This PPT is based upon my training in Yokogawa Chennai. Reference: # Yokogawa Hand Book on CS 3000 # http://www.slideshare.net/bvent2005/dcs-presentation

1. Rehan Fazal
CENTUM CS 3000 ENGINEERING
& MAINTENANCE

2.  Basics
 Classification
 Process Control Loops
 Evolution
 Hardware Configuration
 Human Interface System
 Communication Bus
 Field Control Station
 Projects
Overview

4. Basic Control Loop

5. Process control systems are classified into
Analog Control Systems
Digital Control Systems
Process Control Systems

6. Analog Control System

7. Digital Control System

8. Digital Control Systems are further classified into
Centralized Control Systems
Distributed Control Systems
Digital Control System

9. Centralized Control System

10. Drawbacks Of CCS:
If the CPU fails the entire plant gets affected.
Redundancy concept is not available.
(Redundancy is having two controllers. One would be active
and the other would be standby. If the active controller
f a i l s , t h e s t a n d b y c o n t r o l l e r t a k e s o v e r ) .
Centralized Control System

11. Distributed Control System

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

13.  Information regarding the
process is presented to the
user in various formats.
 Control function is
distributed among multiple
CPUs (Field Control
Stations). Hence failure of
one FCS does not affect the
entire plant.
 Redundancy is available at
various levels.
 Instruments and interlocks
are created by software.
 Generation and
modifications of the
interlocks are very flexible
and simple.
 Field wiring is considerably
less.
 Maintenance and trouble
shooting becomes very
easy.
 Cost effective in the long
run.
Advantages of DCS

14. CENTUM Series (DCS) Evolution
1st CENTUM
2nd CENTUM
CENTUM V
CENTUM-XL
CENTUM CS
CENTUM CS3000
1975
1981 1984
1988
1993
1998
CENTUM has developed as a true open system.
World First DCS
2008CENTUM VP

15. CS3000-System Configuration

16.  FCS (Field Control Station)
• Reliable controller.
• Cost-effective and capable I/O subsystem.
 HIS (Human Interface Station)
• The operator station based on Windows XP or Windows2000. (Both are
selectable.)
• HIS provides easy & flexible operation.
 ENG (Engineering Station)
• Engineering Station is used to do the engineering builder for all the stations like
HIS, FCS, CGW, BCV etc. ENG is a PC loaded with Engineering software.
• The HIS can be loaded with engineering software so that it can be used as HIS
as well as ENG.
► CGW: Communication Gateway Unit used to communicate with
supervisory computers.
► BCV: Bus Converter is used to link two domains.
CENTUM CS 3000 - Major Components

17. V-Net (Communication Bus)
• Real-time control bus.
• V-NET is a used for communication between
HIS, FCS, BCV & CGW.
• Maximum 64 Stations can be connected on the V-net.
ETHERNET (Communication Bus)
• Ethernet is a standard network in CS3000 to
connect HIS, ENG and supervisory computers .
• Transmission speed: 10 MBPS
CENTUM CS 3000 - Networks

18. Types Of Users

19.  The Station for Real time Plant Monitoring/Operation
Human Interface System (HIS)
Easy Operation by a mouse, a keyboard etc.
Real time display of Plant Abnormalities.
Plant Operation by thousands of Graphics

20. Types of HIS
 DESKTOP HIS:
 A IBM PC/AT compatible machine is generally used.
Apart from the general PC, the Yokogawa PC is also
supported. Specifications of the PC HIS Desktop are as
follows:
 CPU : Pentium IV
Processor (Minimum)
 Main Memory : 256 MB (Minimum)
 Hard Disk : 20 GB or more
 Video Display : 1024 x 768 or more, 256 colours
 CRT Monitor : Multi Scan 17” monitor or larger
 Serial Port : RS232C one port or more
 Parallel Port : One port or more
 Extension Slot : PCI slot for V/VL net card,
ISA slot for Ethernet card
 Power Supply : 200-240VAC
 Basic Software : Windows NT with
Service Pack ,Windows
2000 or Windows XP

21.  CONSOLE HIS
 The floor mounted console type HIS
comes with 21” monitor which has a
touch panel operation. It has an
operation keyboard and an engineering
keyboard.
 They are of types
• Enclosed Display Style
• Open Display Style

22.  Engineering Station is used to do the engineering builder
for all the stations like HIS, FCS, CGW, BCV etc.
 ENG station is a PC loaded with engineering software
(Standard builder function). It is mainly used to perform
CS3000 system generation and maintenance
management.
 The HIS can be loaded with engineering software, so that it
can be used as HIS as well as ENG station.
Engineering Station (ENG)

23.  Maximum number of tags that can be monitored from
HIS : One Million.
 Maximum number of windows that can be created per
HIS : 4000.
 Maximum number of Trend Recording Points per HIS : 3328.
Application Capacity of HIS

24. Control Network Evolution

25. Optical
Fibre
R
R R
RT
T
Optical
Fibre
R
R R
R T
T
Max. 500m Max. 500mMax. 500m
Max.
15 km
Max.
15 km
Overall Max. 20 km
Co-axial CableV net
HIS
HISHIS
V net : Extension Details
Protocol : IEEE 802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance : 500m to 20km
Media : Coaxial/Optical
Fiber
Std. max. length : 185 m
Max. length : 20 Km

26.  The FCS controls the plant.
This is the component
where all the control
functions are executed
and hence it is a very
important and critical
component in the overall
system.
Field Control Station- Overview

27. Field Control Station Models

28.  FIO means Field network I/O.
 FIO is Process I/O modules.
 A kind of compact, cost-effective, reliable I/O devices,
targeted as the industrial standard I/O of next-generation.
 FIO includes the latest network technologies and field
experience.
FIO

29.  FFCS is the Compact FIO type Field Control Station
supported by CS3000.
 Components of FFCS:
a) Field Control Unit (FCU)
b) Nodes for FIO
c) Local / Remote Communication Bus
Compact Type FIO - Field Networked Field
Control Station (FFCS)

30. FFCS – AFF50D

31.  The FCU consists of
 Two Power Supply Units
 Two processor modules
 Eight slots for Input Output cards
 Out of these eight I/O slots, if I/O expansion is required, two
slots are used for ESB module and the rest six slots are used
for IO modules.
 It has two V net coupler units for connecting V net Cables.
Field Control Unit of FFCS

32. Power supply unit
CP401 CPU module
Eight FIO slots
EC401 ESB bus coupler
(Note)
Note: Two I/O slots are to be used for NIU extension.
AIP504 Vnet coupler (10BASE2 Vnet cable is used)
Detachable
bottom unit

33. Node Unit of FIO
Node Unit
The node units (NU) for FIO are signal processing units which convert and
transmit analog or digital process I/O signals received from the field
devices to the FCU for FIO.
►Node Unit has two bus units
 ESB Bus Node : For local nodes
 ER Bus Node : For remote nodes

34.  ESB bus Node or Local Node
 Speed : 128 Mbps
 Distance in Total : Max. 10m
 ER bus Node or Remote Node
Based on Ethernet
Speed : 10 Mbps
Distance in total :
10base2 -> max. 185m / 10base5 -> max. 500m
max. 2 km with repeater (Standard of Ethernet)
Up to 3 remote nodes can be installed on a FFCS.

35. FIO: Max. 8
Local node
Max. 3
ESB bus
Up to 6
Modules
Up to 8
Modules
CP401
CP401
PW48X
PW48X
V net
FFCS
CP401
CP401
PW48X
PW48X
EC401
EC401
SB401
PW48X
PW48X
SB401
SB401
PW48X
PW48X
SB401
SB401
PW48X
PW48X
SB401
FFCS
Minimum Configuration
Maximum Configuration
Hardware Configuration- Local Node

36. Hardware Configuration–Remote Node
V net
FFCS
Remote node
Expanded Remote node up to 3
ER bus
EB401
EB401EB401
EB401
EB401
EB401
EB401
CP401
CP401
PW48X
PW48X
EB501
PW48X
PW48X
EB501
Remote node
EB501
PW48X
PW48X
EB501
EB501
PW48X
PW48X
EB501
Remote node
Optical Repeater can be used

37.  Domain is the group of stations connected on one V-net
cable. Maximum 64 stations can be connected per
domain. Bus Convertor (BCV) is used to link two domains.
Domain Concept

38.  Addresses are used to identify the stations on the control
bus.
 Address is composed of a domain number and a station
number.
 The domain number is set in the range of 1 to 16. The
domain number is defined in project property setting
menu dialog box. The domain number cannot be
changed once it is set.
 Station numbers are used to identify the equipments
connected in the same domain of the system. The station
numbers range from 1 to 64.
Network Address Configuration

39. 1
2
3
4
5
6
7
8
OFF ON
24
21
22
23
20
25
26
Parity Check
Domain No.
Station No.
Setting Station Addresses
 Max no. of domains:16
 Max no. of stations:64
DIP Switch

40. Application Capacity Of FFCS
CPU R5432 (RISC)
Memory Size 32MB
Power supply 100/220V AC, 24V DC
No. of I/O slot 8
No. of I/O node total 4 including CPU node
ESB bus I/F EC401/SB401
Local node for ESB bus Up to 4
Remote node for ER bus Up to 3
ER bus I/F EB401/EB501
AP capacity
AI/AO 480
DI/DO 1920
Communication data 4000 words
Global SW 256
Common SW 4000
%ANN 1000
%PR 1000
%OP 500
%RQ 200
No. of control drawing sheet 200
No. of function block (total with %ANN) 2500
Realtime trend 256

41.  The Field Network I/O (FIO) modules are used in the FCS for FIO.
 Advantages of FIO series IOM
 It supports Variety of Field connections.
 I/O modules are available with different isolation types.
 Supports wide range of Installation environment.
 Redundancy is available.
 Provides Replacement capability for the existing Centum V, Centum XL and
Micro-XL systems.
FIO Module

42. Types of Field Connections

43. Pressure Clamp Terminal
 A field signal cable, with its end uncovered, can be
connected directly to an analog or digital I/O module
equipped with the pressure clamp terminal block.

44.  An analog or digital I/O module equipped with the KS
cable interface adapter can be connected with the
terminal board using the KS cable and field signal cables
are connected to the terminal board with M4 screws.
KS Cable Interface Adapter

45.  Input modules convert process signals to the digital data format
used in the FCS. Output modules convert the digital data
format used in the FCS to analog or contact signals.
 Types of I/O Module
 Analog Input Module
 Analog Output Module
 Analog I/O Module
 Digital Input Module
 Digital Output Module
 Digital I/O Module
 Relay I/O Module
 Multiplexers Module
 Communication Module
Input Output Modules

46. Analog Input Modules

47. Analog Output Modules

48. Analog Input Output Modules

49. Digital Input Modules

50. Digital Output Modules

51. Operation Windows
Information regarding the process is gathered as well as monitored by the
following Standard Operation windows on the HIS.
 Tuning Window
 Control Group Window
 Trend Window
 Process Alarm Window
 Operator guide Message Window
 Graphic Window
 Overview Window
 Process Report Window
 Historical Report Window

52. System Message Window

53. Operation Keyboard
All the operations can be performed with the help
of the Operation Keyboard. The same
operations can also
be performed by touch functions available
on the System Message Area Icons.

54. Instrument Faceplate Window

55. Tuning Window (PID)
TUNING WINDOW displays all the
Tuning parameters of the instrument.
The Tuning Window is used to set up the
alarm setting as well as the loop tuning
parameters.
Only the items indicated with a “= “ can
be changed.
Displaying a “Tuning Window”
1.Double click on a Tag’s name on a
“Control Window” and a faceplate window
will appear. Select the “Tuning “
window icon from the toll box.
2. Select “NAME icon in the System Message
Area” then enter the “TAGNAME”.

56. Tuning Window (TIMER)

57. Control Drawing Display

58. Navigator Window

59. Control Group Window – 8 Instruments
Select this icon to display
the Control Group Window

60. Control Group Window – 16 Instruments

61. Overview Window
Overview Window displays the overview of the
current process status.
Information regarding the process is distributed
among the various display blocks.
32 Display Block s per Overview Window.
Each block gives dynamic information regarding the
process.
Double click on the display block to more details.
3 Types of Display Blocks
•Single Tag Block
•Window Display Block
•Comment Block

63. Graphic Window

64. Trend Window
TREND WINDOW records the PV, SV and
MV of various instruments.
Trend can be displayed in Trend Group
Format or in Trend Point Format.
Maximum 8 pens can be assigned in one
Trend Group Window

65. Process Alarm Window
PROCESS ALARM WINDOW displays the
latest 200 process alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.
This icon displays the current PV
Values of the instruments that are in
alarm
This icon displays the important tags
(High Priority Alarms) that are in
alarm.
This icon is used to acknowledge the
process alarms.
Select this icon to call the Process
Alarm Window

66. SYSTEM ALARM WINDOW displays the
latest 200 system alarms.
Alarms can be acknowledged either as a
Group or as Individual alarm.
System Alarm Window

67. Process Report Window

68. System Status Window

69. Control Drawing Function Blocks

70. Sequence Tables (ST-16)
Condition Area
Action Area
Rule Area

71. Logic Charts (LC-64)

72. Relational Block (RL)
Transmitter
Tag Name
Relational
Values

73. Calculation Block (CALCU)
Controlling Conditions in C format

74.  A Project is the basic unit of the engineering database
management. It is a unit which contains the database of the
FCS and the HIS created by the user. All builder files defined by
various builders are managed under the project.
 There are three different types of projects in CS 3000:
1)Default Project
2) Current Project
3)User Defined Project
The project which runs inside the FFCS is called the current
project.
Projects in CS3000

75.  A project is created under the System View. It is the
primary window for system generation to display the
builder files defined by the user and also to start the
builder for editing.
 To open the system view we need to follow the shown
steps.
System View

76.  When the system does not find any project definition, it
automatically prompts for the creation of a default
project. Click on Yes to create a new Project.
Creation Of Project

77. Station & Domain Number Of FCS

78. Creation Of HIS

79. Creation Of Node
As already
discussed
two types of
nodes

80. Creation Of IOMs

81.  All types of analog input(Transmitters) and outputs(Valves)
labels are declared here.
 It shows an analog i/o type.
IOM Builder

82.  The download function transfers the FCS execution data
from the HIS to the FCS. The execution data is a database
containing the application logic to be copied on to the
processor card of the FCS.
 There are three different types of download that can be
carried out on the FCS:
a) Offline download
b) Online download
Downloads

83.  Offline downloading is performed when one of the following
changes is performed in the project:
• When adding • When the FCS properties
an FCS have been changed
Offline Download

84. Online Download

85.  CS3000 R3 system contains 200 control drawings per FCS.
To access control drawing, select FUNCTION_BLOCK
folder under FCS folder.
Control Drawing Builder

86. Components Of Control Drawing Builder
Function
Block Lib.
Wiring
Labelling

87. Signals Monitoring

88. Closed Loop

89. Cascade Loop

90. Cascade Loop Faceplate

94. Multiple Cascade Loop

95. Split Range Controller

96. Multiple Split Range Controller

97. Signal Selector

100. Switch Block

101. Ratio Control Loop

102. Area In & Area Out

103. Velocity Limiter

104. Temperature Pressure Compensated Flow
𝐹𝑙𝑜𝑤 ∝
𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒
𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
Fi : Measured flow rate
F0 : Corrected flow rate
P : Measured pressure [kPa]
Pb : Reference pressure [kPa]
T : Measured temperature (°C)
Tb : Reference temperature (°C)

105. Arithmetic Function Blocks
𝐷1 =
𝑥𝑦 + 𝑦𝑧
𝑥𝑦𝑧 − 𝑥𝑦

106. Motor Control Block

107. Sequential Table

114. Calculation

116. Logic Chart

124. THANK YOU