Integrated Production Control System

01

CENTUM CS 3000
Our Flagship Platform for Launching
Enterprise Technology Solutions

Business Domain
ERP: Enterprise Resource Planning
Yokogawa's Enterprise Technology Solutions
for Real-Time Business Management Control Domain
MES: Manufacturing Execution System

Engineering
Enterprise
To view the enterprise's objectives through the customer's eyes, Operations Modelling
Support CONTROL Optimization
and provide management information and control system support Simulation
to meet these objectives

Technology
Safety Management
Leading-edge Technology
Fieldbus ,Interoperability

Solutions Sensor Technology

Optimum solutions that satisfy the customer's needs and expectations

Yokogawa can provide you with an optimal Enterprise Technology Solution an enterprise-wide system that integrates

management information and real-time control.

In today's highly competitive global marketplace, real-time information and control helps you to quickly meet changing
market needs and remain competitive.

CENTUM CS 3000 is our flagship control-system platform for launching Enterprise Technology Solutions.

CENTUM CS 3000 plus Yokogawa's wide application-specific experience can provide the optimum control solution for

your enterprise.

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02 03

CENTUM CS 3000 represents a new

0
era in large-scale Distributed Control

Systems (DCS). The new CENTUM

CS 3000 integrates the versatility and

reliability of its CENTUM series pre-

decessors with the open environment

of a personal computer.

Easy operation, superior control func-

0
tions, efficient engineering and cost

effectiveness. This new-era DCS will

,
quickly pay for itself in today s severe

business environment.

Its open interfaces for exchanging

CENTUM CS 3000 is a DCS for large plants information with supervisory Enter-

prise Resource Planning (ERP) and

Manufacturing Execution Systems

3
(MES) make it easy to create a stra-

tegic management information system

for your enterprise.

CENTUM CS 3000 is a scaleable,

compatible system designed to

work with your existing systems, and

grow with your business, reducing

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Total Cost of Ownership (TCO).

CS 3000 Reliability and Versatility

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 General-purpose computer
General-purpose workstation

04 System configuration Generic PC Desktop HIS Console HIS 05

Desktop HIS

Router

Desktop HIS
ENG

ACG
V net

Standard FCS
Factory LAN
Standard FCS Desktop HIS
Public digital circuit, or
Optical fiber leased line

Hard-copy unit

Open, Flexible Integrated System Printer Desktop HIS Ethernet

ENG
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Console HIS
Router
With the CENTUM CS 3000 integrated control system,
Standard
FCS
you can create an enterprise network encompassing everything from ERP ACG

and MES supervisory management information systems to the control system and field devices. Standard V net
RIO bus CENTUM CS
Node FCS
Such a system can handle everything from total operations management operation support,
Node
process management, and stock management to production planning; Optical fiber Compact FCS
PLC Fieldbus
Node
it can save energy, increase automation, and improve product quality and yield.
Node
The architecture has the flexibility to handle everything from small-scale to large-scale plants;

it can connect to existing control systems such as CENTUM CS, CENTUM-XL, and CENTUM CS 1000,

and provide a unified operator interface.

Human Interface Station (HIS) Ethernet Compact FCS

The HIS is mainly used for monitoring and Ethernet is used to link HIS, ENG and su- This combines control functions, I/O, and in-
operation it displays process variables, pervisory systems. terface to subsystems in a compact cabinet.
BCV control parameters, and alarms necessary for Communications Gateway Unit (ACG) RIO Bus
users to quickly grasp the operating status This connects the V net control system bus This communications bus links remote I/O
BCV of the plant. The HIS can also provide an to a supervisory computer system or personal units to the FCS control unit.
open environment for engineering. computer. Nodes
VL net HF bus Console-type HIS Bus Converter (BCV) Remote I/O units (nodes) on the RIO bus con-
This high-end human interface station has This connects the V net system bus to other vert between bus signals to/from an FCS
CENTUM the same functionality and reliability as the CS 3000 systems or to an existing DCS. and analog, digital and fieldbus I/O signals.
CS 1000 standard HIS and its CENTUM predecessors. V net Fieldbus
CENTUM-XL
CENTUM-V Desktop-type HIS The V net real-time control system bus links The bidirectional digital fieldbus links the FCS
This is based on a generic PC (running Win- stations such as FCS, HIS, BCV and ACG. to fieldbus devices. (We support the FOUN-
dows NT). Field Control Station (FCS) DATION Fieldbus standard.)
ENG Standard FCS
This is a generic PC used for Engineering. This FCS has powerful control functions, high
reliability, remote I/O and Fieldbus support.

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06 Operation Functions 07

Hierarchical Operation
Optimized Operation Environment

N
An operating environment can consist of sev-
eral hundred to several thousand windows.
f e a t u r e 0 3 They are linked hierarchically, to provide an
ideal operating environment. The Navigator
CENTUM CS 3000 combines the powerful control functions of a DCS with
window tree display makes it easy to moni-

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the ease of operation of a personal computer. tor and switch between plant operation

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The human interface station runs on the familiar Windows NT environment.
The optimized operating environment reduces the operator workload involved in
Alarm Overview
plant monitoring and operation. The system message win-
dow which displays alarm
and alarm windows. The tree representing
the actual plant hierarchy has plant over-
Navigator window
view windows at the top, followed by individual
process and unit windows, and individual con-
trol instrument and trend windows at the bot-

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messages is a protected

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tom.
area of the screen, and
cannot be covered by
other windows. Alarm win-
dows, which pop-up when Open Interfaces

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alarms occur, can be de- Open interfaces supporting DDE and OPC (OLE for Process Con-

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fined. Alarm window
icons, color coded to rep-
Two Types of HIS, to Match Your Needs resent alarm status, ap-
The CENTUM CS 3000 HIS runs on Windows NT, which is the de facto standard. For the pear in the navigator
trol) are available for the HIS allowing process data, message in-
formation, and tag information to be accessed by other users on the
network.
DDE: Dynamic Data Exchange

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Operator Station hardware, choose between a generic PC and a conventional Operator window tree display. OLE: Object Linking and Embedding

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Console* which provides the same high reliability that you have been used to.
*Due for release in the second half of '98.

Support for General Office Applications

General office applications can be displayed in windows side-by-side with con-

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trol-related windows; the circulate key allows you to switch between the two

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Multi-Window mode Full-Screen mode
types of windows.

Security Functions

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To help minimize operator errors and prevent unauthorized
operation, the following types of security are supported:
Long-Term Data Archive Package
User log-on security function
This is used with the standard trend func-
Restricted view of plant (HIS-specific and user-specific)
tions to save long-term process data. It can
Operations restricted by user type (operator, engineer etc.)
display real-time data and previously-saved

F
E

Tag-specific restrictions (important tag, etc.)

historical data in standard trend windows.
Hardware ID system (requires option package)
Two Window Modes Offered
You can choose between two window modes: a mixed multi-Window mode which will run
general office applications side-by-side with control-related windows, and allows you to switch
between control-related and general application windows by clicking a soft key or a conven-
P

tional full-screen dedicated control-related window.

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08
Graphic Windows
In addition to the graphic functions of
previous systems, new overview ele-
ments and instrument faceplate ele-
ments can easily be added to graphic
windows. Realistic dynamic graph-
ics may be used to represent the
plant. ActiveX controls can be at-
tached to graphic windows. Generic
unit definition templates may be cre-
ated, and simply by switching data
tables used to represent multiple
units.
Advanced Graphics plus
all the Key Data
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Overview Windows
32 colored blocks represent plant
operation status and alarm status by
color changes (red, yellow, green)
and flashing. Simply clicking on a
block displays the related window.
Graphics may also be displayed in
overview windows.
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Operation Windows 09
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Control Windows Tuning Windows Trend Windows Status Display Windows
D
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T
Control Drawing Status Display Window
The status of function blocks can be These display trend recordings of tag These display, on the HIS, an over-
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These provide detailed status dis-
represented by instrument faceplate plays for individual instruments, they data. Trend data can also be dis- view of the control status of the plant.
diagrams showing setpoints, ma- contain parameter lists, instrument played from other HIS stations on the Control drawing status display windows
nipulated output values, and status diagrams, and tuning trend graphs. network. Logic chart status display windows
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information. Faceplate diagrams are Sequence table status display windows
available in standard and half-height SFC status display windows*
sizes; up to 16 may be displayed per SEBOL detail display windows*
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window. *SFC=Sequential Function Chart
*SEBOL=Sequence and Batch Oriented Language
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W
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SFC Status Display Window
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10 Control Station 11

V net

Coupler
Pair and Spare Fault Tolerance
Processor card
V net I/F V net I/F
Processor card The standard FCS consists of dual-

Versatile, redundant CPUs (checking each

O
Main CPU 1 CPU 1 Main
memory Compa- Compa- memory
(with ECC) rator
CPU 2 CPU 2
rator (with ECC) other, to catch transient calculation

Reliable Control Stations Power card

RIO bus
com.card
RIO bus
com.card Power card
errors), and dual-redundant (active
and standby) CPU cards. This fault

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Coupler tolerance is transparent no special
Dual-redundant FCU RIO bus
f e a t u r e 0 5 programming/engineering is required.

Com.card

Com.card

Com.card

Com.card
Field Control Stations (FCS) are designed to provide high reliability and high availability. Input

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module

CENTUM CS 3000 uses our field-proven Pair and Spare FCS redundancy together Output
module
Dual-redundant node
with bus and I/O redundancy.
This is a super-reliable, open system.

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HIS

V net

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FCS Components

Field Control Unit (FCU) FCU (Field Control Unit)

This is the CPU that performs calculation and control

R
functions. A high-performance RISC chip is used.
Two FCS types for Flexible System Node
RIO bus
Nodes (Remote I/O Units) Interface
Configuration unit

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This connects to field I/O signals, performs signal
Two FCS types a standard FCS, which can
conversion, and communicates with the FCU via the
be used with remote I/O, and a compact all-in- Node Communication
RIO bus. Nodes consist of I/O units which connect to unit
one type with smaller application capacity to I/O unit
field signals and subsystems, and node interface units
suit your needs.
which communicate with the FCU.

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RS-232C
RS-422
I/O Units RS-485
These consist of I/O modules and the nest containing Analog

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I/O
them. I/O modules process field signals and transfer Subsystem
PLC*, etc.
the data to/from the FCU. Contact
I/O *PLC=Programmable Logic Controller
Analog I/O Modules
These modules can process I/O signals to/from a vari-
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ety of sources. These are high-reliability modules, with Communication Modules
each module dedicated to processing a single signal, *1
These modules support RS-232C, RS-422/485 and Ethernet;

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for high system availability. the protocol for communicating with subsystems such as PLCs
Standard FCS can be downloaded to the modules.
Multiplexer Modules
Each multiplexer module processes multiple I/O Fieldbus Communications Modules*1
Compact, Low-Cost
signals. These cost-effective modules are used for These interface to the Foundation Fieldbus.
Remote I/O Units monitoring and for simple control loops.
O

Remote I/O units greatly reduce the cost of

Contact I/O Modules RIO bus
field wiring, and the space required.
In addition to basic status I/O processing, these can The Remote I/O (RIO) bus connects the FCU to nodes. The bus
count input pulses, provide pulse-width outputs, and may be dual redundant, and its maximum length may be ex-
generate time-proportioning ON/OFF output signals. tended using repeaters and optical fiber links.
Compact FCS
*1 Due for release in the first half of 99
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12 Control Functions 13

Versatile,

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Powerful Control Blocks
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Batch Control

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Regulatory control, batch control, and sequence control blocks are provided.

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CS Batch 3000 is an ISA S88
You can freely link regulatory control blocks, Subsystem Integration Functions compliant total batch process op-
calculation blocks, sequence control blocks, Sequencers (Programmable Logic Controllers, PLCs) are increasingly being eration and management pack-
and faceplate blocks to configure powerful control functions. used for monitoring and automating the operation of plant equipment and age based on Yokogawa's long
large electrical machinery. Data from other intelligent third-party equipment experience. For multi-product,

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such as analyzers and measuring equipment needs to be transferred to variable-volume production, CS
the control system. FCS communication functions are used to integrate these Batch 3000 can handle complex

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Basic Control Functions subsystems with the DCS, and provide integrated monitoring and control. batch control and it offers easy
Many types of basic control function blocks Redundant configurations can also be supported.
Regulatory control Sequence control Batch control operation and a productive en-
Application are provided,and may be combined to V net
gineering environment.

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meet user needs.
ISA S88 Compliant Function
FCU (Field Control Unit)
Configuration
Regulatory Control Blocks Communicates easily with super-

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These are for process monitoring and control,
visory recipe management and in-

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and include PID controllers, self-tuning func-
Function Regulatory control Sequence control Calculation SFC block formation management systems.
blocks function block function block block tions, input indicators, manual loaders, and sig-
Compact Node interface unit
nal selectors. FCS ISA S88 Batch Control Activity Model

Sequence Control Blocks

These are used to implement safety interlock se-
Recipe Schedule Information

N
T
quences, process management sequences, and management management management
sequence control blocks to implement general-
Faceplate Analog faceplate Sequence faceplate Hybrid faceplate Communication module
blocks block block block purpose sequences at the loop instrument level.
Process
Sequences may be expressed by sequence management
tables or logic charts. RS-232C
RS-422
Calculation Blocks

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RS-485 Unit
Calculation function blocks are used to supplement Ethernet management
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regulatory control functions and sequence control
functions. Calculations may be performed on ana-
Subsystems
log signals and contact (logic) signals. High-speed Process control
(function block)
trend function blocks are also provided.
Memocon-SC PLC-5 FA 500 CS Batch 3000

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Faceplate Block Functions SFC Blocks
SIMATIC MELSEC-A FA-M3
Modicon GC 1000 SYSMAC
An instrument faceplate (a single tag) may Sequences may be represented by Sequence
represent one or more function blocks. Function Charts, and these function blocks ex-
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Ready-made analog, sequence and hybrid ecute the SFC language. These are based on
faceplate blocks are provided. IEC SC65A/WG6.
The SEBOL language may also be used for
batch and sequence control.

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14 Engineering Functions 15

N
Can Exchange Data with
General Office Applications
You can exchange data with many common

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office applications, such as MS Excel.

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Runs on Generic PC. Special Computers Not Required.

N
Special, dedicated computers are not required for engineering. You can easily
perform engineering on a generic PC. With the familiar Windows NT environ-

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ment, engineering functions are as easy to use as general office applications.

Online Documentation

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Manuals are provided as Portable Document
Format (PDF) electronic documentation.
Documents can be referenced and printed

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as required.

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Easy Engineering

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Generic PCs running Windows NT can be used for con- Virtual Test Functions
current engineering; data may be easily shared/reused. Controller simulation functions which run on a generic PC

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controller hardware is not required to test and validate

N
Virtual test functions allow engineering and testing to Test screen Test screen
control system operation. You can proceed in parallel with
ENG
proceed concurrently, greatly reducing time to startup. engineering and testing phases. You can even perform
testing using a notebook PC, anywhere.
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FCS simulator

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Virtual Test
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Concurrent Engineering Reusing Engineering Data FCS

Using the disk sharing functions of Windows NT, a Engineering data can be saved in text format, and reused
F
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single database can be shared by several engineer- in a different station or project.

ing stations. You can easily import project engineer-
ing data which was created on another generic PC.
Online Test
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 16 System Migration

Upgrade Your System While Preserving

Your Existing System Investment
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You can preserve your existing

CENTUM-V, CENTUM-XL or

CENTUM CS 1000 resources and

Functionality
existing I/O when upgrading to the

latest system. Existing CENTUM-V New System

or CENTUM-XL CPU nests can be

upgraded to the latest CENTUM CS

3000 CPUs, and the new human in-

Can use all functions of CENTUM CS 3000
terface stations added. You can up- Can integrate several systems
For expansion, use new CENTUM CS 3000 FCS
grade your system incrementally, The CENTUM CS 3000 era
minimizing down time and achiev- Efficient, high-reliability plant operation; open systems.
ing considerable performance im-
Powerful enterprise-wide management information and control systems.

provements at reasonable cost.

Field control station
upgrade

Use existing cabinets, I/O cards and field wiring (no switch-over)
Application software can be ported
All new CS 3000 functions can be used
Control station application capacity greatly increased

Latest Human
Machine Interface
(HMI)
More efficient operation, integration
Integrates information systems and control
HMI capacity and performance is about three times that of current HMI

Better integration
Existing Systems
CENTUM is a registered trademark of Yokogawa Electric Corporation.
ActiveX and Windows NT are registered trademarks of Microsoft Corporation.
Ethernet is a registered trademark of XEROX Corporation.
Memocon-SC is a registered trademark of YASKAWA ELECTRIC CORPORATION.
MELSEC-A is a registered trademark of Mitsubishi Electric Corporation.
Modicon is a registered trademark of Schneider.
C SS 33 00 00 00 SIMATIC is a registered trademark of Siemens.
SYSMAC is a registered trademark of OMRON Corporation.
Other company and product names in this bulletin are trademarks or registered trademarks of their companies.
Integrated Production Control System