S5 FCS Functions

YOKOGAWA TRAINING Section 5.
CS3000 FCS Functions

SECTION 5

CS3000
FCS FUNCTIONS

CONTENTS

5 FCS FUNCTIONS____________________________________________________ 5-2
5.1 FCS DEFINITION _____________________________________________________ 5-2
5.1.1 Creating A New FCS _________________________________________________________ 5-2
5.1.2 FCS Property Configuration____________________________________________________ 5-3
5.2 FCS CONSTANTS _____________________________________________________ 5-5
5.2.1 Definition Item______________________________________________________________ 5-5
5.2.2 Detailed Setting Items ________________________________________________________ 5-6
5.3 Idle Time and Scan Rate Considerations ___________________________________ 5-8
5.4 Process I/O Definition - LFCS/PFCS_______________________________________ 5-9
5.4.1 Procedure __________________________________________________________________ 5-9
5.4.2 Node Definition ____________________________________________________________ 5-10
5.4.3 Configuration ______________________________________________________________ 5-12
5.5 Process I/O Definition - KFCS ___________________________________________ 5-15
5.5.1 Procedure _________________________________________________________________ 5-15
5.5.2 Configuration ______________________________________________________________ 5-16
5.6 Process I/O Definition - Common ________________________________________ 5-17
5.6.1 Detailed Definition for Analog I/O _____________________________________________ 5-17
5.6.2 Parameters for Relay & Contact Inputs/Outputs ___________________________________ 5-26
5.7 PLC Communications__________________________________________________ 5-31
5.7.1 Subsystem Data Identification _________________________________________________ 5-32
5.7.2 Communication Specifications - Modbus ________________________________________ 5-34
5.7.3 Setting Items from System View - Modbus _______________________________________ 5-36
5.7.4 Setting Items in the Communication I/O Definition Builder - Modbus __________________ 5-39
5.7.5 Bit Configuration ___________________________________________________________ 5-45

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YOKOGAWA TRAINING Section 5. CS3000 FCS Functions

5 FCS FUNCTIONS

Objectives: This sections covers common functions related to the FCS. The trainee will learn
how to set up the basic FCS parameters that need to be defined before control functions can
be defined.

5.1 FCS DEFINITION

5.1.1 Creating A New FCS

When a project is created, an FCS is automatically created. A new FCS can be added in one
of two ways:

1. Select [FILE] [CREATE NEW] [FCS]
2. Click on an existing FCS in the System View and drag it to the Project Name.

A dialog box will appear titled Create New FCS. The items to configure are as follows:

Type
Constant
Constant2
State Transition
Line
Network
Edit

See below for detailed information on configuration of these items. A new folder within the
project will appear titled: FCSxxyy, where xx is the Domain number and yy is the Station
number.

Within the FCS folder are eight sub-folders:

CONFIGURATION contains the FCS configuration items
SEQ LIBRARY contains SEBOL definition items
IOM contains I/O card and point definition items
SWITCH contains internal switch definition items
MESSAGE contains message definition items
FUNCTION BLOCK contains control drawings for defining plant control
functions
DISPLAY contains control drawings in graphical display format
APPLICATION

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5.1.2 FCS Property Configuration

The PROPERTIES dialog box appears for an FCS under the following circumstances:

1. The FCS is first created
2. Clicking on StnDef in the Configuration Folder of an existing FCS with the right mouse
button and selecting properties.

There are five tabs in the dialog box and the configuration items within each are as follows:

5.1.2.1 Type

Station type (only available when first defining project)

Select from the different types of FCSs available according to Section 2.4.2
(System Configuration)

Database Type (only available when first defining project)

Select from the different module mixes appropriate for your application
according to Section 2.4.4 (System Configuration).

Station Address

1. Station Number a number between 1 and 64. Note that it is the
convention to start from 1 and count-up for each new FCS. This
address must match the address on the CPU card.
2. Domain Number this number must match the domain on the CPU
card

5.1.2.2 Constant

Fast/Medium Scan Enable the fast and medium scan facility in the FCS.
Fast & medium scan can be set between 50 and 1000 msec, although the menu
provides 200 and 500 msec only. Any function block set to fast or medium
scan will have this scan rate. See section 5.3 for design considerations when
using scan rates.

MC Block Set the pulse width (seconds) for the output pulsing of a Motor
Control block. This, and serial start up are discussed further in section 6.2.

Options Select from a list of optional software to be loaded into the FCS and
add it to the list (eg, dual redundant serial card software)

MLD-SW AUT/CAS Defines the function of the AUT/CAS mode for this
module. See section 6.2 for more details.

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Action When Changing IOM If Block IOP is selected, when a single
analog card is removed, all cards in the same nest go to IOP

Action Type of SEBOL drive Statement - There are 3 action types of
SEBOL drive statement that may be specified. See the section on SEBOL
for the different action types for the "drive" statement.

Blocks with User-Defined Data Items - When using blocks with user-defined
data items (SFC block, unit instrument), a specific area for the user-defined
blocks needs to be specified. [Number of Block Type] displays the allowed
number of block types for the current type of FCS database. [Block-type start
number] may be set with reference of the [Number of Block Type]. For
example, if the allowed number of block types is 20 for both FCS0101 and
FCS0102, and the [Block-type start number] for FCS0101 is set to 0, the areas
from 0 to 19 is re-served for FCS0101. Thus the [Block-type start number] for
FCS0102 may be set to 20 or greater.

5.1.2.3 Constant2

SS-DUAL PV Update during Deviation Alarm - When checked, if a
deviation alarm occurs when the switch position is 3, the data status of PV will
become BAD but the PV itself will continue to update vary with the selected
input signal. The default is not checked, so that when a deviation alarm
occurs, the SS-DUAL will hold its current PV.

5.1.2.4 Line

Define dual-redundant RIO Bus (see Section 1) and if repeaters are installed.
Only available when first defining project.
5.1.2.5 Network

Refer to the Section 2 on System Configuration for more details

5.1.2.6 Edit

Define if control drawing builder is being used. If not selected, function block
definition table is used. Only available when first defining project.
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5.2 FCS CONSTANTS

The FCS Definition panel appears when the StnDef icon is double clicked. Note that not all
the tabs appear when first called up. These appear when Detailed setting Items in the View
menu is selected. The following tab items appear:

Definition Item
Detailed Setting Items

5.2.1 Definition Item

5.2.1.1 Start Condition

The start condition determines which method to be used, initial cold start or restart,
to initiate the FCS, upon turning on the power to FCS which was in the power
shutoff status. FCS performs either initial cold start or restart according to the
specified start condition as follows:

Manual - Initial Cold Start
Auto - Restart
Time - Initial Cold Start after long term power failure
- Restart after short term power failure

See IM 33S1B30-01E Section C2 for more
details on the Start Operation.

5.2.1.2 Digital Filter Coefficient

There are three kinds of digital filter coefficients. These digital filter coefficients are
set by the FCS Constant Definition builder for each FCS.

Digital Filter Coefficient 1: 0 to 1.00 (0.01 unit)

The defaults for these digital filter coefficients are set to the values indicated below.

Digital Filter Coefficient 1: 0.5 - (When the digital filter coefficient is 0.5
and scan period is 1 second, the time constant is 1 second)
Digital Filter Coefficient 2: 0.75 - (When the digital filter coefficient is
0.75 and scan period is 1 second, the time constant is 3 seconds)
Digital Filter Coefficient 3: 0.875 - (When the digital filter coefficient is
0.875 and scan period is 1 second, the time constant is 7 seconds)
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5.2.2 Detailed Setting Items

Defines the operation group in which the FCS resides.

5.2.2.1 Windup Operation

Windup operation is a preparatory processing for organizing time-series data that are
required for control operations. The function blocks input signal processing, control
processing, calculation processing and alarm processing executed during windup
operation are executed in the same manner as in normal operation. All output signal
processing, except for the one that outputs control output signals to the process
output terminal, are executed in the same manner as in normal operation.

Sequence table blocks dont operate while windup operation is running.

The windup operation time is set on the FCS constant definition builder.
Wind Up Time: Set 0 to 100 (sec.).
The default is 60 sec.

5.2.2.2 Idle Time in Processing at FCS

The setting of the processing executed in the idle time in FCSs CPU is defined in
SEBOL/User C time ratio on the FCS constant definition builder. This time
ratio is set as [100 %] as default, means the total idle time of the FCS CPU is used by
SEBOL.

5.2.2.3 Repeated Warning Alarm

The repeated warning alarm retransmits a process alarm message to notify the
operator that a critical alarm is continuing to occur.

The cycle of the repeated warning alarm is defined for each control station in the
FCS Constant Definition Builder.

Repeated warning alarm cycle: The setting value is between 1 to 3600
seconds.
Default is 600 seconds

5.2.2.4 Alarm Mask Specification for Initial Cold Start

The repeated warning alarm has a function in which at initial cold start (include
recovery from a long period of power failure) of the FCS, only the high-priority
alarms are picked up from all the alarms and issued to the operation and monitoring
function.
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When the initial cold start for the FCS is executed, as a rule, only the alarms that
were newly activated after start are transmitted to the operation and monitoring
function by the alarm mask function. However, for the alarms that are set as repeated
warning, if alarm is in process, the process alarm message is transmitted even though
it was not newly activated.

However, if it is set as alarm mask disabled in the FCS constant definition builder,
every alarm that is in progress will be classified as newly activated, and the process
alarm messages will be issued at initial cold start.

5.2.2.5 Inter-Station Communication Period

The inter-station communication period is the time required to complete all inter-
station data link processing within an FCS. It is specified in the FCS constant
definition builder as an FCS-specific constant. The default is one second.

5.2.2.6 Re-transmission skip when Communication Error detected

When a communication error is detected during inter-station data link processing,
interstation communication transmission skips for a period of time then retries the
transmission in the interval of this skip period. This re-transmission skip period is
expressed as follows:

Re-transmission skip period =
(Inter-station communication period) / (re-transmission skip time)
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5.3 Idle Time and Scan Rate Considerations

The FCS CPU performs its functions at a fixed scan rate. Generally most functions are
performed at a 1 second scan.

The highest priority tasks are the Operating System house-keeping functions and the Function
Block execution. Other tasks are performed in the time left within the scan. This period is
known as the idle time.

O/S
Fns
Function Block
Processing
Idle Time
Scan 1 Scan 2 Scan 3
200 msec
Function Block
Processing
Idle Time
Read Inputs
from FIO
card
Write outputs
to FIO card

O/S Fns The Operating System functions also include the Vnet functions, such as
communication of data to the HIS, and ADLs to other FCS. This has the highest
priority.

Function Block Processing this includes reading the required I/O from the FIO (or
SIO or RIO) bus card, performing all of the basic scan (1 sec) function block
processing (except SEBOL, C and SFCs), and writing the outputs to the FIO card.

Idle Time all of the low priority tasks are performed during the idle time. This
includes SEBOL and C programs. There is no guarantee that these functions will be
completed within the scan, or even at all, if there is no idle time.

Idle time is monitored on the FCS Status Display (HIS Operator screen) and is expressed in
seconds/minute. It is an average of the idle time from all of the scans. Thus:

an idle time of 60 secs/minutes means no load
an idle time of 0 secs/minute means full load

If the function block processing takes more than 1 second, the CPU will complete the rest of
the processing in the next scan (after the operating system functions) before starting the next
function block processing cycle. As such, the FCS will continue to control the plant
satisfactorily. However, timers will run slow, as these are actually counters that count 1
second per scan.

Fast and Medium scan blocks are executed during the period between the system functions
and the end of the cycle. Each of these have an idle time, and the total idle time is
significantly affect by the processing of high speed blocks.
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5.4 Process I/O Definition - LFCS/PFCS

The physical specification and installation of process I/O was described in section 1, System
Overview. This section described the process of defining I/O in software through System
View.

5.4.1 Procedure

First, a NODE must be created. This is a subfolder within the IOM folder. The total number
of Nodes that can be created for one FCS is 8. Once these are created, I/O cards can be
placed within them

To create a new NODE and I/O module:

1. Open an FCS folder
2. Click on the IOM folder
3. Either Select [Create New] from the File menu
Or Click on the IOM folder with the right mouse button and select [Create
New]
4. If the control station is a PFCS then goto step 6. If it is a LFCS, then a Node must be
created for the IOM to be placed in. Select [NODE]
5. Select the node number and click on [OK]
6. Select [Create New], [IOM]
7. A dialog box appears where the nest and card type are selected. See Section 1 for details
of the nests and cards available.

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5.4.2 Node Definition

When a new LFCS is added, one node is automatically created. You can create more nodes,
delete existing nodes and change node properties.

The following are node setting items:

Node Number

The node number is a number to identify a node, which is set between 1 to 8.
The default is 1. The value set must match the dip switches on the RIO bus
card of the node.

Dual-Redundant Power Supply

Select Yes or No for dual-redundant power supply. The nodes usually
supplied have dual redundant power supplies.

Installed Method

Select Cabinet or Rack to install nodes. The nodes supplied here are rack
mounted.

HKU Set

Select Yes if you use a housekeeping unit (HKU), No if you do not. The
default is No. If the air aspiration and exhaustion temperatures are 35
degrees C or more and 40 degrees C or more in the I/O Expansion Cabinet
respectively, the HKU turns on a fan to check a rise in the temperature.

Component Number

The component number is a number given to the cabinet to install FCS units,
which is used to identify where to connect a cable. Up to 8 characters can be
used for the number. No characters are entered as the default. This field may
be left blank.

Node Comment

Up to 24 single-byte characters or 12 double-byte characters can be used for
the node comment. No characters are entered at the default. This field may be
left blank.

Start Mode

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This is the start mode on I/O units. Set time within 1 to 16,000 msec, or select
MAN (manual). The default is 2,000 msec. This item is set with for each
I/O module defined.

Initial Cold (MAN) Start for Process I/O area

Initial cold start for process I/O is started with the value the output
module actually outputs at operation start. An initial cold start is
executed for recovery from prolonged power failure, power
disconnection for maintenance, or termination of transmission due to
transient failure.

The following describes the output operation of initial cold start for
process I/O area.

Upon completion of maintenance of power recovery, output is
started from tight shut status (analog output) or from OFF status
(contact output).
For recovery from termination of transmission due to transient
failure, output is started with the actual output value of PIO
immediately before recovery.

Restart for Process I/O area

Restart for Process I/O area is a start operation in which output
operation is started after the output value immediately before is
recovered. Restart is executed at recovery from momentary power
failure.

The following describes the output operation of restart operation for
process I/O area.

Begin output after restoring the output value to the saved output
value immediately before the power failure.
Even though output data in the output module is erased by a power
failure, the RIO bus interface card (RB301) independently restores
the last output value.

High Speed Read Data

Select Yes or No for high-speed read data of I/O units. The default is
No. This item is set with each I/O module defined.
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5.4.3 Configuration

5.4.3.1 Identifiers of Process Inputs/Outputs

Process inputs/outputs are identified with element numbers. The structure of
element numbers is shown below.

%Znnuscc

where:
%Z: Process input/output identifier (fixed as %Z)
nn: Always 01 for a CENTUM CS 1000s PFCS and CENTUM CS
3000s SFCS;
or node number (01 to 08) for a CENTUM CS 3000s LFCS
u: Unit number (1 to 5)
s: Slot number (1 to 4)
cc: Terminal number (01 to 64)

In factory plant operation, for monitoring purposes you may be required to assign a
tag name for each point of process input/output signals. In this case, a tag name or a
user defined label can be assigned to each point.

Process inputs/outputs can be accessed from a SEBOL program or general software
for Windows such as Visual Basic programs by specifying their element numbers,
tag names, or user-defined labels.

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5.4.3.2 Process Inputs/Outputs Definition

Parameters of process inputs/outputs are shown below for each IOM category.

Table 5.1 Parameters for Each IOM Category

*1: CENTUM CS 3000 LFCS only.

For more details each of these items see
IM 33S1B30-01E, Section B3.3

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5.4.3.3 Access

To configure IOM definition, double click on the IOM in the System View. This
provides a display with basic I/O definition. Not all items shown in the above table
are displayed. They are broken into three categories:

1. Basic I/O Definition (eg, Signal Details, Signal Conversion, Service
Comment)
2. Detailed I/O Definition (eg, Range, Units, Tagname, etc)
3. Set Detail (eg, Burnout Details, Input Open detection, etc)

To access detailed definition items, select [Detailed Setting Items] from the VIEW
menu.

For analog I/O, to access specific card details, select [SET DETAILS] from the
TOOLS menu.

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5.5 Process I/O Definition - KFCS

The physical specification and installation of process I/O was described in section 1, System
Overview. This section described the process of defining I/O in software through System
View.

5.5.1 Procedure

First, a NODE must be created. This is a subfolder within the IOM folder. The total number
of Nodes that can be created for one FCS is 10. Once these are created, I/O cards can be
placed within them

To create a new NODE:

1. Open an FCS folder
2. Click on the IOM folder
3. Either Select [Create New] from the File menu
Or Click on the IOM folder with the right mouse button and select [Create New]
4. Select [NODE]
5. Select the node number, select LOCAL or REMOTE (see note) and click on [OK]

Note that before a Remote Node can be created, a Local Node must be created with an ER bus
card in it. Then, when Remote Node is selected, select from the list of configured ER cards to
connect this node to.

To create an IOM:

1. Click on the required NODE.
2. Select [Create New], [IOM]
3. A dialog box appears where the nest and card type are selected. See Section 1 for
details of the cards available.

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5.5.2 Configuration

5.5.2.1 Identifiers of Process Inputs/Outputs

Process inputs/outputs are identified with element numbers. The structure of
element numbers is shown below.

%Znns1cc

where:
%Z: Process input/output identifier (fixed as %Z)
nn: Node number (01 to 10)
s: Slot number (1 to 8)
1: always 1
cc: Terminal number (01 to 64)

In factory plant operation, for monitoring purposes you may be required to assign a
tag name for each point of process input/output signals. In this case, a tag name or a
user defined label can be assigned to each point.

Process inputs/outputs can be accessed from a SEBOL program or general software
for Windows such as Visual Basic programs by specifying their element numbers,
tag names, or user-defined labels.

5.5.2.2 Access

To configure IOM definition, double click on the IOM in the System View. This
provides a display with basic I/O definition. Not all items are displayed. They are
broken into three categories:

1. Basic I/O Definition (eg, Signal Details, Signal Conversion, Service
Comment)
2. Detailed I/O Definition (eg, Range, Units, Tagname, etc)
3. Set Detail (eg, Burnout Details, Input Open detection, etc)

To access detailed definition items, select [Detailed Setting Items] from the
VIEW menu.

For Analog I/O, to access specific card details, select [SET DETAILS] from the
TOOLS menu.

For Digital I/O, to access specific card details, click on the card with the right
mouse button, select PROPERTIES and SET DETAILS.

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5.6 Process I/O Definition - Common
5.6.1 Detailed Definition for Analog I/O

Description of each parameter to be set for IOMs classified as control inputs/outputs is given
below:

Items Defined in the IOM Definition Builder Window

Signal details
Signal conversion
Service comment
Range
Unit of range
Details setting
Dual Redundant
P&ID tag name
User-defined label

Items Defined through TOOLS SET DETAILS in the IOM Definition Builder Window

Input open detection (IOPE)
IOP Detection Level (SIOP)
High-limit detection level (HIIOP)
Low-limit detection level (LOIOP)
Output open detection (OOPE)
Fallback (FBEN)
Fallback output value (FBOUT)
Total resistance (RESIST)
Input filter (PLFL)
Transmitter power supply (VTTSEL)
Square root extraction (SQRT)
SQRT low input cut value (LCUT)
Reference Junction Compensation (RJCD)
OOP output clearance specification (OPCLS)
OOP output clearance time (TOPCLS)

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5.6.1.1 Detailed Definition Items

Signal Details - Control I/O

This item is used to specify the IOM type. This item is defined in the IOM definition
builder. The following IOM types can be selected:

Current input (AAM11)
Voltage input (AAM11)
Current input/Single function (AAM10)
Voltage input/Single function (AAM10)
mV input (AAM21)
Thermocouple input (AAM21)
Resistance temperature detector input (AAM21)
Potentiometer input (AAM21)
Pulse input (APM11)
Current output (AAM51)
Voltage output (AAM51)
Current output/Single function (AAM50)

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Signal Conversion - Control I/O

This item is defined in the IOM definition builder. The selection list varies with the IOM
type. The selection list and default value for each IOM type are shown in the table below:

Table 5.2 - Selection Lists and Default Values for Signal Conversion

Service Comment - Control I/O

These items are defined in the IOM definition builder. A character string consisting of up
to 40 characters can be entered.

The service comment setting is optional and can be left blank.

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Range - Control I/O

The high-limit and low-limit of the terminal measurement range are defined in the IOM
definition builder.

Values which can be selected as the high-limit and low-limit vary with the IOM type and
signal conversion type. Most are fixed. Those that can be changed are given in the table
below:

Low Limit High Limit IOM Type Signal Conversion Units
Selection
Range
Default Selection
Range
Default
Voltage input (AAM11) No conversion V 0 to 10 1 0 to 10 5
mV input (AAM21) No conversion mV -50 to 150 -50 -50 to 150 150
Potentiometer input (AAM21) No conversion Ohm 100 to 30000 100 0 to 30000 2000

Unit of Range - Control I/O

The unit of measurement range is defined in the IOM definition builder. Selectable units
of measurement range vary with the IOM type, although all except thermocouple inputs
are fixed and cannot be changed.

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Details Setting - Control I/O

The IOM details are defined in the IOM definition builder. Selectable items vary with the
IOM type. The selection list and default value for each IOM type are shown in the table
below.

Table 5.3 - Selection Lists and Default Values for IOM Details Setting

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Dual Redundant - Control I/O

The dual redundant can be specified Enable/Disable in the IOM definition builder. The
dual redundant can be designated to the current output module AAM51 or AAM50, only
for the odd numbered IOM. The IOM is called duplex source.

If the Dual redundant is defined as Enable to the IOM, the signal of the duplex source
will be copied to its corresponding duplex destination. Once the signal is copied,
definition change on the duplex destination IOM become impossible.

The table below shows the relationship between terminal numbers of duplex source IOMs
and destination IOMs.

Table 5.4 - Dual Redundant Definition

Duplex source 1 3 5 7 9 11 13 15
Duplex destination 2 4 6 8 10 12 14 16

If the entries in the fields (e.g., Maximum Range, Dual Redundant) except for the
Signal Details field for a duplex source IOM are changed, the changes will also
reflect on the corresponding duplex destination IOM. If the dual redundant for a
duplex source IOM is set to Disabled, setting of the corresponding duplex
destination IOM will be possible. If the entry in the Signal Details field for a duplex
source IOM is changed or duplex source IOM itself is deleted, the record for the
corresponding duplex destination IOM will be deleted too.

P&ID Tag Name - Control I/O

A P&ID tag name of up to sixteen characters can be specified in the IOM definition
builder. The setting is optional, and blank as the default.

User-defined Label - Control I/O

A user-defined label of up to 16 characters (as the name of the function blocks
input/output terminal) can be specified in the IOM definition builder. The setting is
optional, and blank as the default.

The entry format of user-defined labels is as follows:
%%Mnnnnnnnnnnnnn
Where
%%: Always %%
M: One uppercase letter
nnnnnnnnnnnnn: Up to 13 alphanumeric characters

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5.6.1.2 Set Detail Items

Detect Input Open (IOPE) - Control I/O

The detection for wire breakage (input open) of the input signal can be defined in the IOM
definition builder. The default is Enabled.

This applies to all analog inputs except pulse inputs.

IOP Detection Level (SIOP) - Control I/O

The IOP detection level can be specified in the IOM definition builder. The
default setting is Disabled.

High-Limit Detection Level (HIIOP) - Control I/O

The IOP high-limit detection level can be defined in the IOM definition builder.
The level can be defined within a range of -25.0 to 125.0 (max. 5 digits, in %). If
the high-limit is defined lower than the low-limit (LIOP), an error will occur. The
default is +106.3. HIIOP can be defined only when Enabled is set for SIOP.

Low-Limit Detection Level (LOIOP) - Control I/O

The IOP low-limit detection level is defined in the IOM definition builder. The
level can be defined within a range of -25.0 to 125.0 (max. 5 digits, in %). If the
lower-limit is defined higher than the high-limit (HIOP), an error will occur. The
default is -6.3. LOIOP can be set only when Enabled is set for SIOP.

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Output Open Detection (OOPE) - Control I/O

The detection for wire breakage (output open) of the output signal can be defined in the
IOM definition builder. The default is Enabled.

This is available for current outputs only (not voltage).

Set Fallback (FBEN) - Control I/O

On the IOM definition builder, fallback may be set. The default setting is no fallback.

When check the Set Fallback item, then it is required to check the option button for
either Maintain Current Value or Output data. The default option is Maintain
Current Value.

When not check the Set Fallback item, the current value will be held when the
processor unit or the interface of the processor unit fails. However, the occurrence of
the abnormality will not be notified even when the failed processor unit or the
interface of the processor unit returns to normal state.

This is available for both current and voltage outputs.

Fallback Output Value (FBOUT) - Control I/O

The output data value (FBOUT) for fallback may be defined on IOM definition
builder. Up to 5 digits may be used for FBOUT, the range for current output is
-17.2 to 112.5 while the range for voltage output is -25.0 to 225.0 (unit: %).
There is no default setting. The output data value (FBOUT) may be defined
only when the "Set Fallback" item is checked.

All Resistance Value (RESIST) - Control I/O

The total resistance of potentiometers may be defined on the IOM definition builder. All
resistor values (RESIST) may be defined in up to 7 digits number in the range of 0 to
3000 (unit: ohm). When value is not defined, the high limit of the total resistance value
will be used. There is no default setting. This is available for potentiometer inputs only.

TE 33AU1C3-01 5-24

Pulse Input Filter (PLFL) - Control I/O

The pulse input filter function can be defined in the IOM definition builder. The default is
Disabled. This is available for pulse inputs only.

Transmitter Power Supply (VTTSEL) - Control I/O

The voltage of the pulse input transmitter power supply (APM11) can be defined
in the IOM definition builder. The voltage is defined to either 12 or 24 (V). The
default is 24.

Square Root Extraction (SQRT) - Control I/O

The square root extraction can be defined in the IOM definition builder. The default is
Disabled. Available for AAM11 module only.

SQRT Low Input Cut Value (LCUT) - Control I/O

The low input cut value for square root extraction can be defined in the IOM
definition builder. When the input signal is below the low input cut value, the
square root extraction will not be performed, the output equals to the input value.
The default is 0.6 (%). LCUT can be defined only when SQRT is selected
Enabled.

Reference Junction Compensation (RJCD) - Control I/O

The reference junction compensation can be defined in the IOM definition builder. The
default is Enabled for signal conversion other than thermocoupler type B, and is
Disabled for thermocoupler type B. Available for thermocouple inputs only.

OOP Output Clearance Specification (OPCLS) - Control I/O

OOP output clear may be specified so that to make the output into tight-shut state
automatically when a certain time period elapsed after OOP occurs. The item OOP
Output Clear may be checked on IOM definition builder. The default setting is that the
item OOP Output Clear is not checked. Available for current outputs only.

OOP Output Clearance Time (TOPCLS) - Control I/O

OOP output clear time is the time limit to make the output into tight-shut state
automatically after OOP occurred. OOP output clear time may be set on the IOM
definition builder. OOP output clear time may be defined in an up to 4 digits value in the
range of 0 to 25.5 (unit: seconds). The default setting is 4 seconds.

TE 33AU1C3-01 5-25
5.6.2 Parameters for Relay & Contact Inputs/Outputs

Description of each parameter to be set for IOMs classified as relay inputs/outputs,
contact terminals or contact connectors are given below.

Items Defined in the IOM Definition Builder Window

Point mode
P&ID tag name
Tag name
Tag comment
Switch position label
Label direction
Label colors
Security level
Tag mark
Upper window
Help window

Items Defined through SET DETAILS in the PROPERTIES dialog box

Filter time
Detection edge
Dual redundant
Fallback

Items Defined through the TOOLS SET DETAILS in the IOM builder

Time-proportional ON/OFF pulse period
Operation start offset

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5.6.2.1 Detailed Items

Point Mode

The point mode of each terminal of a module can be specified in the IOM definition
builder. The available selections for the point mode and the default setting vary according
to the input/output type as shown in the table below.

Table Point Mode Setting:

Point mode
Input/output type
Selection list Default setting
Status output SO, PO SO
Pulse-width output PW (fixed) PW
Time-proportional on/off output TP TP

A time-proportional on/off output can be specified for an odd-numbered terminal of a
module. When user set the point mode for a time-proportional on/off output, the point
mode of the next terminal number (even-numbered) is automatically set to the same.

P&ID Tag Name

A P&ID tag name of up to 16 characters can be specified in the IOM definition builder.
The setting is optional, and blank as the default.

Tag Name

A tag name of up to 16 alphanumeric characters can be specified in the IOM definition
builder. The setting is optional, and blank as the default.

Tag Comment

A tag comment may be defined on the IOM definition builder. The setting is optional, and
blank as the default is blank. Up to 24 alphanumeric characters (12 double-byte
characters) may be defined as tag comment.

Switch Position Label

The switch position label can be specified in the IOM definition builder. Set ON or
OFF for each of labels 1 to 4 in the following format:

<ON/OFF for label 1>,<ON/OFF for label 2>,<ON/OFF for label 3>,<ON/OFF for label 4>

Use a comma as a separator. The default setting is as follows: ON,,OFF,ON
TE 33AU1C3-01 5-27

Label Direction

The direction in which the switch position label should be displayed, can be specified in
the IOM definition builder. Set Direct or Reverse. The default is Direct.

Label Colors

The label colors can be specified in the IOM definition builder. The default setting for
each label is R (red).

Security Level

The security level of the module data can be defined in the IOM definition builder. Select
the level from 1 to 8. The default is level 4.

Tag Mark

The tag mark type is specified in the IOM definition builder. The following are the
available selections. The default setting is Ordinary tag w/o acknowledgment.

Important tag mark without acknowledgment
General tag mark without acknowledgment
Auxiliary tag mark 1 without acknowledgment
Auxiliary tag mark 2 without acknowledgment
Important tag mark with acknowledgment
General tag mark with acknowledgment
Auxiliary tag mark 1 with acknowledgment
Auxiliary tag mark 2 with acknowledgment

Upper Window

The name of the window to be called up as the window upper in the hierarchy is specified
in the IOM definition builder. The window name must be 16 uppercase alphanumeric
characters. This setting is optional.
TE 33AU1C3-01 5-28

Help Window

The name of the Help window defined by the user must be specified in the IOM definition
builder. The setting is optional. The help message may be identified by assigning the help
window a unique ID. The entry format of the Help window name is as follows:

HWnnnn
Where
HW: Always HW
nnnn: Help ID of four-digit number

5.6.2.2 Detail Set Items Properties Sheet

Filter Time Status Input

Chattering will occur as shown below during contact input.

Figure Contact Input Chattering

Chattering may cause a malfunction of the system. To prevent malfunction, a filter
time must be defined. The filter time is set on the property sheet for the Input/Output
Module. In the system view, select the filter time from 0, 20, 40, 60 or 100
(ms). The default is 0.

Detection Edge - Pushbutton Input

Whether to detect a change from OFF to ON or from ON to OFF for a pushbutton input, is
set on the property sheet for the Input/Output Module. The detection edge can be selected
from the following choices. The default setting is OFF.

ON: Detection of OFF to ON edge
OFF: Detection of ON to OFF edge
BOTH: Detection of both OFF to ON and ON to OFF edges

TE 33AU1C3-01 5-29
Fallback Status Output

The fallback function is set on the property sheet for the Input/Output Module. The
fallback function outputs the preset fallback value when error occurs in the processor unit.
When the fallback function is enabled, the fallback type must be selected from the
following choices.

All points maintain the current values
When a fallback condition is detected, all the contacts hold their previous
ON or OFF status.

All points OFF
Turn OFF all the contacts.

Dual Redundant

The dual redundant function with the adjacent IOM can be defined in the IOM property
sheet. The default is Not checked.

5.6.2.3 Detail Set Items Tools Menu

Time-proportional ON/OFF Pulse Period

When using the Time-proportional ON/OFF Output Module of the LFCS, set a Time-
proportional ON/OFF Pulse Period between 0 and 300 (seconds) on the IOM Definition
Builder. The default is 10 seconds.

Operation Start Offset

When using the Time-proportional ON/OFF Output Module of the LFCS, set an
Operation Start Offset between 0 and 300 (seconds) on the IOM Definition Builder. The
Operation Start Offset is time setting to define the phase of ON/OFF period for each
output when using multiple time-proportional ON/OFF outputs in the same module. The
default is 0 second.

TE 33AU1C3-01 5-30

5.7 PLC Communications

The subsystem communication package is used to perform communication between the FCS
and PLC using communication I/O.

Subsystem communication packages are available for following models:

FA-M3 communication package (for use with Yokogawa Electrics FA-M3)
DARWIN communication package (for use with Yokogawa Electrics DARWIN
series data acquisition unit DA100, hybrid recorder DR230, DR231, DR241 and
DR242)
Gas chromatography communication package (for use with Yokogawa Electrics
GC1000/FC6/GC8)
MELSEC-A communication package (for use with Mitsubishi Electrics general
use PC, MELSEC-A)
Modbus communication package (for use with AEG Schneiders Modicon, and
Yaskawa Electrics Memocon-SC)
A-B communication package (for use with Allen Bradleys PLC-5 family)
SYSMAC communication package (for use with Omrons SYSMAC C series)
Siemens communication package (for use with Siemens SIEMENS PLS
SIMATIC S5)

The following communication modules are used to connect the CS 1000/CS 3000 with the
subsystem.

ALR111: RS232 communication card (KFCS)
ALR121: RS422/485 communication card (KFCS)
ALE111: Ethernet communications card (KFCS)
ACM11: RS-232C communication module (LFCS)
ACM12: RS-422/RS-485 communication module (LFCS)
ACM21: RS-232C communication card (LFCS) (*1) (*2)
ACM22: RS-422/RS-485 communication card (LFCS) (*1) (*2)

*1: ACM21/ACM22 communication cards may be used in PFCS.
*2: ACM21/ACM22 communication cards may be used in SFCS.

TE 33AU1C3-01 5-31
5.7.1 Subsystem Data Identification

In subsystem communication, subsystem data are identified by the element numbers. This
section explains the identification method of the analog data and contact I/O data that are
assigned to the regulatory control block, sequence control block and other blocks.

Element Numbers for Data Handled by Subsystem

Data handled by subsystem are identified by their element numbers. There are the
following two types of element numbers.

Table Element Numbers for Subsystem Data

Access method Element number Explanation
Word data %WWnnnn nnnn is a number within the area. The head is 0001.
Bit data %WBnnnnbb nnnn is a number within the area. The head is 0001. bb is
a bit number (1 to 16) within the word. The most
significant bit is 1.

The same data may be accessed both in word units and bit units. For example, each bit
in the 16-bit data %WW0020 can be accessed respectively as %WB002001 to
%WB002016.

Figure Identifying Data in Word Units and Bit Units

TE 33AU1C3-01 5-32
The following figure illustrates an example of connecting with word data.

Figure Subsystem Data (Word Data) Link Example

Data Items Handled by a Subsystem

Table Data Items for Subsystem Data

Identifier Data item Description
%WWnnnn PV Word data access. The data format depends on the
definition in the communication definition
PV Bit data access. On/Off of the specified bit is returned as 1
or 0.
PV16 A 16-bit data starting with LSB (the Least Significant Bit)
first is returned.
%WBnnnnbb
OPMK Information for the operation mark assigned to the relevant
bit is returned.

When the data identified by %WB is accessed by PV16, 16 bits are stored starting with the bit
specified by %WBnnnnbb as the most significant bit, towards the least significant bit (when
the word boundary is reached, advances to the next word).

TE 33AU1C3-01 5-33
5.7.2 Communication Specifications - Modbus

5.7.2.1 Communication Capacity - Modbus

The capacity specific to Modbus when performing subsystem communication with a
Modbus PLC is indicated below:

Table Capacity of Communications Between FCS and Modbus PLC

Item Maximum quantity Explanation of words
Amount of data that can be
communicated with one
communication module
1000 words (KFCS)
500 words (LFCS)
(1 word=16 bits)

Restricted by the maximum amount may
be accessed from the regulatory control
block/sequence control block.
Number of subsystem stations
that can be communicated with
one communication module
30 stations
Applies to RS422/485 communications.
RS232 is point-to-point communications
only.

TE 33AU1C3-01 5-34
5.7.2.2 Transmission Specifications - Modbus

The transmission specifications when performing subsystem communication with the
Modbus PLC are indicated below:

Table Transmission Specifications - Modbus

TE 33AU1C3-01 5-35
5.7.3 Setting Items from System View - Modbus

This section explains the setting items pertaining to the Modbus PLC. The following items
can be set using the Detail setting tab strip of the New IOM dialog box called from the system
view:

Connected equipment
Transmission speed
Parity
Data bit
Stop bit
RS control
DR check
CD check
Communication error handling
Options

Connected Equipment - Modbus

This sets the type of the equipment (subsystem) connected. This setting is done using
the Detail setting tab strip of the New IOM dialog box called from the system view.
When using Modbus PC, select MODBUS as the connected equipment. Always
perform this setting since the default is FA-M3.

Transmission Speed - Modbus

This sets the transmission speed between the communication module and Modbus PC.
This setting is done using the Detail setting tab strip of the New IOM dialog box
called from the system view. The transmission speed can be selected from the
following options:

1200
2400
4800
9600
19200

The default setting is 19200. The recommended value for the transmission speed is
19200.

TE 33AU1C3-01 5-36
Parity - Modbus

This sets the method for checking the parity of the subsystem data to be transmitted.
called from the system view. The parity can be selected from the following options:

Odd parity
Even parity
No parity

The default is even parity. The recommended setting for the parity is even parity.
When the transmission speed is set to 19200, the no parity choice cannot be set.

Data bit - Modbus

This sets the data bit length of the subsystem data to be transmitted. This setting is
done using the Detail setting tab strip of the New IOM dialog box called from the
system view. When using a Modbus PC, select 8 bits for the data bit length. The
default is 8 bits.

CAUTION

For the Modbus PLC, always select 8 bits for the data bit length. A
communication error will occur if 7 bits is selected.

Stop Bit - Modbus

This sets the stop bit of the subsystem data to be transmitted. This setting is done
using the Detail setting tab strip of the New IOM dialog box called from the system
view. When using the Modbus PLC, select 1 bit for the stop bit.

The default is 1 bit.
2 bits cannot be used as the stop bit.

RS Control - Modbus

This sets whether or not RS control is performed during subsystem data transmission.
called from the system view. For Modbus PLC, do not place a mark in the RS
control check box to enable RS control.

The default is no mark in the RS control check box.

DR Check - Modbus

This sets whether or not DR check is performed during subsystem data transmission.
called from the system view. For Modbus PLC, it is required to enable the DR check
function by marking the DR check check box.

TE 33AU1C3-01 5-37
The default is that the DR check check box is marked.

CD Check - Modbus

This sets whether or not CD check is performed during subsystem data transmission.
called from the system view. For Modbus PLC, do not place a mark in the CD
check check box to enable the CD check.

The default is no mark in the CD check check box.

Communication Error Handling - Modbus

This sets the parameters related to communication error handling during subsystem
data transmission. This setting is done using the Detail setting tab strip of the New
IOM dialog box called from the system view. The setting items include the following
three:

No response detection time - This sets the time for detecting no response in
the Modbus PLC. The setting unit is seconds.
The setting range is 0 to 99.
The default is 4.
Number of communication retries - This sets the number of retries when a
communication error occurs.
The default is 1.
Time interval for recovery communication - This sets the time interval for
FCS to send a communication request packet to the station that a
communication error occurred. The setting unit is seconds.
The default is 30.

The recommended settings for communication error handling are the default setpoint
values.

Options - Modbus

Settings of communication parameter options vary depending on the equipment
connected. Set options by clicking the [Option] button in the Detail setting tab strip of
the New IOM dialog box called from the system view. In the case of Modbus PLC,
define a method of recovery communication at the Option 1, and 0 at the Options 2
to 4.

The default is no setting.

TE 33AU1C3-01 5-38
5.7.4 Setting Items in the Communication I/O Definition Builder - Modbus

This section explains the items set via the communication I/O definition builder with respect
to the Modbus PLC. The following items are set via the communication I/O definition
builder.

Element number
Program name
Buffer size
Station number
Device & Address
Data size
Data type
Reverse Bits
Service comment
User-definable label name

Element Number - Modbus

With respect to the address of the subsystem data buffer, the element number is indicated in
the communication I/O definition builder as shown below. The element number is not for set,
only for display.

%WWnnnn

%WW: Fixed
nnnn: For PFCS standard type: 1 to 1000 (*1)
For PFCS expansion type: 1 to 4000 (*1)
For LFCS or KFCS: 1 to 4000 (*2)

*1: Setting range on CS 1000.

TE 33AU1C3-01 5-39
Buffer Size - Modbus

This sets the size of the buffer for the communicated data. This setting is done via the
communication I/O definition builder. The range of the size that can be set is indicated
below. The setting is done in word units.

For PFCS standard type: 1 to 1000 (*1)
For PFCS expansion type: 1 to 4000 (*1)
For LFCS or KFCS: 1 to 4000 (*2)


There is no default setting.

Items for consideration when setting the buffer size are shown below:

Always set the buffer size since this is a required setting item of the
communication I/ O definition builder. Other setting items cannot be set unless
the buffer size is set.
When an odd number is used to define the size, the buffer is reserved for the
size of the next even register by adding 1.
In the case of PFCS, make sure that the total buffer size setting does not
exceed 1,000 for the standard type and 4,000 for the expansion type (*1). If the
size set exceeds these values, it will automatically be cut off to fit the range.
In the case of SFCS/LFCS, make sure that the total buffer size setting does not
exceed 4,000. If the setting exceeds 4,000 (*2), it will be automatically
adjusted to a value within the allowable range.
If the buffer size is set so that it becomes smaller than the data size setting, an
error will result and it will automatically be adjusted to fit the data size.
After properly setting the buffer size and moving to the setting in the next line,
an *(asterisk) is displayed in the sections for the program name of the
reserved area and buffer size. No setting is required for the sections marked
with asterisks.


TE 33AU1C3-01 5-40
Program Name - Modbus : PFCS/SFCS

The program name is displayed in the communication I/O definition builder as unit
number, slot number and the connected equipment name defined when the IOM was
created. Set this name as the program name.

u-s program name

u: Unit number
s: Slot number
program name: Connected equipment name defined when the IOM was
created

Program Name - Modbus : LFCS

When setting the name of the program for accessing the subsystem, entering the unit
number and slot number then the connection device name input when the I/O module
was created may be displayed on the communication I/O definition builder. This name
is the same as the program name.

n-u-s ProgramName

n: Node number
u: Unit number
s: Slot number

ProgramName: The device name for connection input when the
I/O module was created.

Program Name - Modbus : KFCS

When setting the name of the program for accessing the subsystem, entering the unit
number and slot number then the connection device name input when the I/O module
was created may be displayed on the communication I/O definition builder. This name
is the same as the program name.

K1-n-s ProgramName

n: Node number
s: Slot number

ProgramName: The device name for connection input when the
I/O module was created.

TE 33AU1C3-01 5-41
Data Size - Modbus

This sets the data size (data length) from the head address set in the Device &
Address. This setting is done via the communication I/O definition builder. The size
can be set as below in word units:

For analog input and analog output: 1 to 125 words
For contact input and contact output: 1 to 8 words

There is no default setting.

Items for consideration when setting the data size are shown below:

Up to 30 data settings are possible for each buffer.
Always set the data size since this is a required setting item for the
communication I/O definition builder. Other setting items cannot be set
unless the data size is set.
When an odd number is used to define the size, the buffer area is reserved
for the size of the next even register by adding 1.
If the set buffer size exceeds the buffer size, it will automatically be
adjusted to fit the data.
After properly setting the data size and moving to the setting in the next
line, an * (asterisk) is displayed in the sections for the size that has been
reserved, station number, device & address, data type and bit reversal.
Settings cannot be done for the sections marked with an asterisk.
The following shows the buffer size and corresponding data size.

Figure Buffer Size and Data size - Modbus

TE 33AU1C3-01 5-42
Port Number (KFCS)

Specify the port number on the ALF card through which this packet of data is
communicating. This is a value of 1 or 2.

Station Number and IP Address - Modbus

This sets the station number of the Modbus PLC. This setting is done via the
communication I/O definition builder.

If the communications is serial, then set a number between 1 and 255 in the Station
Number Field.

If the communications is ethernet, then set the PLC IP address in the IP Address
field.

Device & Address -Modbus

The head address of Modbus PLC data is set via the communication I/O definition
builder. The addresses can be set using 3 to 7 alphanumeric characters in the formats
given below:

Coil: A0xxxx, B0xxxx, X0xxxx, Y0xxxx
Input relay: A1xxxx
Link relay: ADxxxx, BDxxxx, XDxxxx, YDxxxx
Step status: ASxxxx
Input register: A3xxxx
Holding register: A4xxxx, B4xxxx, C4xxxx, X4xxxx, Y4xxxx, Z4xxxx
Constant register: ACxxxx, BCxxxx, CCxxxx, XCxxxx, YCxxxx, ZCxxxx
Step elapsed time: A5xxxx
Link register: ARxxxx, BRxxxx, CRxxxx, XRxxxx, YRxxxx, ZRxxxx
Extended register: AAxxxx, BAxxxx, CAxxxx, XAxxxx, YAxxxx,
ZAxxxx
4 byte register: AWxxxx
Special coil: SP001
Communication status:STSxxx

xxxx is the address within the Modbus PLC device. The range is 1 to 65535
(1H to FFFFH) and is set as a decimal or hexadecimal number. If it is set with
a hexadecimal number, add H at the end. Also, with respect to the xxxx
portion, the 0 prefixed at the head can be omitted. For example, A023, A0023
and A00023 are all the same address for the coil.

TE 33AU1C3-01 5-43
Data Type - Modbus

This sets data type of the subsystem data. This setting is done via the communication
I/O definition builder. The data type can be selected from the following:

Analog input (16-bit signed integer data. I16)
Analog input (16-bit unsigned integer data. U16)
Analog input (32-bit signed integer data. I32)
Analog input (32-bit unsigned integer data. U32)
Analog input (32-bit floating point data. F32)
Analog input (64-bit floating point data. F64)
Analog output (16-bit signed integer data. I16)
Analog output (16-bit unsigned integer data. U16)
Analog output (32-bit signed integer data. I32)
Analog output (32-bit unsigned integer data. U32)
Analog output (32-bit floating point data. F32)
Analog output (64-bit floating point data. F64)
Contact input (DI)
Contact output (DO)

Reverse Bits - Modbus

This sets whether or not to make the bit arrangement in FCS in reverse order of the
subsystem data. This setting is done via the communication I/O definition builder.

Service Comment - Modbus

A comment can be set. This setting is done via the communication I/O definition
builder. Service comment setting can be omitted. A character string of up to 40
single-byte or 20 double-byte characters can be set as the service comment.

User-Defined Label Name - Modbus

The name of the function block I/O terminal can be set as a user-defined label name.
This setting is done via the communication I/O definition builder. The user-defined
label name is an optional setup item. The user-defined label name can only be set
when the [optional setup items] on the [display] menu bar is selected. The user-
defined label name setting can be omitted. A character string of up to 16 single-byte
characters in the following format can be set as the user-defined label name.

%%[A-Z] [A-Z0-9]
%%: Fixed
A-Z: The third character must be an uppercase character
A-Z0-9: From the fourth letter on are alphanumeric characters

TE 33AU1C3-01 5-44
TE 33AU1C3-01 5-45
5.7.5 Bit Configuration

Many Words that are read/written between the FCS and the PLC contain digital I/O.
Up to 1000 of these can be assigned tag names.

To configure the Tag definition for these bits:

Select TOOLS Call %WB Tag Number Definition

The Tag definition table appears. The tag configuration is very similar to Switch and
Digital I/O configuration, except that the Element number needs to be defined.

The element number is created as follows:

%WBxxxxyy

Where - xxxx is the %WW number between 0000 and 1000
- yy is the bit number within that word between 01 and 16

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YOKOGAWA TRAINING Section 5.

CS3000 FCS Functions

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