be defined to show the alarm status of an operation window.
Oper ation Mar k allows the creation and customization of the operation marks text and color.
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Learn the functions of the Pr ocess report and Histor ical report pages: 1. 2. 3. Search for specific tags. Display past alarm occurrences. Define a search for specific date and time.
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I/O Search
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5.1 Architecture
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6 Control Concept
6.1 Tag naming standards
In all system is created one tag standard and programming standard. This standard will include PCS and also SCS controllers. I/O tag name should consist of the following figures and characters:
XXX-YYZZZS
Description of tag creation:
Description 102, 107 TI, TO, etc. A - Analysis F - Flow L - Level P - Pressure Q - Gas detector T - Temperature X - Motor/driver, push button Z - Valve I - Input signal O - Output signal X - Signal from panel controller T - Temperature transmitter C - PID regulator Y - SW element A - Alarm 001, 002, etc. A, B, C O - Open C - Close R - Run F - Failure
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Standar ds Each tag in control system can have alarm detection option. For analog tag signals we can use L alarm, LL alarm, H alrm, HH alarm and Open loop alarm. Optionally we can use also deviation alarm. For digital tag signals we can use Status alarm and Change of state alarm. Tag alarming will be applied according process design requirements. We will use three levels of alarms: High Alarm (Critical alarms) Low alarm Log alarm Each alarm level gives its importance. High alarm is most critical alarm for the technology and in control system will have separate critical alarm display. Low alarm has lowest priority. Log alarm will not be represented on alarm screen, but will be written to alarm history file. By these alarm levels we can optimally manage our alarm strategy. Also each alarm will have audible and graphical representation. Each alarm will have graphical representation on the process screen and on alarm summary screen. Alarm Representation for analog signals: Bad Measure High Alarm HH High Alarm H Low Alarm L Low Alarm LL High Alarm Bad Measure include open loop, out of the measure range and other, according the control system capabilities. On the alarm summary screen we can clearly distinguish importance of the incoming alarms: Not acknowledge alarm Blinking Acknowledge alarm remaining Remain current alarm colour without blinking
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Stop - White
Run - Green
Failure - Red
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Close - White
Open - Green
Failure - Red
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Manual
Close - White
Auto
Cascade
Open - Green
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Alarm
- Number of decimal places shall be designed by technological requirements. - Engineering units shall be always visible.
7.4.5 Regulator
Set point value Measurement value Output value
Alarm
Measurement value: Green if measurement value is in operational limits. Red if measurement value reaches LO or HI limits or LL or HH limits.
7.4.6 Faceplates
- Faceplates shall be designed according technological requirements and possibilities of selected control system.
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