Analog Control / Digital Control

Analog Control Analog Control In analog control, PID computation is carried out with an electric current or voltage by a hardware. It is very hard to change the control algorithm. High accuracy computations used for the advanced control are also difficult.

SV

Deviation

PID unit PID

MV

PROCESS (including control valve )

Process variable

PV

Controller
Sensor and Transmitter

Numerical Data

Digital Control

Digital Control In digital control, PID computation is carried out by a software. It is easy to change the control algorithm. High accuracy computations used for the advanced control are also easy.

SV

Deviation

CPU

D/A & hold

PROCESS (including control MV valve )

Process variable

A/D

Controller

PV

Sensor and Transmitter

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Centralized Control System

Logger At the initial stage, a computer was used as a logger only for the monitoring and logging.
Alarm

Report
Operator Station
(monitoring and logging)

A/D MPX

I/O Buffer

CPU (Computer)

I/O Buffer

D/A MPX

SPC
INPUT UNIT

(Setpoint Control)

OUTPUT UNIT

SV PV

SV

SV

SPC (Setpoint Control) Then the computer was used for setting optimum setpoints on individual controllers. DDC (Direct Digital Control) And then a single computer is used to executes control computations for controlling multiple control loops.

MV

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Distributed Control System (1)

Node
Communication module

I/O Image

Input module

Output module

The concept of I/O processing of the distributed control system. Each signal conversion module in the node (I/O processing unit) has a CPU.

Isolato r

Isolato r
Data/Communication processing A/D conversion CPU Data/Communication processing D/A conversion V/I conversion

CPU

I/O signal processing is distributed.

Signal conversion

Analog input

Analog output

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Distributed Control System (2)

Distributed control and centralized operation & monitoring

Control Network
FCU FCU FCU

The concept of computation processingI/O of Image the distributed control system.

CPU

CPU

CPU

CPU

CPU

CPU

I/O Image

I/O Image

Independent control stations for each plant. Node

Control processing is distributed.
I/O Image

Node

Node

I/O Image I/O

I/O Image I/O

I/O

Field Control Station Plant A

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Field Control Station Plant B

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Field Control Station Utility

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CENTUM CS Lineup
CENTUM CS 3000 R3
DCS based on Windows for large-scale factories
The new production control system of Yokogawa. The CENTUM CS 3000 R3 features sophisticated functions and components to meet all production state requirements.

CENTUM CS 1000 R3
DCS based on Windows for small- and medium-scale factories
The CENTUM CS 1000 R3 has the same architecture as CS 3000. It is specifically designed for the requirements for the middle and small scale plants.

CENTUM CS
DCS based on UNIX for large-scale factories
The CENTUM CS was put on market in 1993. Since then, the CENTUM CS proudly keeps its overwhelming high reliability.

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History of DCS
Development of digital control technology and Yokogawas DCS.

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Position of DCS
Total information system in manufacturing.
Business system

Customer management
Order reception

Demand prediction
Production plan

Order

Production management
Production system

DCS
(Production control system)

Process control management

Production equipment

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Concepts of Modern DCS

Open information network Operator/work station ( Open environment ) Real-time control network

Advanced control station

Field bus

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CENTUM CS Configuration
HIS (Operator station)
The interface functions of operation and monitoring are executed by HIS.

V-net
(Communication bus) Real-time control network
TIC101

FCS (Control station)

I/O operations to and from the field, control computation and so on are executed by FCS.
ooo

PID FIC101

PID

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CS and Single Loop Controller

FCS
FCU
(Field Control Unit) Control computation
TIC001 TIC002 TIC003 TIC004

V net

HIS

ESB or RIO bus

I/O images Output processing (D/A conversion)

YS100 Single loop controller

Node

TIC001

TIC002

TIC001

I/O modules

TIC003

TIC002

TIC004

TIC003

TIC004

Output conversion

Input processing (A/D conversion)

Computation Input conversion

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Signal Flow in CS (Example)

Measuring range is set by each function block.
OUT
Process variable PV Engineering data Ex. 350 C -200 1200 C Digital data TIC100 PID IN 0 100 % Digital data I/O images -200 1200 C Digital data
A/D

Engineering data SET Ex. 6.5 M3/M IN

Terminal connection (Soft-wiring)

Process variable PV Engineering data Ex. 5.2 M3/M

FIC100 PID
OUT

0 100% Digital data

I/O (PIO) connection (Soft-wiring)

0 100 % Digital data

A/D D/A

0 100% Digital data 4 - 20mA Analog data

Internal RIO/ESB bus communication

-5.9 48.8mV Analog data

4 - 20mA Analog data

Field device connection (Hard-wiring)

-200 1200 C Type K TC TE33Q4T30-01E

0 - 10.0 M3/M
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System Function Concept

Production Management (MES*, PIM**)
Ethernet communication

Engineering Function* (ENG)

*Can be executed by HIS.

Operation & Monitoring Function (HIS)

V-net/VL-net communication

Control Function (FCS)

CENTUM CS1000/CS3000
*MES:
Manufacturing Execution System

Subsystem (PLC, DARWIN etc)

Process I/O, Subsystem I/O, Fieldbus I/O etc.

**PIM:
Plant Information Management

Field Devices (Production Plant)

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System Configuration (CS1000)

Console type HIS No. of monitoring tags: 8,000 No. of stations: 24 No. of domain: 1 No. of HIS: Max. 8 VL-net extension: 185 m* Desktop type HIS

Ethernet (Optional)

VL-net

Compact type PFCS

* Extension length is for 10Base2 cable.

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System Configuration (CS3000 small)

Console type HIS No. of monitoring tags: 8,000 No. of stations: 256 No. of domains: 16 No. of stations per domain: 64 No. of HIS: Max. 16 V-net extension: 500m* Desktop type HIS

Ethernet

Communication gateway unit

CGW

V-net
Bus Converter

BCV

CS3000 in another domain or XL/XL

Compact type FFCS-S (for FIO)

Supervisory computer

Out of the system The BCV connects the stations on the V/VL-net on another domain. Other non-V net systems manufactured by Yokogawa may be connected via BCV.

* Extension length is for 10Base5 cable.

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System Configuration (CS3000)

Console type HIS No. of monitoring tags: 100,000 (Expandable up to 1,000,000) No. of stations: 256 No. of domains: 16 No. of stations per domain: 64 No. of HIS per domain: Max. 16 No. of HIS per network: Max. 64 V-net extension: 500m*
Bus converter

Desktop type HIS

Ethernet

Communication gateway unit

CGW

V-net

BCV

CS3000 in another domain or XL/XL

Compact Type SFCS

ooo ooo

Supervisory computer

Out of the system

(Sub-system)

Standard FCS Standard FCS (for RIO) (for FIO)

* Extension length is for 10Base5 cable.

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Engineering Environment in TC
Ethernet

HIS 0124 Engineering data

HIS 0123

VL net

Left-hand side HIS is HIS0124, which has an engineering database. (Use Reactor A control system.) FCS 0101 (PFCS)

Right-hand side HIS is HIS0123, which has no engineering database. HIS0123 shares the database with HIS0124. (Use Reactor B control system.)

HIS0124 should be activated before HIS0123.

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Sub-system Integration
Desktop type HIS The subsystem communication function enables CENTUM to use the data of PLCs, recorders, measuring systems as the data from process I/O.
V-net
Compact Type FCS

Ethernet General-purpose PC

GSGW
(OPC client)

OPC* Server

General-purpose subsystem gateway Subsystem communication network

Subsystem communication module

Subsystem communication network

Subsystem Subsystem

* OPC: OLE for Process Control TE33Q4T30-01E

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Remote Desktop Function

HIS LAN

Internet / Intranet

V-net

PC
ooo

LFCS

KFCS

The remote desktop function of Windows XP Professional enables to use the functions of CENTUM CS 3000 from the remote location. By logging on the host machine from a client machine, the client machine can execute operation and monitoring or builder functions. It is also possible to log on the host machine via internet.

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