Yokogawa PCS

CS3000 R3
Engineering Course

By

Jonathan C. Quiazon

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2006
 Instructor: Jonathan C. Quiazon

Email: jonathan.quiazon@ph.yokogawa.com

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 Schedule

Session: 8:30 am ~ 4:30 pm

Coffee/Tea Break: 10:00 am ~ 10:15 am

3:00 pm ~ 3:15 pm

Lunch Break: 12:00 nn ~ 1:00 pm

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 Centum CS3000 R3.07

Course Outline

Regulatory Control Function

Day 2 Sequence Control Function
Hands-on Exercise

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 Regulatory
Control Function

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 Regulatory Control Blocks

Regulatory control blocks are function blocks that

perform control computation processing mainly
on the analog input as input signals. The
calculated results are used for process monitoring
and process control.

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 Types of Regulatory Blocks

Input Indicator – PVI, PVI-DV

Controller – PID, PI-HLD, PID BSW, ONOFF, PID TP,
PD MR, PI BLEND, PID STC
Manual loader – MLD, MLD-SW, MC2, MC3
Signal setter – Ratio, PGL13, BSETU2/3
Signal selector – SS-H/M/L, SS Dual
Signal distributor – SPLIT, FOUT

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 Regulatory Control Function

Regulatory Control Function

Internal Switch
Sequence Control Function Annunciator message
Arithmetic Calculation Function Sequence message
Faceplate Function
Unit Instrument

Analog I/O Contact I/O

CommunicationFieldbus
I/O I/O

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 Structure of a Function Block

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 I/O Connection

Process I/O (Analog I/O, Contact I/O)

Software I/O (Internal Switch, Message Output)
Communication I/O (Word Data, Bit Data)
Fieldbus I/O (Fieldbus Block Parameters)

Other Function Blocks (Data Items or I/O Terminals of other

function blocks)

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 Input Processing

The function blocks are provided with various types of input

processing methods to convert the input signals for the
control calculation and arithmetic calculations.

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 Input Processing
PV/FV/CPV Scale out
Digital Filter if data status is BAD,
reduce noise in the PV is set to SH or SL
input signal

signal read from

input module is
converted to PV

Calibration Integration
for maintenance or the data item
test purposes PV SUM is set to
can be manually the integrator
set value

33.15 MP3

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 Input Signal Conversion
signal read from input module is converted to PV

Digital Filter
executes first order lag processing to reduce input signal noise

Integration
the data item SUM is set to the integrator value

PV/FV/CPV Scale out

if input signal is BAD, PV is set to SH or SL

Calibration
for maintenance or test purposes PV can be manually set

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 PID Block Terminals

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 I/O Terminal

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 PID Control Computation
The PID control computation is the core of the PID control computation processing,
calculating a manipulated output change (∆MV) by using the PID control algorithms.
The PID control is the most widely used, it combines three types of actions:
proportional, integral and derivative.

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 PID Computation Expression

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 PID Control Algorithm

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 PID Data Items

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 PID Data Items

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 Output Processing

Output processing execute certain process to the

values obtained from the control computation
before giving an output. Various forms exist for
different block types.

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 Output Processing Output Velocity
Limiter limits amount Preset Manipulated Output
of change bet current upon an ext command, the
and previous out to block is put to manual and
avoid bumps MV to a predetermined value

Output Limiter
limits the MV to be
within high and low Output Tracking
limits (MHI or MLO) forces the output
value to match the
value of its output
destination

converts the result of

the calculation process
compatible with the
output destination

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 Output Limiter
limits the MV to be within high and low limits

Output Velocity Limiter

limits the amount of change between current and previous out to
avoid bumps

Output Clamp
prevents MV from being varied above or below the current value

Preset Manipulated Output

upon an external command, the block is put to manual and MV to a
predetermined value

Output Tracking
forces the output value to match the value of its output destination
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 Output Range Tracking
forces the MSH/MSL of the MV to match the scale high/low limits of
its destination

Manipulated Output Index

displays two indexes in the MV, indicate the feasible limits of MV

Output Signal Conversion

converts the result of the calculation process compatible with the
output destination

Auxilliary Output
MV, dMV, PV, dPV is available for final control elements e.g.
compensation control equipment, or external indicator

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 Alarm Processing

The FCS alarm processing includes an alarm detection for

detecting any abnormality in the process and an alarm
notification function for giving notification of the detection
results.

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 Alarm Processing

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 Input Open Alarm Check
generates an alarm to indicate that the input signal is in the high or low limit
(IOP+, IOP-)

Input Error Alarm Check

determines whether the data status of the input value is invalid (BAD)

Input High-High and Low-Low Alarm Check

indicates that the input signal is in high-high or low-low alarming
status (HH, LL)

Input High and Low Limit Alarm Check

indicates that the input signal is in high or low alarming status (PH,
PL)

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 Input Velocity Alarm Check
generates an alarm to indicate that the velocity in positive or negative direction
is in alarming state (VEL+, VEL-)

Deviation Alarm Check

determines the absolute value of the deviation (PV-SV) whether
positive or negative is in alarming state

Output Open Alarm Check

indicates an alarm to indicate that the output is open (OOP)

Output Fail Alarm Check

determines whether the status of the MV is output fail an
OOP alarm is generated

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 Alarm Priorities

There are 5 levels of alarm priority.

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 Alarm Flashing Actions

Locked Type (LK: Locked).

Non-Locked Type (NL: Non-Locked).

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 Alarm Flashing Actions

Self-Acknowledged Type (SA: Self-Acknowledge).

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 Process Alarm Messages
process alarms that had been detected by the alarm detection functions and
transmitted by the function block to the operation and monitoring function

System Alarm Messages

represent system abnormalities that occurred in the FCS and
function blocks and transmitted to the operation and monitoring
function

Alarm Detection Stop Function (Deactivate Alarm Detection)

alarm detection function can be stopped in accordance with the
alarm detection specification

Alarm Inhibition (AOF)

can be used to temporarily inhibit a process alarm while the alarm
detection is active

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 Block Mode

Information that represents the control state and the output

state of a function block.

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 Basic Block Mode
9 modes shared by all function blocks

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 Block Mode Relationships

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 Compound Block Mode
refers to the state where the multiple basic block modes exist simultaneously

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 Sequence Control Blocks

Sequence control blocks are function blocks that perform

sequence controls. The sequence control follows each
control step in sequence according to predefined conditions
and order.

Sequence Control Blocks which execute the sequence

control include Sequence Table Blocks, Logic Chart Blocks,
SFC Blocks, Switch Instrument Blocks, Sequence Element
Blocks and Valve Monitoring Blocks.

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 Sequence Control Description Method

Sequence Table Block

The conditions and operations are arranged in table format and specifies which
operation is performed by the combination of conditions. This is suitable for the
description of all sequences such as the parallel operation, interlock operation &
sequence operation.

Logic Chart Block

In a logic chart block, the conditions and operations are listed, and the combination
of conditions with the logic operators corresponding to the logic requirement may
manipulate the operation signals. This block can be used as the description of an
interlock sequence control or a logic chart.

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 Sequence Control Description Method

SFC Block
The SFC Block is a graphical flow diagram suitable for describing a process control
sequence. It is standardized by the international standard, IEC SC65A/WG6.
The SFC block is used for relatively large-scaled sequence controls and for
controlling devices. The flow of the entire sequence is defined by the SFC block.
Each step in the SFC is described by the sequence table and SEBOL (Sequence
and Batch Oriented Language).

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 Types of Sequence Control Blocks

Sequence Table Block

Logic Chart Block

SFC Block

Switch Instrument Blocks

Sequence Element Blocks

Valve Monitoring Blocks

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 Types of Sequence Control Blocks

Sequence Table Blocks

ST16 – Sequence Table Block

ST16E – Rule Extension Block

Logic Chart Block

LC64 – Logic Chart w/ 32 inputs, 32 outputs & 64 logic elements

SFC Blocks

_SFCSW – 3-position Switch SFC block

_SFCPB – Pushbutton SFC block

_SFCAS – Analog SFC block

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 Types of Sequence Control Blocks

Switch Instrument Blocks

SI-1 – Switch Instrument Block w/ 1 input

SI-2 – Switch Instrument Block w/ 2 inputs

SO-1 – Switch Instrument Block w/ 1 output

SO-2 – Switch Instrument Block w/ 2 outputs

SIO-11 – Switch Instrument Block w/ 1 input, 1 output

SIO-12 – Switch Instrument Block w/ 1 input, 2 outputs

SIO-21 – Switch Instrument Block w/ 2 inputs, 1 output

SIO-22 – Switch Instrument Block w/ 2 inputs, 2 outputs

SIO-12P – Switch Instrument Block w/ 1 input, 2 one-shot outputs

SIO-22P – Switch Instrument Block w/ 2inputs, 2 one-shot outputs

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 Types of Sequence Control Blocks

Sequence Element Blocks

TM – Timer Block

CTS – Software Counter Block

CTP – Pulse Train Input Counter Block

CI – Code Input Block

CO – Code Output Block

RL – Relational Expression Block

RS – Resource Scheduler Block

Valve Monitoring Block

VLVM – Valve Monitoring Block

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 Alarm Processing of Sequence Control Blocks

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 Block Modes of Sequence Control Blocks

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 Sequence Table Blocks (ST-16 and ST-16E)

Sequence Table block is a decision table type function block that describes the relationship
between input signal and output signal in a “Y/N” fashion. By making sequence connection with
other function blocks, they control the monitoring of processing and phase step sequences.
Sequence Table blocks include the basic ST16, and ST16E that is only used for rule extension.

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 Sequence Table Configuration

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 Types of Sequence Table

Non-Step
All 32 rules are subject to condition testing, and the operation is performed according to the
conditions.

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 Non-Step

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 Types of Sequence Table

Step
The process control sequence of a phase-step process is divided into the smallest phase units
(steps) of the condition monitoring & operation, then these steps are executed one by one.
Only step label 00 and the rule corresponding to the current step number are subject to
condition testing & operation.

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 Step

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 Step

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 Logic Chart Block (LC-64)

Logic Chart Block is the function block that describes the relations of the input signals, the
output signals and the logic calculation operators in the interlock diagram form, so that it can
perform its main function, the interlock sequence control using the same expressions as those
used on the logic chart blue prints.

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 Logic Chart Elements

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 Logic Chart Operation Elements

AND: Logic Product

It gives one output based on multiple inputs. When all the inputs are True, the output
becomes True. The maximum number of inputs is 21.

OR: Logic Sum

It gives one output based on multiple inputs. When any of the inputs are True, the output
becomes True. The maximum number of inputs is 21.

NOT: Negation
It gives the inverse of the input as an output.

SRS1-R (1 output), SRS2-R (2 outputs): Flip-Flop (Reset Dominant)

It gives one output or two outputs shown in the ff. truth table based on the set and reset
input signals.
One flip-flop operation is counted as two logic operation elements

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SRS1-S (1 output), SRS2-S (2 outputs): Flip-Flop (Set Dominant)
It gives one output or two outputs shown in the following truth table based on the set and
reset input signals.
One flip-flop operation is counted as two logic operation elements.

OND: On-Delay Timer

When the input status changes from 0 to 1, the internal timer starts. When the set time t,
elapsed, its output changes from 0 to 1. When the input status changes to 0, the output
will be reset to 0 immediately.

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 Manual Loaders

MLD
Manual Loader Block (MLD) may be applied to output manipulated output value (MV) to
manually operate final control elements, such as control valves.

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 Motor Control Blocks

MC-2, MC-3
The Motor Control Blocks, MC-2 and MC-3 are applied to operate motor-driven pumps and
motor-operated valves. These blocks may be used to start or stop motors from operation and
monitoring functions or to control them automatically.
There are 4 models of Motor Control Block which behaves in different output manner:

 Two-position motor control block (MC-2)

 Three-position motor control block (MC-3)

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 Motor Control Blocks Data Items

MC-2, MC-3

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 Motor Control Blocks Data Items

MC-2, MC-3

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 Exercise

1. Using a sequence table block (ST16), create an operator guide

message. Also, use a software switch to trigger the operator guide
message.

2. Using a logic chart block (LC64), create a logic so that when two
common switches are actuated a Global Switch will be triggered in
one FCS and an annunciator message will be executed in another
FCS.

SYNTAX:

Input Element Output Element

Tag Name.Data Item.Condition Tag Name.Data Item.Condition

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