Yokogawa CS-3000 Engineering Training

GIZA SYSTEMS COMPANY presents:
YOKOGAWA CS-3000
Engineering Training
By:
Engineering Team
Yasser Alabassery
Amr Sedky
Mahmoud A. Elaraby
Amir Abdelaziz
Course contents
• Overview: Introduction To Process Control System
• Lesson 1: DCS System Overview
• Lesson 2: HIS Startup
• Lesson 3: Engineering Environment
• Lesson 4: Project Creation
• Lesson 5: FCS Configuration

Course contents (contd.)
• Lesson 6: Process Input/Output
• Lesson 7: Control Drawing Builder
• Lesson 8: Regulatory Control F.Bs and

Sequence Functions
• Lesson 9: Defining HIS Functions and Configuration
• Lesson 10: HIS Graphic Builder
• Lesson 11: Scheduler
• Lesson 12: Trend Group And control Group

Configuration
Overview: Introduction To Process Control System
A temperature control loop using a controller is

shown in the figure below.
The operator sets the temperature “setpoint (SV)”, and the
controller automatically adjusts the “manipulated variable
(MV)” i.e. output (opening of valve which controls steam
flow) so as to minimize the deviation between measured
(temperature) “process variable (PV)” and target value
“setpoint”.
•The process of adjusting the manipulated variable to

minimize the deviation between process variable and
setpoint is called “Feedback control”.
•The indicating (PID) controller displays the measured

process variable (temperature of the liquid of the tank), and
using a PID (P-Proportional, I-Integral and D-Derivative)
control algorithm, computes the manipulated variable
output (steam flow) that will minimize the deviation
between process variable and setpoint temperatures; i.e. it
controls the tank temperature.
• PROCESS CONTROL FUNCTIONS

• The method to directly control process is roughly divided into two categories:
the loop control that inputs analog measured values (including feedback
control and feed forward control) and the sequential control that inputs
operating sequences and process status signals:
» Feedback Control
Control that acts to correct the process variable (e.g. Temperature in a
tank) to agree with the target value (setpoint) by comparing both.
» FeedForward Control
Control which takes a corrective action by measuring the disturbances
(e.g. Ambient temperature) and directly driving the valve before it affects the
process.
» Sequential Control
Control that successively advances each control step in accordance with
the pre-determined sequence.
• PROCESS CONTROL FUNCTIONS

To perform temperature control as discussed before, a control system ( a device
to perform the control computation) is required. There are many control systems
available, which are generally classified into analog, and digital control system.
» Analog Control System

Control device that makes a control computation with analog signals (e.g.
Voltage) using operational amplifiers etc. I this case sequence control is not
available.
» Digital Control System

Control device that makes control computation with digital values using a
processor (processing unit).
Generally referred to control in which the controller functions are
implemented with digital equipment. Inputs and outputs of the controller may be
analog signals. Also refers to a supervisory control scheme when a
higher-level computer drives the output of a digital controller directly.
Lesson 1
DCS System Overview

Lesson 1: DCS System Overview
For the Distributed Control system to function 2 major components are necessary:
A. The EWS / OWS – From which the operator controls the plant and the same component
can also be used to do configuration changes. The operator station or the Man Machine
Interface (MMI) is called the Human Interface Station (HIS) in CS3000 R3 system while the
component used for configuration is called the Engineering station (ENG).
Both these components can reside in one hardware.
The no. of HIS based on the no. of operators required.
B. The Field Control Station – which is the interface between the Field instruments and the
control room. This is the component where all the control functions are executed and hence is
a very important and critical component in the overall system.
C. The above two components are the minimum requirement components to start any DCS
project and connected via a real time control network which communicates all the parameters
to and from the Field Control Station to the Human Interface station. This network is called the
V-Net / VL-Net in CS3000 R3 system.
The following are the various components that form the CS3000 R3 Control System.
Each of the components on the real-time network is called as Station with a unique
station address.
HARDWARE COMPONENTS:
A. Human Interface Station (HIS)

B. Engineering Work Station (EWS)
C. Field Control Station (FCS)
D. Safety Control Station (SCS)
E. ProSafe COM
F. Communication Gateway Unit (CGW)
G. Bus Converter (BCV)
H. EXAOPC Server (EXAOPC)
I. Plant Resource Manager (PRM)
COMMUNICATION COMPONENTS:
A. Fieldbus (FF)
B. V-Net / VL-Net
C. Ethernet
Lesson 2
HISStartup
Lesson 2: HIS Startup
When the CS3000 operation and monitoring package is loaded, an account with a user name
“CENTUM” is created as part of the installation steps. Hence to login to the CS3000 operation
and monitoring function on the HIS, the operator has to login as a “CENTUM” user. The HIS
starts the operation and Monitoring package based on the selection done in the HIS utility.
Virtual Test Function
In the absence of actual FCS and the VL Net control bus card, using the virtual test function, the
memory of the HIS can be used to generate the FCS simulator and emulate FCS control functions
and HIS Operation and Monitoring functions based on the FCS and HIS chosen. The following
procedure describes the steps to start the Virtual test function.
In The Generation Message Dialog that appears
after selecting the test function.
Dialog to select the HIS

Station for Operation
and Monitoring function.
Window to indicate the completion of FCS test

function processing.
Virtual HIS Operation and Monitoring

function in Full-Screen Mode.
Lesson 3
ENGINEERING
ENVIRONMENT
Lesson 3: Engineering Environment
The engineering work is done on the ENG (Engineering Station), which has the
standard builder function or system generation function installed. There are potentially
following two types of engineering environment.
• TARGET SYSTEM
the system generation is done on the ENG and loaded to the
components connected on-line. In this case all the system
HW is connected in the network.
• Non-TARGET SYSTEM
the system generation is done on a non-target ENG without
any of the CS3000 system components. Once all the
generation is completed, the same is tested using the virtual
test function. The project is then copied into a secondary
media and loaded on to the target ENG and then off-line
downloaded to all the components after the complete network
is connected. This function allows the engineering work to
start even before the actual CS3000 HW components are
procured.
• Concurrent Engineering
Using the Windows 2000/XP networking features, one engineering database is shared among
several users thus achieving concurrent engineering. With this feature, a team of systems
engineers could generate different sections of the project like, I/O generation, sequence/logic
generation, graphics etc., thus reducing the system engineering time.
• Engineering Flow
Start System view
Project Creation
FCS Function Definition
HIS Function Definition
Project Common Definition
Virtual Test Function

Lesson 4
PROJECT
CREATION
SEARCH
ACCESS
Lesson 4: Project Creation
• TYPES OF PROJECT
A project is a folder that contains the project database i.e. all the system component folders
and the files. All the builder files are modified and created under this project folder. There are
three types of projects: Default Project, Current Project and User Defined Project.
• Default Project
It is automatically created when the system view is started for the first time. Once all the system
generation is carried out using the default project and the FCS is off-line loaded, this default project
is converted to a current project automatically. If a project is defined as a default project, on-line
functions can’t be performed unless it is converted into a current project. With a default project,
virtual test function can be performed.
• Current Project
This allows on-line functions to be performed. Both default and current project can’t co-exist.
The image of the current project components is same as the actual components installed in the
network. Hence only one current project can exist. A target test function can be performed if a
project is a current one.
• User-Defined Project
A project copied from a default or a current project is referred as a user-defined project. There
could be as many user-defined project assigned in a system view.
On-line functions cannot be performed from a user-defined project. A virtual test function can
be performed from this type of project.
• CREATING A DEFAULT PROJECT
Start system view.
When the system doesn’t find

any project definition, it
automatically prompts for a
creation of a default project.
• Project out-line
Allows entering the user name and project information. It is mandatory to

enter the project information details at least an arbitrary character.
• Project Property
Allows entering the Project name (an

alphanumeric characters less than 8
characters).
This would be the main folder of the
project under which all the sub-folders
and files are created.
• Creating FCS folder

For a CS3000 minimum system at least one FCS and one HIS are
required. This prompts to create a FCS. The station number and address
are assigned from this dialog. Once this is confirmed, the station number
cannot be changed. Additional FCS stations can be created from the system view
later.
• Creating HIS
For a CS3000 minimum system at least one FCS and one HIS are
required. This prompts to create a FCS. The station number and address
are assigned from this dialog. Once this is confirmed, the station number
cannot be changed. Additional FCS stations can be created from the
• CHANIGING PROJECT ATTRIBUTION

Project attribution utility is an engineering tool to register projects, modify the
project type and delete project registration. Before the project attribution utility is
started, The System View has to be closed.
Deleting A Project
Registration
Registering A New Changing Project

Project attribution
Lesson 5
FCS CONFIGURATION
Lesson 5: FCS Configuration
• Types Of FCSs
There are generally 3 types of Field Control Station:
1. KFCS - Standard Field Control Station with Field Input/Output Modules (FIO)
2. LFCS - Standard Field Control station with remote Input/Output (RIO) Bus
3. PFCD - Compact Field Control Station
Now we’ll illustrate each type ……………..

1. KFCS-Standard Field Control Station with Field Input/Output Modules (FIO)
2. LFCS - Standard Field Control station with remote Input/Output (RIO) Bus
3. PFCD – Compact Field Control station
• FCS Hardware
1. Field Control Unit (FCU)

2. Processor Card
3. Control Bus Coupler Unit
4. Power Supply Unit (PSU)
5. Rack
6. Back Up Batteries
7. Remote Input/Output (RIO) Interface Card and RIO Bus
8. Process Input Output Units (PIO) or Input/Output Units (IOU)
9. Node Interface Unit (NIU)
10. ESB Bus Coupler Unit
• Network
CS3000 R3 uses VL/V net and Ethernet for data communication. The specifications of the
network are as below. SPECIFICATION V NET VL NET
Transmission Speed 10 Mbps 10 Mbps
Cable 10base2 cable used between HIS 10base2 cable
stations
10base5 cable used between FCS, ACG,
ABC etc
Transmission 500 m/segment (for 10base5) 185 m/segment
distance 185 m/segment (for 10base2)
Repeater – Coaxial Maximum 8 sets, 1.6 Km Maximum 8 sets, 1.6 Km
Maximum 4 sets, 20 Km Maximum 4 sets, 20 Km
• System Capacity
SPECIFICATION CS3000 R3
Max. no. of HIS monitored tags 100,000
Max. no. of stations 256
Max. no. of domains 16
Max. no. of stations per domain 64
Lesson 6
Process
Input / Output
Lesson 6: Process Input/Output
There are 3 types of process I/O:
1. Analog input/output
2. Status input/output
3. Communication input/output
Process input/output signals are used as I/O

signals for the regulatory control, arithmetic
calculation and sequence control.
• CREATION OF A NEW NODE

Create a new node for installing an I/O module. While selecting the [IOM] folder, select [Create New]
[Node] from the [File] menu.
• CREATION OF A NEW MODULE

Once the node is created. The IOM that are installed in the node are defined.
on the created node, right click and select create new IOM.
• types Of IOM
The tables below show many types of I/O modules:
• IOM BUILDER
A terminal of a process I/O or a Fieldbus I/O can be numbered in accordance with its physical position and the I/O module location.
The format of a terminal number is as follows.
%Znnusmm
%Z: Identifier of process I/O (Fixed)

nn: Node Number (01 - 10)
u : Unit Number (1 - 8)
s : For a Fieldbus comm. module, s stands for
segment number (1-4). When using modules
compatible to HART comm., for measured
analog data s=1, while for the data via
HART
comm.
IOM BUILDER FOR AAI835 s=2. For other I/O modules s is fixed as 1.
mm: Terminal Number (01 - 64)
Lesson 7
CONTROL
DRAWING BUILDER
Lesson 7: Control Drawing Builder
• Control Drawing
CS3000 R3 system contains 200 control drawings per FCS.
• Control Drawing Environment
• Registering F.B
The Select F.B dialog box appears, displaying a list of

F.Bs that can be registered.
• Control Drawing Environment
• Control Drawing Wiring

Wiring can be drawn by specifying an output connection terminal and an input connection terminal of block
symbols in the drawing pane.
Automatic wiring when there

is one connection destination
Wiring icon
Branching Of Wiring
Lesson 8
Regulatory Control F.Bs and

Sequence Functions
Lesson 8: Regulatory Control F.Bs & Sequence Functions
• Regulatory Control F.B
The regulatory control blocks are the F.Bs that perform control computation processing mainly on the analog
input as input signals. The calculated results are used for process monitor and process control. The regulatory
control blocks support the following types of processing: input processing, control computation processing,
output processing and alarm processing.
• Functions Of The Regulatory Control F.B
1. Input Processing: Receives a signal from the input terminal and outputs a process variable (PV).
2. Control Computation Processing: Performs control computation processing by reading the process
variable (PV) and outputs a manipulated output value (MV).
3. Output Processing: Reads the manipulated output value (MV) and outputs the result of control
computation processing to the output terminal as an output signal.
4. Alarm Processing: Detects an abnormality in the process variable (PV) or manipulated output value
(MV) and notifies the operation and monitoring functions. Control computation processing
can be performed independently via data setting or data reference between the F.Bs, without involving
input processing or output processing.
The regulatory control blocks are classified into these blocks below:
• Input Indicator Blocks, Controller Blocks, Manual Loader Blocks

• Signal Setter Blocks, Signal Limiter Blocks, Signal Selector Blocks
• Signal Distributor Blocks, Pulse Count Input Block, Alarm Block, YS Blocks
• Regulatory Control F.B classifications
Input Indicator Blocks Signal Setter Blocks
Controller Blocks
Signal Limiter Blocks
Signal Selector Blocks
Pulse Count Input Blocks

Manual Loader Blocks
Signal Distributor Blocks

Common F.Bs Details:
1. BASIC:
A. Tag Comment
B. Security Levels
C. Scan Period
D. Open/Close Mark-
Instrument Display Area
E. Input Signal Conversion
F. Totalizer time unit PID Block
G. Low-Input Cut
H. Control Action Direction
K. Measurement Tracking
L. Output Signal Conversion
To edit F.B Details click on:

PVI Block
From Tool Bar
Common F.Bs Details:
2. TAG: 4. ALARM:
A. Tag Mark A. Alarm Level
B. Double Authentication B. Input Open Alarm
C. Help C. PV HH/LL Limit Alarm
D. MV Display on Faceplate D. Deviation Alarm
E. Scale Low/High Limit, Scale E. Bad Connection Alarm
Reverse Display Double Authentication
F. Scale-Division 5. Control Calculation:
A. PID Control algorithm
3. INPUT:
B. Deadband Action
A. Process variable range High
and low limits
B. Engineering unit 6. OUTPUT: 7. CONNECTION:
C. Input Signal Filtering A. Output Change
B. Auxiliary Output 8. OTHERS - Constant:
• Other Regulatory Control F.B
Splitter Block (SPLIT)
Manual Loader SW Block (MLD-SW)
Auto-Selector Blocks (AS-H/M/L)
Ratio Set Block (RATIO)
Motor Control Blocks (MC-2, MC-3)

• Sequence Control Function
Types Of Sequence Control Blocks:

• Sequence Table Block
This F.B realizes sequence control by operating other F.B and/or process I/O or software I/O.
The following 2 models of blocks are categorized as Sequence Table Block.
• Sequence Table Block (ST16)
• Rule Extension Block (ST16E)
Outline Of Sequence Table Elements
• Condition Signal, Action Signal, Rule Number,

Condition Rule, Action Rule, Tag Name.Data
Item, Data, Comment.
EXAMPLES
The basic logical circuit figure for the AND and OR commands is described in the sequence table as shown
in the following figure.
AND Circuit Example
OR Circuit Example
• Sequence Control Function Processing Timing
A sequence control block and a logic chart block have the following four types of execution timing:
• Periodic Execution (T)

• One-Shot Execution (O)
• Initial Execution/Restart Execution (I)
• Restricted Initial Execution (B)
2. Logic Chart Block (LC-64)
Logic Chart Block (LC64) may combine or arrange the signals of other F.Bs; process I/O and
software I/O into an application for interlock sequence control.
LC64 block is a sequence control F.B with 32 input and 32 output signal channels and it can
handle 64 logic operators.
F.B Diagram of Logic Chart Block (LC64)
Configuration of the Entire Logic Chart

LOGIC CHART PROCESSING FLOW
Input Processing
The true or false status of a condition signal is determined by the condition test performed on the input signal.
Calculation Processing
The logic calculation is based on the result of condition test of the input signal (true = 1, false = 0). The logic
calculation algorithm is expressed by combinations of logic operators.
Output Processing
Status manipulation output is determined based on the result of logic calculation processing. The status
manipulation will be output as the output signals to the operation target. The status manipulation can send
commands such as starting, data setting, and status change to the contact output terminals or to other F.Bs.
Logic Chart Processing Flow

MOST LOGIC CHART LOGICAL OPERATORS
AND: Logic Product

It gives one output based on multiple inputs. When all the inputs are True, the output becomes True. The
maximum number of inputs is 21.
OR: Logic Product
It gives one output based on multiple inputs. When any of the inputs are True, the output becomes True.
The maximum number of inputs is 21.
NOT: Negation
It gives the inverse of the input as an output.
SRS1-S (1 output), SRS2-S (2 outputs):

It gives one output or two outputs shown in the following truth table based on the set and reset input
signals. One flip-flop operation is counted as two logic operation elements.
MOST LOGIC CHART LOGICAL OPERATORS
WOUT: Wipeout
It gives an output which is an inverse of reset signal when reset signal is true, otherwise, it gives the set
signal as output, shown in the following truth table based on the set and reset input signals. One wipeout
operation is counted as two logic operation elements.
OND: On-Delay Timer And OFFD: OFF-Delay Timer
When the input status changes from 0 to 1, the internal timer starts. When the set time t elapsed, its
output changes from 0 to 1. When the input status changes to 0, the output will be reset to 0
Immediately, and the vise versa for Off- Delay Timer.
OFFD OND

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GIZA SYSTEMS COMPANY presents:

• Overview: Introduction To Process Control System

• Lesson 1: DCS System Overview

• Lesson 2: HIS Startup

• Lesson 3: Engineering Environment

• Lesson 4: Project Creation

• Lesson 5: FCS Configuration

• Lesson 7: Control Drawing Builder

• Lesson 8: Regulatory Control F.Bs and

• Lesson 9: Defining HIS Functions and Configuration

• Lesson 10: HIS Graphic Builder

• Lesson 11: Scheduler

• Lesson 12: Trend Group And control Group

A temperature control loop using a controller is

•The process of adjusting the manipulated variable to

•The indicating (PID) controller displays the measured

• PROCESS CONTROL FUNCTIONS

• PROCESS CONTROL FUNCTIONS

» Analog Control System

» Digital Control System

DCS System Overview

A. Human Interface Station (HIS)

Dialog to select the HIS

Window to indicate the completion of FCS test

Virtual HIS Operation and Monitoring

FCS Function Definition

HIS Function Definition

Project Common Definition

Virtual Test Function

• CREATING A DEFAULT PROJECT

Start system view.

When the system doesn’t find

• CREATING A DEFAULT PROJECT

Allows entering the user name and project information. It is mandatory to

Allows entering the Project name (an

• CREATING A DEFAULT PROJECT

• Creating FCS folder

• CHANIGING PROJECT ATTRIBUTION

Registering A New Changing Project

Now we’ll illustrate each type ……………..

1. Field Control Unit (FCU)

There are 3 types of process I/O:

Process input/output signals are used as I/O

• CREATION OF A NEW NODE

• CREATION OF A NEW MODULE

%Z: Identifier of process I/O (Fixed)

• Control Drawing Environment

The Select F.B dialog box appears, displaying a list of

• Control Drawing Environment

• Control Drawing Wiring

Automatic wiring when there

Regulatory Control F.Bs and

• Regulatory Control F.B

• Functions Of The Regulatory Control F.B

• Input Indicator Blocks, Controller Blocks, Manual Loader Blocks

• Regulatory Control F.B classifications

Input Indicator Blocks Signal Setter Blocks

Signal Selector Blocks

Pulse Count Input Blocks

Signal Distributor Blocks

• Functions Of The Regulatory Control F.B

Common F.Bs Details: