An Introduction

to
TDC 3000

Automation Engineering Academy

Abridged by Cliff Lawson

 Introduction
The purpose of this module is to acquaint you with the
architecture of a TPS system that includes the following
networks:

 Local Control Network (LCN)

 Data Hiway
 Universal Control Network (UCN)
 Open System Plant Information Network (PIN)
 Dedicated Plant Information Network
 Programmable Logic Controller device interface
 MODULE OBJECTIVE
From memory, be
able to draw an
architecture diagram
containing the
fundamental TPS
networks, hiways,
modules, and
devices.
What is the TPS LOCAL
CONTROL NETWORK
(LCN)?

From the Course:

“An Introduction to TDC 3000”
 Information:
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 LCN
This makes it
possible for you to
see what is
happening at the
process without
leaving your
workstation, on the
Local Control
Network.
 Overview of TPS Local
Control Network System
The TPS local control network system consists
of the local control network (LCN) and at least
one process network. There are three possible
process networks, the data Hiway, the universal
control network (UCN), and the programmable
logic controller (PLC) subsystem.
Example of TPS System

The system
consists of
connected nodes
(modules) on a
Local Control
Network (LCN)
and process-
connected devices
that are resident
on the process
networks.
What Are the different
types of WORKSTATIONS
on a TPS System?
From the Course:
“An Introduction to TDC 3000”
 Information:
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 Types of Workstations
Your TPS workstation can be a
Universal Station (US), Universal Station
X (U X S), or Universal Work Station
(UWS), or Global User Station (GUS).
Combinations of these devices are also
possible.
 Universal Station (US)

The Universal Station (US) is one of the primary

TPS human/machine interfaces. This workstation
provides a single window to the entire system at the
LCN level and below, whether the data is resident in
one of the LCN nodes or in one of the process-
connected devices. The US can be used to
accomplish different tasks; it can be used by an
operator, a process engineer, and by a maintenance
technician to accomplish each of their different tasks.
 Universal Station X
(UXS)
A Universal Station X (U X S) is another primary TPS
human/machine interface. This workstation provides the
same window to the system as the Universal Station
(US). In addition, it provides a window to the Plant
Information Network (PIN). This window can be used to
accomplish different tasks. The operator may have the
need to access other systems on the total plant
network. Engineers may use this same window for
system administration and development.
 Universal Work Station
(UWS)
The Universal Work
Station (UWS) is an
alternate
human/machine
interface. It is capable
of virtually all of the
same functions as the
Universal Station, but is
designed for an office
environment. The
keyboard and monitor
sit on a desktop.
 Global User Station
(GUS)
The Global User Station is the latest version of TPS
system human/machine interface. This Microsoft NT
based workstation provides a Native Window through
which information access is available from the entire
system. Process data is accessed at the LCN level and
below. Information is made equally available from the
data that is resident in LCN nodes as well as data
resident in process-connected devices. Plant wide
information is made available through its connection to
the Plant Information Network (PIN).
What Are GATEWAYS
on a TPS System?
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Gateway
Each of the process
networks has an
interface (called a
“gateway”) that allows it
to communicate with
the local control
network, which is where
your TPS workstation(s)
are located.
 Data Hiway

The gateway for the

Data Hiway is called
the Hiway Gateway
(HG). The Hiway
Gateway provides the
hiway with a
connection to the LCN.
 UCN and PLC Gateways
The gateway for the
Universal Control Network
interface is called the
Network Interface Module
(NIM). The NIM provides the
UCN with a connection to the
LCN.
The gateway for the
Programmable Logic
Controller subsystem
is called the PLCG.
The PLCG provides
the PLC Subsystem
with a connection to
the LCN.
 Processing Data
The process networks (Data Hiway, Universal
Control Network, or Programmable Logic
Controller subsystem) transmit process data
from/to process-connected devices such as
controllers and data acquisition devices (such
as temperature, flow, land level) through their
gateways to the Local Control Network (LCN).
Network Gateway (NG)

Network Gateways are special

Gateways that allow one LCN to
be connected to another LCN,
thus allowing the sharing of data
between two different TPS
systems.
 Network Gateway (NG) cont.

The Network Gateway provides the capability for file and point
access between multiple LCNs. Note that the LCNs

can be geographically separated,

provide current data,
allow internetwork control by way of the Application Module

The LCNs are connected through a dedicated Plant Information

Network that consists of the necessary hardware, such as modems
and connection devices, customized to match your installation needs.
The figure on the next slide illustrates one possible use of Network
Gateways.
Example of two LCNs connected
with Network Gateways
What Are HISTORY
MODULES on a TPS
System?
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History Module (HM)
The History Module
(HM) provides mass
storage of data on
hard disk media.
It is available with
redundant hard disk
drives and allows
you to store and
quickly access large
blocks of data.
 History Module
Continued
Some examples of the types of data that you can store and
access are the History of:
•Process alarms
•Operator changes
•Operator messages
•System status changes
•System errors
•System maintenance recommendations
•Continuous process history to support logs and trends
•System files of all types such as, load images and
•the data required to load nodes
•Checkpoint data for maintaining an up to date
•copy of the database in the event the node
What Are APPLICATION
MODULES on a TPS
System?
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Application Module (AM)

The Application Module (AM)

permits the implementation
of more complex control
calculations and strategies
than are possible when
using only process-
connected devices. A set of
standard advanced control
algorithms is included.
Custom algorithms and
control strategies can be
developed by using a
process-engineer-oriented
Control Language (CL/AM).
 Application Module X (A
X M)
An Application ModuleX (AXM) provides all of the
functionality that is provided by an Application
Module (AM). In addition, the A X M provides a high
performance UNIX-based coprocessor that can be
used in two ways:
 Execute prebuilt or user-
developed solutions on the
UNIX-based coprocessor.
 Serve as information
collector/generator for Open
System use.
What Are Computing MODULES
on a TPS System?

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 Information:
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Computing Modules
A Computing Module
is the combination of
an LCN node and a
host computer, such as
a Digital Equipment
Corporation (DEC)
VAX system, together
with a software
package to utilize this
combination.
 Computing Modules
Continued
The Computing Module provides an
environment for user programming,
communications with other computers, and the
use of preprogrammed applications performing
such functions as process optimization,
advanced custom report generation, long-term
data storage, scheduling,and plant
management.
 For Example...
For example, the
combination of a
computer system =
(DEC VAX) with an Computing
LCN node called the Module 50S
Computer Gateway or
CM50S
(CG) as shown in
the figure to the right
is considered a
CM50S.
Computing Module 50N
The combination of a
computer network and
the Plant Network
Module (PLNM) is
considered a CM50N.
 CM50S vs CM50N
CM50S software enables a DEC VAX computer to function as a
module on the LCN.
CM50S requires an LCN node for its LCN access. The LCN
node can be a CG as shown in Figure 1, or a node called the
(PLNM).
CM50N software enables a network of computers to interface to
the LCN. CM50N requires the Plant Network Module (PLNM)
LCN node for its LCN access.
If a Computing module exists in a system, it would generally
have one node or the other (CG or PLNM) but not both.
What Are the Devices on a Data
Hiway?

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 Information:
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Hiway Gateway (HG)

The Hiway Gateway (HG) is a node

on the LCN that interconnects the
Data Hiway and LCN.
It makes the transition from the
transmission technique and
protocol of the LCN to the
transmission technique and
protocol of the hiway.
 Hiway Traffic Director
(HTD)
The Hiway Traffic Director (HTD) is
required when there are more than 28
devices or more than one preferred
access device such as a 4500/45000
computer, a Basic Operator Station, or an
Enhanced Operator Station. The HTD has
a maximum of three branches.
 Basic Controller (CB)
The Basic Controller (CB)
processes eight control
loops on a 1/3-second cycle.
This “processing” includes
reading signals from
transmitters, calculating
outputs to be sent to field
devices according to
algorithms selected by the
user, and determining
whether alarm trip points
have been exceeded.
Extended Controller (EC)
The Extended
Controller (EC)
processes 16
control loops on a
1/2-second cycle
and can have
an optional 16
digital inputs.
Multifunction Controller (MC) and
Advanced Multifunction
Controller
(A-MC)

The Multifunction
Controller (MC) and
Advanced Multifunction
Controller (A-MC)
handle modulating
control, digital
input/output, logical
operations, and
sequential control for
batch operations.
Differences
The primary differences
between the two are
packaging (the A-MC
takes less space) and slot
processing rate, which is
once per second for the
MC and twice per second
for the A-MC. Peer-to-
peer communications are
possible over a C-link
cable.
 Process Interface Units
(PIUs)
The family of devices called Process Interface Units
(PIUs) are intended mainly for data acquisition, rather
than automatic control. The High Level Process
Interface Unit (HLPIU) can process digital inputs, pulsed
(counter) inputs, and analog inputs. In addition, it can
provide manual control of digital and analog outputs.
The Low Level PIU (LLPIU) accepts up to 250 low-level
analog input signals, and the Low Energy PIU (LEPIU),
which is used where intrinsic safety is a requirement,
accepts up to 254 analog inputs.
Amplitude
The levels refer to the
amplitude (voltage or
current) of the signals with
which the PIUs
interface. The HLPIU scans
±5, 0 to 5, and 1 to 5 volt
signals. The LLPIU scans up
to ±100
millivolt signals and, with
attenuator cards to reduce
the voltage to millivolts, up to
±40 volts.
What Are the Devices on a
Universal Control Network (UCN)?

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 Network Interface
Module (NIM)
The Network Interface
Module (NIM) is a node on
the LCN that interconnects
the UCN with the LCN. It
converts the transmission
technique and protocol of
the LCN to the
transmission technique
and protocol of the UCN. A
NIM almost always has a
redundant partner.
 The Process Manager
The Process Manager (PM) provides a complete
range of data acquisition and control capabilities,
including digital inputs and outputs, analog inputs and
outputs, and up to 160 regulatory control loops. The
number and types of control functions to be
implemented, along with the PM processing rate, are
configurable by the user. Custom control strategies can
be developed by using a process engineer oriented
control language (CL/PM). Peer-to-peer
communications with other devices on the UCN is
possible.
Advanced Process
Manager (APM)
The Advanced Process
Manager (APM) provides
the functions of the Process
Manager, plus

1-millisecond sequence of
events,
device control point for
process area motor control,
array point for mapping
variables to a serial
interface device,
increased memory, and
time and string variable
support for CL programs.
 High Performance
Process Manager (HPM)
Software release R500
supports the High
Performance Process
Manager (HPM), which
provides the functions of the
Advanced Process Manager,
plus
Increase of processing units
(2.5 X APM)
Maximum number of points
increase
Point mix and scan rate
change without reload
 Logic Manager (LM)
The Logic Manager (LM) is a process-connected
controller that provides high-speed logic control that
is typical of a Programmable Logic Controller
(PLC). Logic Managers are supported by TPS
systems running R300 software or later. Peer-to-peer
communications to other devices on the UCN is
possible.
 Safety Manager (SM)
Software release R500 supports
the Safety Manager (SM). This
Safety Manager is a triple
redundant PLC that is is used to
implement Plant Safety Shutdown
strategies or mechanisms. It
operates independently but is
connected to the TPS for UCN
peer-to-peer access and operator
view.
This is the end of
Section 1
At this point, please go
to your manual and
complete the
assignments that are
necessary in Section 1.
Operate PM/APM/HPM
Control Points

Section 2
 INTRODUCTION
This module provides definitions of process
terms encountered in normal operation of the
TPS system, a brief overview of the User
Station (US, GUS, or U X S), and the TPS
console from a control room operator's
viewpoint.
 The Focus
The main focus of the The Process Manager,
module is how to Advanced Process
interpret and Manager, and High
manipulate the
information provided Performance Process
on the Group and the Manager are the names
Detail displays of the of the controller
Process Manager (PM), devices. All of the
the Advanced Process information in this
Manager (APM), and course module applies
the High Performance
to all three devices.
Process manager
(HPM).
 OBJECTIVES
Given a User Station (US,
GUS, or U X S) be able to:
Use the Group and Detail
displays to determine a
point's mode, alarm limits,
operating limits, and
ranges.
Perform the Group display
operations including
changing setpoints, outputs,
modes, and building a
group.
What Are the Major Parts of a
Universal Station?

From the Course:

“An Introduction to TDC 3000”
 Information:
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“Introduction to TDC3000” by Cliff Lawson
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 UNIVERSAL STATION
OVERVIEW
A Universal Station is
a video screen and
keyboard designed to
be used as an
operating panel for
control room process
operations.
Universal Station
 Universal Station Keyswitch
The 3-position keyswitch on the
Operator's keyboard uses two
keys for access to database
entries. One key, called the
Supervisor's key, unlocks
certain functions such as
changing an alarm limit. The
second key, called the
Engineer's key, unlocks all
functions.
 Keylevel Access
The key access level of certain items (such
as changing time and date) is configured by
your
programmer or engineer to be Operator,
Supervisor, or Engineer. If you try to access a
function without the proper key, the
message ACCESS LEVEL ERROR appears.
Universal Station Touchscreen
A US can have a “touchscreen” that allows the
operator to point to the screen to select an item.
Selectable items on the screen are called “targets.”
There is a row of Light Emitting Diodes (LEDs) across
the top of the screen and another down the left side
of the screen. A row of photo optic receivers across
the bottom of the screen and another row down the
right side of the screen detect the light beams emitted
from the LEDs, forming an x,y grid of beams across
the front of the screen. By touching the screen, a set
of beams is broken and the cursor moves to the
coordinates of the broken lines. When the beams are
restored (when you lift your finger), a “select”
function is performed and, if the cursor is positioned
at a configured “target,” the appropriate action
occurs.
Universal Station Keyboards
The US has an Operator's keyboard and can
have an Engineer's keyboard. Many of the
keys on the Engineer's keyboard can be used
only in the Universal Personality. If an
Engineer’s keyboard is permanently
installed on a US, a cover can be placed over
the keyboard when it is not in use. There is
also a portable Engineer’s keyboard that can
be connected to the US when needed.
 Operator's Keyboard
The Universal Station Operator's keyboard
is a “membrane” keyboard, meaning that it
has a plastic sheet over the keyboard
electronics instead of individual key caps.
Spills are less likely to damage the keyboard
and can be cleaned up easily. The
recommended operating procedure is to avoid
placing liquids on the station.
Trackball

A Universal Station
can have a trackball
for moving the
screen cursor and
selecting a target on
the screen.
Tab and Select Keys
The “tab” keys can also be
used to position the screen
cursor. “Tab stops” are at
all target locations. When
the cursor is positioned at
the target, press the select
key to select the target.
 Alarm Lamps
The keyboard has alarm
lamps on some of the keys. It
is a good idea to periodically
test the operation of the
lamps. Simply hold down the
[LED TEST] key. It is
marked as a red dot on the
left side of the keyboard. The
lamps will flash until the key
is released.
 The Reset Button
The [RESET] key is used when reloading
the station. The key is under a cover to
prevent accidental pressing. When [RESET]
is pressed, the station becomes inoperable
until a personality and database are loaded.
The keyboard shown in Figure 1 is one of
several versions in existence today.
Operator’s Keyboard
What Are Universal Station
Personalities?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
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Universal Station Personalities
The personality of a Universal Station is the type of
software loaded into its memory. The Universal
Station (US) can be loaded with the Operator or
Universal Personality. The Operator and Universal
Personality are used for normal control room
operations. The Universal Personality is also used by
Engineers to create or modify the system database.
Personality Changes
The Universal Station’s
personality can be
changed at any time. To
change the personality of
a station you would
“reload” it, which takes
several minutes. The
station can be reloaded
using the hard disks or
cartridges (diskettes
encased in a cartridge).
 View Only Stations
After the Operator Personality
is loaded, a US can be set as a
view-only station if desired.
No changes can be made from
a view-only station. A station
installed in a remote enclosure
out in the plant might be view-
only, so outside operators and
maintenance technicians can
monitor the process but cannot
make changes.
How do I Clean the Touchscreen
and Keyboard?

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Keyboard and Screen Cleaning
Use a soft, damp cloth to clean the surface
of the video screen and keyboard. Mild
detergent can be used if necessary. After
wiping the screen, you may need to degauss it
to restore the proper colors.
 Touchscreen Cleaning
If the cursor does not move in response to touching the
screen at a new position, the LEDs or receivers may need to
be cleaned. They can be cleaned with cotton swabs soaked in
alcohol. The cleaning procedure for earlier versions of the
touchscreen requires that the monitor be removed from the
enclosure to gain access to the LEDs and receivers that are
behind an opaque cover. In the newer systems, this cover is
not present and the LEDs and receivers can be accessed
through the slot around the front of the screen.
How can I adjust screen settings on
the Universal Station?

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Screen Adjustments
There are two dials at the
right side of the screen to
adjust the brightness and
contrast to your personal
preference. Other screen
adjustments for color,
alignment, etc., are inside
the station and require a
trained technician.
Screen Adjustments
The degauss button is
used to “degauss” the
screen. The face of the
CRT can become
magnetized and affect the
color. When the color
does not appear normal,
hold down this button for
five seconds to
demagnetize (degauss) the
screen.
What are the major parts of a
Global User Station?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
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 GLOBAL USER STATION
OVERVIEW

A Global User Station (GUS) is a PC based user

station running Microsoft NT software. It is used as a
window through which the operator controls process
operations.
Three Hardware versions
There are three versions of GUS hardware
available. They are:
Deskside (looks like a Personal Computer) -- for use in
an office environment
Ergonomic furniture version (sometimes referred to as
“Z” furniture) -- for use in control room consoles
Classic furniture version -- for use in control room
consoles.
An ergonomic furniture version is shown in the
next illustration.
Trackball

A GUS Integrated
Keyboard in
console versions
of furniture has a
trackball for
moving the screen
cursor and
selecting a target
on the screen.
Ergonomic Furniture
Version of GUS
 Global User Station Keyboard
Both console versions of the GUS have an
Integrated keyboard. The Integrated Keyboard is
available as an option with the deskside version
which normally has a standard Personal Computer
type of keyboard. The Integrated keyboard on the
console versions has a trackball which is used to
move the cursor and select targets on the display
screen. The deskside version of GUS has a mouse
instead.
The Integrated
Keyboard
 A Closer look...
A closer look at the Integrated keyboard is provided in the following
illustrations. Programmable keys with relegendable key tops (upper
portion of Integrated Keyboard). Please refer to our manual for clear
diagrams.
The Standard Keyboard

(center section of Integrated Keyboard)

Special Operator Keys

(lower portion of the Integrated Keyboard)

 Screen Adjustments
Monitor controls to adjust the brightness and
contrast to your personal preference are
provided at the bottom center of the screen.
Other screen adjustments for color, alignment,
etc., are inside the station and require a
trained technician.
What is a Console on a TPS
System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
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 CONSOLE OVERVIEW

Console Equipment:

A TPS console is made up of a collection of Universal Stations or

Global User Stations and their shared peripherals. Peripherals
include drives for Zip and/or cartridge disks, printers, and strip chart
recorders.
Console Equipment ( US
Stations Illustrated)
 Console Status Display
The console equipment status is shown on the
Console Status display. (see next slide) On the Console
Status display, printers, cartridge drives, and chart
recording pens are called peripherals (PERIPHS) of the
User Station (GUS or US).
Each peripheral is listed on the same line as the number
of the station to which the peripheral is connected.
The station has to be operational before you can use any
of its peripherals.
The station must have its personality software loaded in
order to access/use the peripherals. Notice in the Console
Status display, the Trend Recorders are identified as pens.
Console Status Display
On the Console Status
display shown in Display
1, the Area Database
named “North” has been
loaded into stations #1, #4,
#7, and #10.

The Area Database

provides the displays that
operators use to see the
process Area, such as
Group displays, Alarm
Summaries, Trends,
Custom displays, etc.
What are the differences between
Area, Unit, and Point on a TPS
System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
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 Area, Unit, and Point
Definition
The TPS system is designed to control three
different sections: an Area, a Unit, and a point or
points in a process.

A process Area is a portion of the process plant,

typically operated by one operator at a Station. A
Station provides the operator’s view to the process.
There are a maximum of 10 areas in the TPS System.
Examples of Process Areas:
the polymer area of a chemical plant,
the antibiotic area of a pharmaceutical
plant,
the catalytic cracking area of a refinery,
the utilities area of a manufacturing
complex,
the wet end area of a paper mill
 Units
Units are used to divide points for alarm and
message purposes and to define the limits of
an operator's control responsibility. If the Unit
is not assigned to a station, the operator can
only look at the points in the Unit. A TPS
system can have a maximum of 100 Units.
 UNITS
Typically, a Unit a reactor Unit in a polymer
Area of a chemical plant,
would include all of a fermenter Unit in an
the points associated antibiotic Area of a
pharmaceutical plant,
with one piece of a regenerator Unit in a
equipment in an catalytic cracking Area of a
refinery,
operating Area.
one boiler in a utilities Area
Examples of process of a manufacturing complex,
Units are: the dry end Unit of a paper
machine Area in a paper mill.

There is no limit to the number of points assigned to a Unit.

 Points
A point is all of the information about any
one particular process-related item. Several
examples of points are an analog controller,
an analog indicator, and a digital point.
(Analog refers to a directly measurable
quantity, such as a voltage or current. Digital
relates to data being presented as on or off.)
 Point IDs

The “instrument” name of the

point is called its Point ID.
For example, FIC200 is the
Point ID of a flow controller.
The terms Point ID, Point
Name, Tag Name, and Point
Tag Name can be used
interchangeably. Throughout
this course module, we use
the term Point ID.
 Points, Units, Areas,
Stations
Each Point is assigned to a Unit and the Unit is
either assigned or not assigned to the station's Area.
Figure 3 shows an example of a TPS system with
seven Stations, three Areas, and five Units, and it
shows the relationship between Points in a Unit,
Units in an Area, and an Area in a Station. Refer to
Figure 3 as you read these explanations:
Point, Unit, Area, Universal
Station Relationship
 Unit Assignment
The Area's Unit Assignment display is used to
assign and unassign Units. To call up the Unit
Assignment display, press the [CONS STATS] key;
the Console Status display appears. Select the UNIT
DISPLAY target. An Area can have a maximum of
36 units assigned to it. In the example below, all of
the Units are assigned, except Unit 33. The Operator
at this station could not make changes to Points in
Unit 33.
Unit Assignment Display

RULES:
• A point must be in a Unit that is
assigned to the Area of the User
Station before the operator can
make changes to the point from
that station.
• If you try to change a point that
is in a Unit that is not assigned
to the User Station’s Area, the
message UNIT NOT ASSIGNED
appears in the upper-left corner
of the screen.
• If a Unit is not assigned to the
Area of a User Station, the
alarms for points in that Unit are
not annunciated on the Station.
PROCESS
FUNDAMENTALS
What is a Point or Tagname on a
TPS System?

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 Points
The basic element to which control
functions are applied is the point. A point,
identified by a Point ID, is a named collection
of data values called parameters that are
accessible by point name and parameter
name, and to which specific sets of functions
are assigned.
 Point Types

To facilitate
functions like Point Type Function
point building
and point Analog Input Points Data acquisition
displays, points Digital Output Points Output digital state
are categorized Counter Points Count input pulses
Timer Points Indicate time
according to their interval
principal Regulatory Points Indicate and
functions. For control
example...
 Point Functions
The set of functions defines the operation of a
point. Functions can be selected from a set of
preprogrammed algorithms, user-written algorithms,
or user-defined procedures (sequence programs).
In addition to algorithms, other predefined
functions such as Input processing, Setpoint limiting,
Output limiting, and alarming may be included.
These functions are processed in a predefined order.
 Point Internal Structure
The internal structure
of a point varies
according to its
assigned functions and
its residence; however,
the main elements, the
Point ID, the
parameters, and the
functions remain.
 For example:
The main elements
of a point are
Point ID Function
TT1200 Data
Point ID
Acquisition
Parameters
FC248 Control
Functions
What are parameters on a TPS
System?

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 Parameters
The parameters in a point can consist of
input data (flow, temperature), tuning
constants (gain, integral time), Recipe data,
Output data (output to control element), alarm
state, etc. All, or a subset of point parameters,
are accessible to other points or subsystems
through a data access mechanism.
How does a Point read data into a
TPS System?

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I/O Processors
Each point is associated
with a conceptual “slot” of
memory in the control
device. Each slot’s input and
output connections to the
process are made through
I/O Processors (IOPs).
Figure 4 in your manual
illustrates three points that
make up a control loop and
where the points are located
within the control device.
Slot Concept
Entering a
point into the
TPS System is
accomplished
by the
engineer using
the Data Entity
Builder, as
described in
the Data
Entity Builder
Manual.
 Creating Points
The initial information required by
the Data Entity Builder is the point ID, the
point type, and the point’s residence. The
Data Entity Builder presents the user with sets
of questions based on this initial information
and these questions must be answered in order
to completely define a point.
What is a Process Variable on a
TPS System?

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 Process Variable
On a TPS system, an actual process
input is called a Process Variable (PV).
Some operators call the PV the “present
value.” Figure 5 shows a fuel gas flow as
the PV. On the conventional panel-
mounted display in Figure 5, the pointer
on the meter indicates the current fuel
gas flow.
PV Display for an Analog Point
 Note:
If you are not using the TPS system to control your
process, but are using it for data acquisition and
monitoring only, you might not be interested in the
following discussion of such terms as Setpoint,
Output, and Mode. In that case, proceed to the
“Digital Type Displays” section of this course
module.
What is a Setpoint Variable on a
TPS System?

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 Setpoint
The Setpoint (SP) of a controller is the desired value for the
PV. When the PV is equal to the Setpoint, no further
corrections are made by the controller until either the PV
deviates from the Setpoint or the operator changes the
Setpoint. On a conventional display, the Setpoint is indicated
on the meter by some type of pointer. On the Universal
Station (US) display, the Setpoint is indicated by a blue dash
mark beside the PV bar. The actual Setpoint value in
engineering units is shown beside the SP label. In the
example in Figure 6, the Setpoint is 130 gallons per minute
(GPM).
Setpoint Display for an Analog
Point
What is a Output Variable on a TPS
System?

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 Output
The Output (OP) of a controller is the signal
that goes to the final control element.
Output Display for an Analog Point
 A Comparison

The following is a
comparison of a
conventional output
meter with a US
Output display.
Conventional Output
Meter
User Station Output
Display
 Output Range
The output of the
TPS controller can
go from -6.9% to
106.9%. This
provides the operator
with an overrange to
compensate for
calibration offsets in
the field equipment.
What are a Controller’s Control
Modes on a TPS System?

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CONTROL MODES

There are three major

control modes:
Manual
Automatic
Cascade
 Manual Control Mode

Manual mode stops the

control action. The output
is held at its current
position. In Manual mode,
the operator is direct
control of the output. To
change the output, the
operator at the Universal
Station uses the [OUT]
key or the touchscreen.
Automatic Control Mode
In Automatic mode, the
controller automatically adjusts
the output to keep the PV on
Setpoint. In Automatic mode,
the operator controls the
Setpoint. To change the
Setpoint, the operator at the
User Station uses the Setpoint
[SP] key or the touchscreen.

Refer to Diagram 11 in your manual for an example.

 Cascade Control Mode
In Cascade mode, the output of
one controller drives the
Setpoint of another controller.
The controllers are "cascaded”
together. The "driver" is called
the Primary or master. The
controller that follows the
primary is called the Secondary
or slave. The Secondary
normally operates in Cascade
control mode. The Primary
normally operates in Automatic.
 Cascaded Controllers
If a computer (Application
Module, for example) controls
the Setpoint or Output of a
Secondary controller, the
secondary normally operates in
Cascade mode also. The two
controllers shown at the right are
cascaded together. Usually, a
convention is established by the
engineer, so that cascaded
controllers are side by side and
the primary is always on the left.
Simple Level Cascade Example
What are Digital Points
on a TPS System?

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 Digital Type Displays

Conventional running lamps that indicate

the current state of field equipment, such as
motors, pumps, and fans, are seen on the US
as colored boxes, that act like lamps. Any
label can be written under the lamps to
customize them for your process.
 Digital Type Displays

Conventional running lamps that indicate

the current state of field equipment, such as
motors, pumps, and fans, are seen on the US
as colored boxes, that act like lamps. Any
label can be written under the lamps to
customize them for your process.
Conventional vs. Digital Input Display
 Other Types of Displays
Look in your manual (diagrams 15 & 16) at the US display example
of an "indicator." The name of the item, FI200, indicates that it is a
"flow indicator" as compared to a "Flow Indicator Controller” (FIC).
Notice that no Output or Control mode is displayed. Analog indicators
can have a "Setpoint" value displayed also, but it is not a true Setpoint
because the point is not a controller. In this case, the Setpoint is only a
"target value,” that is, a reference value for the operator.
This target value can also be used for alarming purposes. In diagram
16, an "output only" item on a US display does not have a PV. The
other types of PV displays on the TPS system will be discussed later
in this course module.
What are basic system displays
used
on a TPS System?

From the Course:

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Monitoring & Controlling
On a conventional control panel, the various
instruments that are needed to monitor and
control a particular part of a process are
usually mounted in arrangements convenient
to the operator. On the US, the items can be
grouped together in similar arrangements on
Group displays.
 GROUP DISPLAY
A Group display is a visual representation of from one to eight process points
grouped together in one display:

 Each Process Point can be repeated in as many Group displays as the operator
needs.
 Point changes can be done from any Group that the Process Point is in.
 Each Area (User Station) can have up to 400 Group displays.

On the left side of the Group is a 0 to 100% scale for analog points. For example,
if 250 degrees is the full transmitter range of TIC21242 and the temperature is at
full range, the blue PV bar would be all the way to the top of the scale.
 Graphic Components
Above each point on the Group display is a graphic
representation of the point’s PV:
Digital points have a set of two lamps showing the point’s
status. For example: open/closed, on/off depending on how
the point was built by your engineer.
Analog points have a bar that represents % of range.

Note that on the upper-left side on the Group display is a

0-100% scale that applies to the analog point’s % of range.
 Displays
This Key... Calls Up... And Can be Used To
DISP FWD The next higher numbered Page through the Group
Group display. Displays. A method
commonly used by operators
DISP BACK The next lower numbered to monitor the
Group Display. process.

ASSOC DISP The preassigned Associated Each Group display can

display. have one Associated display
and one Help display
HELP The preassigned Help assigned. The message
display. “Display Not Configured ” will
appear if no display has
been assigned by
your engineer.
 Group display updates
The data shown in the Group display updates (brings in new values)
and the following update options apply:
 Data in the Group display is updated every four seconds.
 Press the [FAST] key to turn on the fast update rate of the data.
 It is a good idea to increase the update rate when you are making
changes so you can see the change immediately.
 Be sure to turn off the fast update rate when you no longer need
the faster update rate.
Changing the display turns off the fast update rate automatically.
What are Point Forms
on a TPS System?

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Point Forms
Process Manager,
Advanced Process
Manager, and High
Performance Process
Manager points (tags) are
built in one of three forms:
full point form
component point
form
untagged point form.
 Full Point
A Full point includes
tag name, descriptors,
alarm functions, and
control modes. It is
intended for use by the
operators and includes
everything necessary
for an operator to
communicate with the
point.
Component Point
A Component point is a point
that the system needs
knowledge of, but that the
operator does not need to know
about. It can be displayed, but it
has a less complete point
structure in that it includes a tag
name, but not descriptors, alarm
information, or control modes.
 Untagged Point
In rare cases an Untagged point can be used
to connect other points. It is not available on
Group or Detail displays. An Untagged point
does not have a tag name and is referenced by
module Input/Output Processor (IOP) type,
module (IOP) number, and slot number. An
untagged point is displayable only on the Slot
Summary display.
 Using Untagged
References...
If you decide to use untagged references, we
recommend that:
 operators and technicians are aware that they are in use
and what the syntax represents,
 technicians and engineers know how to use Find
Names to locate them, and
 the use of untagged references is documented, so that
the same point is not configured more than once.
What are Detail Displays
on a TPS System?

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 Detail Display
The Detail display of a point contains all the
information that exists in the system about
that point. The Detail display is typically used
in a way that is similar to pulling the
conventional board-mounted instrument out
of the panel to check and adjust the tuning
constants, alarm limits, control action, etc.
 Detail Display
continued….

The contents of the

Detail display will
vary depending on the
type of point called up
(detailed).
 How it Works:
A Detail display consists of one or more pages of
information. Only points built in full or component
form can be called up.
On the right side of the Detail display is the
parameter PNTFORM, which indicates the form of
the detailed point.
The PERIOD parameter indicates how often the
point is being processed (1/4, 1/2, or 1
second).
 The Way to Do it...
There are two ways to call up the Detail display of
a point:
 One way is to press the [DETAIL] key, then type in the
desired tag name in the entry box that appears at the
top of the screen and press [ENTER].
 The other way is to select the point in a display, then
press the [DETAIL] key. You may call up the Detail
display from any display that allows you to
select the point, such as Group displays, Alarm
Summary displays, and Schematics.
 Navigating From Detail to
Other Displays
Upon selection of the FIRST PAGE
target in the upper-right corner of the
Detail display, additional targets
appear on the left side of the screen.
These targets allow you to directly
access a page of the Detail display
and to navigate between the Detail
display and other related displays.
You may access the navigation
targets from any page of the Detail
display.
 More Info?
For more information on the various
displays available and detailed diagrams,
please see your local Honeywell TPS
Bookset.
Conditions that
Affect the Point
 What is PV Filter
on a TPS System?

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 PV Filter
Filtering is available to dampen signals from field devices
that exhibit some form of jitter (noise) such as from a bubble
tube on a level input. To access the filter, the Detail display
of
the analog input point must be called up. In the lower-right
corner of the display is the time filter parameter TF. Values
of 0 to 60 minutes can be entered, with 0 indicating no filter
action. Care must be used when adjusting this filter. Too
much filter dampens actual process changes.
 What is PVRAW
on a TPS System?

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 Raw PV

If Sensor Type Then Pvraw The PV raw value indicates

Is… Is In… the raw input value of the PV
from the Field Termination
Voltage or Percent
Current Assembly (FTA) before PV
characterization is performed.
TC Microvolts The Field Termination
RTD Milliohms Assembly provides the
0-100 mV Millivolts physical connections for
sensor/transmitter wiring.
How do I set the range of a PV
on a TPS System?

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 PV Range Limits

PV Range Limits (PVEULO,PVEUHI)

show the range of the instrument in
engineering units and must match the sensor's
calibrated range. Note that an analog input
point displays its range and the controller
point also displays its range. They must
match. If a transmitter is reranged, the range
of the input point and the controller point
must be changed to match the new range.
 Extensions
An extension can be added to the PV range, so the PV is
considered good if it is within the extended range. A PV
outside the extended range can be “clamped” to a specified
limit. In certain types of failures, the PV can be “uncertain”
or “unreasonable.” In either case, the PV is not to be trusted.
If a thermocouple is wired into an Analog Input (AI)
module (FTA) that is configured to check for open
thermocouples, the letters OTC above the point ID indicate
that the PV is not accurate because of an open thermocouple.
How do I know if a UCN Point is
Active
on a TPS System?

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 Point Active/Inactive

When the system engineer initially loads the database into a

PM, an APM, or an HPM, all points are “inactive.” Before
control action can be started, all points must be made
“active.” On the Detail display of the point is a parameter,
Point Execution State (PTEXECST). Select this parameter
and a menu appears from which you can select the proper
active/inactive setting. The active state (together with the
other database information) can be saved to storage media, so
that the next time the database needs to be restored, all of the
points will be placed in the active state.
 Special Note for Controllers
and Composite Points
Remember that the input and output points for
analog controllers and digital composite (ON/OFF)
controllers must be called up also and made “active.”
If you do not remember the point name of a
controller's input and/or output tag, detail the
controller, then page forward to the “connections”
page of the display. The input and output points are
listed there.
How do I know if my PV is bad
on a TPS System?

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Bad PV
If the Process Variable
(PV) signal goes
outside of its range,
the PV goes bad” and
an alarm is
annunciated. The letter
B appears beside the
PV value, indicating
that it is a bad PV.
 What is PVSOURCE
on a TPS System?

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 Source of the PV
The parameter
PVSOURCE is shown on
the Detail display and is
normally set to
AUTOMATIC. This
means that the PV value
is being obtained from the
“configured
source” that is usually a
field transmitter.
 PVs for Dummies
If a transmitter goes bad and the PV is no
longer available, the engineer could choose to
change the PVSOURCE to MANUAL. This
allows the entry of a “dummy” PV to be used
in reports and other system functions until the
transmitter is replaced. The value inserted
usually comes from a local indicator on the
process.
The Substitute PV

The PVSOURCE of a
Point can also be set to
SUBSTITUTED. This
allows the PV value to
be input from a program
calculation. For example,
PVs could be substituted
when the engineer is
testing a control scheme.
 AUTO and SOURCE
The value beside the PVAUTO label is
always the value from the configured source.
So, although the PV value has been manually
entered or substituted, the “real” PV can still
be seen.
For controller points, the PVSOURCE
parameter can be changed only when the
controller point is in MANual mode.
Conditions that
Effect the
Output
How do I set Output Limits
on a TPS System?

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 Output Limits
The Output High Limit in Percent (OPHILM) and
Output Low Limit in Percent (OPLOLM) clamp the
output of a controller and keep it from going outside
of the desired range. For example, if a valve on a
fuel line is to always remain partly open, the Output
Low Limit of that controller could be set at 5%.
Output limits can be overridden in Manual mode, but
a warning indicator would appear beside the Output
value.
CAUTION!
If you have manually
set the output outside
a limit, the output will
adjust back to the
limit when you put the
point into Automatic
or Cascade mode.
Output limits do not
apply when in the
Manual mode.
Can I set an Output Tolerance Limit
on a TPS System?

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 Output Tolerance Check
You can provide a tolerance limit for a
manually-entered OP value for regulatory
control and analog output point types. The
entered value is tolerance-checked by
comparing the difference between the new
value and current value against the configured
OP tolerance limit. The tolerance limit is
established by parameter $OPTOL. $OPTOL
is in percent.
 Exceeding Your
Tolerance Level?
If the difference exceeds the tolerance limit
in either a positive or negative direction, the
operator is alerted by a beep from the
keyboard and a warning message (Warning:
Over Tolerance! ENTER to Store) on the
screen. Operator confirmation, by pressing the
[ENTER] key, is required before the over-
tolerance value can be the new output value.
What does RED TAG mean
on a TPS System?

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 Red Tag
REDTAG is a safety feature to
prevent controller outputs from
being changed when the valve
or other final control element is Red Tag
out of service. To turn ON the
REDTAG, the point must be in Special Today!
MANual and External Mode DO NOT
Switching (ESWENBST), if CHANGE!
present, must be disabled. The
output cannot be changed by the
operator or by a program when
the Point is “Redtagged.”
What is Initialization Mode for an
Output
on a TPS System?

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“Introduction to TDC3000” by Cliff Lawson
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below this frame.
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choose “Full Screen” for best resolution for your
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 Initialization Manual Mode
Initialization prevents a bump in the process when a
controller is placed back into service after some disruption of
normal operation. In the Process Manager, Advanced Process
Manager, and High Performance Process Manager,
initialization occurs on controllers configured to write (push)
their outputs to some other point and that point cannot accept
the value. Examples are a controller whose Output point is
INACTIVE or is mistakenly configured as a FULL point, or
the module (IOP) itself is IDLE or FAILED.
 Initialization cont……
The most frequent
occurrence of
initialization is in a
cascade loop situation.
Bumpless Mode Transfer
Initialization is used to provide “bumpless” mode
transfer at any time the operator takes the secondary
controller out of Cascade mode and later returns it to
cascade mode. Normally, when the secondary is
placed back into Cascade mode, it is necessary to
balance the primary’s output to the existing
secondary’s Setpoint. Initialization does this
automatically, so upon setting the secondary back
into Cascade mode, the primary’s output is forced to
match the secondary’s setpoint.
More on this...
Please refer to the
Honeywell Bookset
for more info on
Initialization...
 What is PV Tracking
on a TPS System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
You may navigate using the links on the left.
Required notes accompanying each slide are
below this frame.
You may want to go to the View menu and
choose “Full Screen” for best resolution for your
computer.
 PV Tracking
If a Point is configured with “PV Tracking,” you
won’t be able to change its SP in Manual mode,
because tracking is activated in Manual. The
message CANNOT CONF TRACK appears. PV
Tracking automatically changes the SP to keep it
equal to the PV and thus provides “bumpless” mode
transfer from Manual to Automatic or Cascade. Any
form of Manual mode turns on tracking (if
configured), including Standby Manual and
Initialization Manual.
How do I change Setpoint Limits
on a TPS System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
You may navigate using the links on the left.
Required notes accompanying each slide are
below this frame.
You may want to go to the View menu and
choose “Full Screen” for best resolution for your
computer.
 SP Limits
There may be high and low
limits on the setpoint. The
error message LIMIT OR
RANGE ERROR appears
in the upper-left corner of
the screen if you try to
enter a Setpoint outside of
the limits. Indicators
appear beside the SP if the
setpoint is limited by
Output limits
or SP limits
SP Tolerance Check
You can provide tolerance limits
for a manually-entered SP value
for regulatory control point
types. The entered value is
tolerance-checked by comparing
the difference between the new
value and current value against
the configured SP tolerance
limit. The tolerance limit is
established by parameter
$SPTOL. $SPTOL is in
engineering units.
What is a Digital Composite point
on a TPS System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
You may navigate using the links on the left.
Required notes accompanying each slide are
below this frame.
You may want to go to the View menu and
choose “Full Screen” for best resolution for your
computer.
 DETAIL DISPLAY FOR
DIGITAL POINTS
An operator controls a device such as a
pump, conveyor, electrically operated valve,
etc. using a Digital Output of a Digital
Composite point. When used this way, the
composite point is usually configured to
provide a confirmation display to inform the
operator whether the desired result did or did
not take place.
 DIGITAL POINTS
Each digital point can have input, output or both (composite).
Figure 22 below shows how you can tell the difference.
Operating Digital
Composite Points
To command an output, select
the point, press the [OUT] key
on the
keyboard and then use the
single arrow buttons to
command the desired output.
Then press the [ENTER] key.
You may also use the
touchscreen by selecting
(touching) the Commanded
Output State box and pressing
the [ENTER] key.
 Digital Composite Point States
A composite point can have two states (0, 1) for
devices such as a pump indicating on and off, or
three states (0, 1, 2) for devices such as conveyors
needing forward, stop, and reverse, or valves
needing open, moving, and closed, etc. Notice on
Display 20 in your manual that the lower-half of the
indicator boxes is split into two lamps. The right
lamp indicates the output last commanded and the
left lamp can indicate the input signal (status) of the
device.
 Permissive & Override
Inputs
Interlocking of state changes is provided with
permissive and override inputs. The permissives
must be “on” to allow the state to be active but will
not cause the state to change. Overrides must be
“off’ to allow a state change and will cause a state
change if they come “on” and a different state is
presently active. The digital input point shown in
Display 21 provides the current state of a device as
ON or OFF.
 REFERENCE MATERIAL
Process Operations Manual from Honeywell Bookset
The Process Operations Manual is the basic guide for
anyone using a TPS User Station to operate their process and
the TPS equipment.
The Process Operations Manual's primary purpose is to
show how to use the Station's Operator Functionality.
Look over the following Group display and Organizational
Summary display discussions in the Process Operations
Manual. The intent here is to help you become familiar with
the manual.
It is a good idea to begin by reading Section 1 of the
manual, which is an introduction to the manual's organization
and structure.
 You have reached the
end of Section 2 of this
CBT!
Now, go to the
manual and
complete any
required tests or
evaluations.
 MODULE OBJECTIVE
Given a cascade loop, be able to operate the
cascade appropriately by manipulating the primary
and secondary points in Manual and Automatic
modes, with and without PV Tracking, with and
without Initialization, including closing the loop
without causing a bump (i.e., bumpless). Bumpless
mode transfer means that no change to the output
occurs when the operator changes modes.
Operate PM/APM/HPM
Cascades

You have reached the final section

of this CBT courseware...
What are the basic fundamentals of
a Cascade Loop?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
You may navigate using the links on the left.
Required notes accompanying each slide are
below this frame.
You may want to go to the View menu and
choose “Full Screen” for best resolution for your
computer.
 Cascade Control Mode
In Cascade mode, the output of
one controller drives the
Setpoint of another controller.
The controllers are "cascaded”
together. The "driver" is called
the Primary or master. The
controller that follows the
primary is called the Secondary
or slave. The Secondary
normally operates in Cascade
control mode. The Primary
normally operates in Automatic.
 Cascaded Controllers
If a computer (Application
Module, for example) controls
the Setpoint or Output of a
Secondary controller, the
secondary normally operates in
Cascade mode also. The two
controllers shown at the right are
cascaded together. Usually, a
convention is established by the
engineer, so that cascaded
controllers are side by side and
the primary is always on the left.
 Remote Cascade Option
A cascade that involves a supervisory
program is often referred to as “computer
control.” If the supervisory program fails, the
controller reverts to its backup mode, as
determined by your engineer or programmer.
Simple Level Cascade Example
Supervisory Program Flow
Controller Cascade
Backup Cascade
 How does Initialization and
PVTracking affect Cascade loops
on a TPS System?

From the Course:

“An Introduction to TDC 3000”
 Information:
This topic is presented in the course
“Introduction to TDC3000” by Cliff Lawson
You may navigate using the links on the left.
Required notes accompanying each slide are
below this frame.
You may want to go to the View menu and
choose “Full Screen” for best resolution for your
computer.
 Operating Cascade Loops
There are two options that can be used to provide
bumpless mode transfer for cascades: PV Tracking and
Initialization.
The operator should recognize when the PV Tracking
and Initialization options are activated and when they are not.
If the options are not activated, the operator must perform the
operations manually to prevent an output change during a
mode transfer.
This module reviews the PV Tracking and Initialization
options as they relate to cascades and reviews the operations
required to close cascades with and without the options.
 PV TRACKING
If PV Tracking is configured for a point, whenever the
point is put in the manual mode the SP is automatically made
equal to the PV. If the operator makes an output change, the
SP follows right along with the PV. Because the SP tracks the
PV when the point is in the Manual mode, there is never a
deviation; therefore, no output change occurs when the
operator returns the point to the Automatic mode. This is
often referred to as a bumpless transfer from Manual to
Automatic mode control.
PV Tracking Examples
 INITIALIZATION
Initialization is a
means of preventing a
bump in the process
when a controller is
placed back into
service after some
disruption of normal
operation.
 Initialization
Normally, when the secondary is placed
back into the Cascade mode, it is necessary to
balance the primary's output to the
secondary's Setpoint. Initialization does this
automatically, so when the secondary is
placed back into cascade mode, the primary’s
output matches the secondary's Setpoint.
 More on Initialization
In the Process Managers (PM, APM, HPM),
initialization occurs on controllers configured to
PUSH their outputs to some other point when that
point cannot accept the value. An example is a
controller whose output point is INACTIVE or
whose output module is IDLED.
 Initialization for a Single
Controller
If the controller point is not able to dispose of its output to
the output point because the output point is INACTIVE or
because the circuit card handling the output point (called the
IOP) is in IDLE, the controller point shows INIT above its
mode indication. If we were to build a group display with
both the controller point and the output point in it, the output
indication of the controller point might not match the output
indication of the output point while in the INIT condition.
The actual Initialization takes place at the instant the output
point becomes available to the controller point. At that time,
the controller point’s output value is forced to match that of
the output point.
Initialization and Cascade Loops

Initialization can also

occur in a cascade loop
situation. It is used in this
situation to provide
bumpless mode transfer
any time the operator
takes the secondary
controller out of Cascade
mode and later returns it
to the Cascade mode.
Thank You.
You have reached the end of
this three part series for
Introduction to TDC 3000.
Please proceed to the tests
and labs to complete the
coursework.

For Comments or Feedback regarding

this course, please email:
Nan.Shastry@iac.honeywell.com