CENTUM CS3000 R3

MAINTENANCE COURSE

Instrumentation & Automation Education Center (IAEC) Professional Instrument Engineer Training Program
Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

CENTUM CS3000
MAINTENANCE COURSE

OBJECTIVE : In this course, the participants will be introduced to the hardware

and software maintenance aspects of the CENTUM CS3000 system.
By the end of this course, the participants will be able to perform
front-end maintenance of CENTUM CS3000 system.

DURATION : 2 days

PARTICIPANTS : For CENTUM CS3000 engineers and technicians who need to perform
maintenance on the CENTUM CS3000 system.

PREREQUISITE : Participants should have attended CENTUM CS3000 Engineering Course.

Instrumentation & Automation Education Center (IAEC) Professional Instrument Engineer Training Program
Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

1
Day 1

Centum CS3000 system overview

Setup Configuration

Network setup

Down load project

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Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

Centum CS3000
System Overview

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Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

2
 Field Control Station

Human Interface Station

Ethernet

V-net

Instrumentation & Automation Education Center (IAEC) Professional Instrument Engineer Training Program
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CS3000
CS3000 System
System Configuration
Configuration -- Overview
Overview
ETHERNET

HIS

Vnet

Field Control Station

FFCS KFCS LFCS PFCS

Field Network
Input/Output

Foundation Fieldbus HART

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3
System configuration

Bus cable connection :LFCS

HIS Max. 16
station/domain

Twisted pair cable or Optical Fiber

Single/Duplex
2 MB/S , Polling
750 m / 20 km ( Twisted pair/Fiber)
MAX. length
MAX. 1280 AI/O & 4096 DI/O
MAX. 8 NIUs
5 IOUs / NIU

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CS3000
CS3000 System
System Configuration
Configuration LFCS
LFCS
Ethernet

HIS0164 HIS0163 HIS0162

Eng

V net

FCS0101 FCS0102 FCS0103

NODE RIO
1 1 1

2 2 2

3 3 3
MAX : NODE 8 PER FCS
4 4 4
MAX : UNIT 5 PER NODE
5 5 5

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4
CS3000
CS3000 System
System Configuration
Configuration LFCS
LFCS
Ethernet

HIS0164 HIS0163 HIS0162

Eng

V net

FCS0101 FCS0102 FCS0103

1 2 1 2 1 2
NODE RIO

3 4 5 3 4 5 3 4 5

MAX : NODE 8 PER FCS

MAX : UNIT 5 PER NODE

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Field Control Unit(FCU) Overview for LFCS

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5
Field control unit Picture : LFCS
RIO Bus Master Interface Card (RB301)

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Connection of Vnet Cables

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6
Connection of Vnet Cables

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Connecting the RIO Bus Cables

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7
Connecting the RIO Bus Cables

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Connecting the RIO bus

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8
Remote I/O (RIO)

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Remote I/O (RIO)

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Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

9
Nodes Picture of LFCS

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Nodes Picture of LFCS

RIO Bus
Slave Interface card ( RB401 )

Power supply Node Interface Unit

( NIU )

Nest For I/O

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10
Nodes Picture of LFCS

RIO Bus Slave Interface card ( RB401 )

Power supply

Node Interface Unit

( NIU )

Nest For I/O

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Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

CS3000
CS3000 System
System Configuration
Configuration KFCS
KFCS
Bus cable connection :KFCS

HIS Max. 16
station/domain

ESB bus: Length 10 m. or less(YCB301)

Speed 128 megabits pre second
No. Node Unit Connectable Redundancy : Available
Local Node Unit: Max. 10/FCU ER bus: Length 185m(Coaxial cable) or
Remote Node Unit: Max. 8/FCU Less(YCB141), 500m(Coaxial cable) or
When both Local and Remote Node - less(YCB311),185m (Coaxial cable)
Unit used: Speed 10 megabits pre second
Max. 10/FCU Redundancy : Available

Local Node

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11
CS3000
CS3000 System
System Configuration
Configuration KFCS
KFCS
Ethernet

HIS0164 HIS0163 HIS0162

Eng

V net

FCS0101 FCS0102 FCS0103

MAX : LOCAL NODE 10

MAX : REMOTE NODE 8 ESB BUS ESB BUS ESB BUS

LOCAL NODE

REMOTE NODE
ER BUS

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Connecting the FIO bus

ESB bus cable

BUS 1 BUS 2
Local node unit
(ANB10D)

EB401 ER bus
Connector unit for (YCB 141) To next node
ESB bus
Remote node unit
Connector unit with (ANR10D)
Terminator For
ESB bus To next node EB501
Install the terminator if connection ends.
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12
Connection
Power supply
(specify with Suffix Code)
Voltage : 100-120 Vac, Frequency : 50/60 Hz
Voltage : 220-240 Vac, Frequency : 50/60 Hz
ESB bus interface master card ( SB301 ) Voltage : 24 Vdc
Processor Card

V net coupler unit Bus 1

V net coupler unit Bus 2

Battery Back-up for main Memory : Max. 72 hours
Battery Recharge Time : Min. 48 hours
ESB bus 1
ESB bus 2 Fan units

ESB bus cable ( YCB301 )

ESB bus interface slave card ( SB401 )

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Node in FCS Architecture

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13
Fieldnetwork I/O (FIO)

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Local Node in FCS Architecture : KFCS

1 2 3 4 5 6 7 8

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14
Local Node in FCS Architecture : KFCS

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Remode Node in FCS Architecture : KFCS

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15
ESB Bus Interface Slave Module ( SB401 )

Connector unit with terminator for ESB Bus Connector unit for ESB Bus

Setting node addresses

Bit 1 ------- Node address parity (1 bit, odd parity )

Bit 2
Bit 3
Bit 4 Node address
Bit 5
Bit 6

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ER Bus Interface Master Module ( EB401 )

Local Node

ER bus cable connector ( CN1 )

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16
ER Bus Interface Slave Module ( EB501 )

Remote Node
Connector for maintenance
IP Bus address setting
ER Bus cable connector

Instrumentation & Automation Education Center (IAEC) Professional Instrument Engineer Training Program
Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

CS3000
CS3000 System
System Configuration
Configuration FFCS
FFCS
Bus cable connection :FFCS

HIS Max : 16 station/domain

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Yokogawa (Thailand) Ltd. CS3000 Maintenance Training Course

17
Nodes Picture of FFCS

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Nodes Picture of FFCS

IO Modules CPU Card

Power Supply Unit

V net coupler unit Bus 1 V net coupler unit Bus 2

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18
Node in FFCS Architecture

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Node in FFCS Architecture

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19
V net Cable

Using VLnet interface card

Cable : Thin coax. cable with BNC connector (10Base2 comp.)
V net - 10Base5 cable up to 500 m.
- 10Base2 cable up to 185 m.
Communication speed : 10Mbps
High reliable token passing communication
(Performance guaranteed)
Std. max. length : (10Base2) + 0.4(10Base5) < 185 m
Max. length : 20 km with optical repeater
1.6 km with coax. repeater
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Control Bus Interface Card (VF701)

SW 1 : Set Domain SW 2 : Set Station

BNC connector BUS 1

BNC connector BUS 2

V net Interface card

Dual redundant V net

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20
Control Bus Interface Card (VF701)
Installation VF701 CARD in PCI slot computer.

VF701 CARD

PCI SLOT
COMPUTER

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Connet Vnet (VF701)

Terminator

Three Connector

VF701 CARD

BUS 2 BUS 1 NAME PAGE

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21
Connet Vnet Cable

CONNECT V-NET CABLE BUS 1

CONNECT V-NET CABLE BUS 2

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CS3000
CS3000 System
System Configuration
Configuration FFCS -L
FFCS-L

HIS0164 HIS0163 HIS0162

Eng

V net

MAX : LOCAL NODE 3

FCS0101 FCS0102 FCS0103
MAX : REMOTE NODE

ESB BUS

LOCAL NODE

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22
CS3000
CS3000 System
System Configuration
Configuration FFCS -L
FFCS-L
8 FIO slots Vnet/IP

EC401 ESB bus coupler (Note) CP451 CPU module Power supply unit

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Control Bus Interface Card (VI701)

SW 1 : Set Domain SW 2 : Set Station

VI701 Specification
Interface: PCI/PCI-X
32bits
3.3V/5.0V
Mac Address: Vnet/IP bus1
Vnet/IP bus2
Vnet/IP on TCP/IP
Ethernet (for Open)

BNC connector BUS 2 BNC connector BUS 1

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23
Control Bus Interface Card (VI701)

L2SW (Switching Hub)

CAT5E UTP Cables

Fiber Optics Cables

Note : L3SW* (for multi domain)

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Actual System Configuration

HIS1 HIS2 HIS3

Eng

L2SW

FFCS-
FFCS-L FFCS-
FFCS-L

Vnet/IP bus1

Vnet/IP bus2
FFCS-
FFCS-L

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24
Actual System Configuration
Domain 1 Domain 2

HIS1 HIS2 HIS3 HIS4 HIS5

Eng

L3SW

L2SW L2SW

FFCS-
FFCS-L FFCS-
FFCS-L FFCS-
FFCS-L FFCS-
FFCS-L FFCS-
FFCS-L FFCS-
FFCS-L

Vnet/IP bus1 Vnet/IP bus2

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Ethernet

Hub Link 10/100 Mbps or 1 Gbps

Network Cable (RJ-45connector)
Network Interface Card

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25
CENTUM CS3000 Networks Specification

Ethernet
General
Communication
HIS0164 HIS0163

Vnet

Terminator ( 50 ohm ) Controller Terminator ( 50 ohm )

Communication

FCS0101

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HIS Communication Function Overview

CS3000

1. Both Vnet and Ethernet are mandatory.

2. Ethernet is always used for communications in HIS-HIS. If a failure occurs on Ethernet,
communications are not switched to Vnet. (This is to protect the control bus and FCS in a large
scale system).
3. TCP/IP socket communications in HIS/FCS are made via Vnet.

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26
Ethernet Communication Load

A CENTUM CS3000 system uses two networks V net and Ethernet for control
communication and management data communication.

Need for Ethernet

In CENTUM CS1000 system, Ethernet is not essential. For a small-scale
CENTUM CS1000 system, Ethernet is essential for a CENTUM CS3000
system . Ethernet is used according to the world standard interface protocol
for transmitting large amounts of data, file transfer, and file sharing.
A CENTUM CS1000 system has a function to switch over the route of
communication from Ethernet to Vnet automatically in case Ethernet fails;
however, this switching does not occur in a CNTUM CS3000 system

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Data Carried on Ethernet

The data transmitted by the following processes are carried on Ethernet:

1. Data base equalization ( between an HIS in which the engineering
function is installed and other HISs ).
2. Collection of data for the sequence table, drawing, SEBOL, SFC status
displays ( between an HIS in which the engineering function is installed
and other HISs ).
3. Other-station trend ( between HISs ).
4. Invocation of download, IOM download, and tuning parameter save commands
via a status display windows ( between an HIS in which the engineering function
is installed and other HISs ).
5. Equalization of recipe data ( between HISs ).
6. Client/Server system control in the process management function ( between HISs ).
7. Data communication via the open interface ( between an upper-level computer
and an HISs ).

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Vnet Communication Load

The Vnet bus for control data communication can transmit a large a mount of data at
high speed, bus its carrying capacity is not limitless. Although it is difficult to forecast
actual operation and hence Vnet load precisely, estimate the Vnet load during system
engineering to prevent overload.

Factors That Affect Vnet Communication Load

The following factors affect the Vnet communication load:
Time equalization communication
FCS self-diagnostics communication
FCS alarm summary communication
Link transmission communication
Trend data acquisition communication
Alarm communication
Communication for operation panels

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Monitoring the Vnet Communication Load

The current communication load of Vnet can be monitored by carrying out the vhpload command in
the < CS3000\Net\Tool > folder.

Before the factory acceptance test, check that the Vnet communication load does not exceed 60%
under typical operations.

Where,
Vnet Load = Vnet communication load in present.
The frequency of the token per minute = Number of the times the token circles the Vnet per minute.
The number of STN = Number of stations connected on Vnet bus.
The number of GAP = Number of disconnections in the stations numbers.

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System Setting

If I want to startup the Field Control Station.

How can do it ?

!*@ ?

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1. Confirming The Project

Type of project :Three are three type of projects

Default Project Current Project

User-Defined Project

1. Default Project : The first time engineering work for a project preformed on the default project.
This project is download to the FCS and HIS.
This project is downloadable off-line to the FCS of the target system.
2. Current Project : When any one of the FCS created in default project is successfully download,
the attribute of project change from default project to a current project. Online
engineering become enabled.
3. User-Defined Project : For test function.

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29
2. Networks Setup

Ethernet
HIS0164 HIS0163

FCS0101

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2.1 Ethernet [ IP Address ]

IP address: 172:17:<domain>:<station>
Subnet mask: 255:255:0:0
Default gateway: No setting is required

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2.2 VL net Interface card [ IP Address ]

SW 1 : Set Domain SW 2 : Set Station

Ex.( HIS0164 )

Domain Setting Station Setting

: odd 0 0 16 8 4 2 1 : odd 64 32 16 8 4 2 1
Bit : 1 2 3 4 5 6 7 8 Bit : 1 2 3 4 5 6 7 8
: 0 0 0 0 0 0 0 1 : 0 1 0 0 0 0 0 0

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2.3 Controller Bus Vnet [ IP Address ]

IP address: 172.16.<domain>.<station>
Subnet mask: 255.255.0.0
Default gateway: No setting is required

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31
2.3.1 Controller Bus VnetIP Bus1 [ IP Address ]

1 3

IP address: 192.168.<domain>.<station>
Subnet mask: 255.255.255.0
Default gateway: No setting is required

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2.3.2 Controller Bus VnetIP Bus2 [ IP Address ]

1 3

IP address: 192.168.<128+domain>.<129+station>
Subnet mask: 255.255.255.0
Default gateway: No setting is required

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32
2.4 Computer Name ( Station Name ) and Workgroup

A station name is a name uniquely specified according to the Control bus address in
the CS3000 system..

HISddss : dd is a domain number and ss is a station number

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2.5 Field Control Station ( FCS ) IP Address

Domain

Station

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33
2.6 Connection

Ethernet

HIS0164 HIS0163

Vnet
Terminator ( 50 ohm ) Terminator ( 50 ohm )

FCS0101

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Check Network

C:\>ping <IP Address>

Successful

IP Address

Unsuccessful

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Check Referenced database

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OFF LINE DOWNLOAD TO FCS

Confirming the hardware

Download the project common

Download the contents: ( Common )
1. Station Configuration
2. Security definition

Download the HIS

Download the items defined by HIS builder for
each HIS to the HIS all at once.

Download the FCS

Download off-line the items defined by FCS
builder for each FCS.
! All function of FCS will be stop.
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Note

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36