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REMARKS
FINAL ISSUE -
-FOR APPROVAL FIRST ISSUE
REVISION HISTORY
DATE OF REVISIONREV.NO BRIEF DESCRIPTION OF REVISION SHEET NUMBERS REVISED
FOR INFORMATION
NAME CUSTOMER : TITLE : FUNCTIONAL DESIGN
PRD.RK
CHK. RS PROJECT :
APP. PVD
YOKOGAWA INDIA LIMITED
PETROQUIMICASUAPE PETROCHEMICAL CO. LTD PROJ DOC NO: AU2103-K06-006
PAGE NO : II/II
SPECIFICATION FOR SUB SYSTEM COMMUNICATION
DCS & ESD SYSTEMS FOR PQS PTA
YIL DOC NO: MP17-DS1-SCS
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 1 of 34
FUNCTIONAL DESIGN
SPECIFICATION FOR SUB SYSTEM COMMUNICATION
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 2 of 34
CONTENTS
1 General ................................................................................................... 3 1.1 Introduction ............................................................................................................................ 3 1.2 Scope ..................................................................................................................................... 3 1.3 Structure ................................................................................................................................ 3 1.4 Definitions, Abbreviations and Terminology .......................................................................... 4
2 Subsystem Overview .............................................................................. 5
3 DCS Subsystem Communication: MODBUS – RTU .............................. 6 3.1 Philosophy ............................................................................................................................. 6 3.2 Communication Function ....................................................................................................... 8 3.2.1 Communication Function – Outline ........................................................................................ 8 3.2.2 Redundancy ......................................................................................................................... 11 3.3 DCS Communication Capacities ......................................................................................... 11 3.4 Communication Performance .............................................................................................. 12 3.5 Communication Interface ..................................................................................................... 12 3.6 Cable connection specification for ALR121 ......................................................................... 13 3.6.1 Cable Specifications for RS-422/RS-485 Communication Links ......................................... 15 3.7 Transmission specifications ................................................................................................. 15 3.8 CS3000: Setting items for ALR121 ...................................................................................... 17 3.9 Subsystem Addressing and Function Codes ....................................................................... 18 3.10 Time Synchronization With Subsystem ............................................................................... 19 3.11 Setting Items on Communication I/O Builder ....................................................................... 21 3.12 System Alarm Message ....................................................................................................... 23 3.12.1 System Alarm Messages ..................................................................................................... 23 3.12.2 Communication Error Codes ............................................................................................... 25 3.13 Subsystem I/O mapping ...................................................................................................... 27 3.13.1 I/O Mapping Principle .......................................................................................................... 27 3.13.2 Accessing Subsystem Data from a Function Block ............................................................. 28 3.13.3 Overview of Accessing Subsystem Data ............................................................................. 28 3.13.4 Access in case of Analog input from subsystem ................................................................. 29 3.13.5 Access in case of Analog output to the subsystem ............................................................. 30 3.13.6 Access in cases of discrete input and output to and from the subsystem ........................... 31
4 Sub-Systems used in the Project. ......................................................... 33
5 Sub-System Mapping Format ............................................................... 34
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 3 of 34
1 General
1.1 Introduction
This section describes the basic specifications for communication with other sub-systems, via the ALR121 Communication Module using Modbus Protocol.
This section also describes a Simplified Redundant Function with Read / Write to be implemented in the CENTUM-VP, the hardware requirement, communication interface details, error codes and engineering methodology.
1.2 Scope
This document describes the Functional Design Specification for the DCS Communication with various third party sub-systems in the “DCS & ESD SYSTEMS FOR PQA PTA PROJECT “.
1.3 Structure
The document Structure is:
Chapter 1: General information on this specification including definitions and abbreviations used.
Chapter 2: Outlines the Subsystem overview and communication interface.
Chapter 3: Describes the MODBUS RTU protocol implementation, communication capacity and details the signal flow, exchange mechanism.
Chapter 4: Lists the subsystems in this project.
Chapter 5: Provides a format in which tags details are to be furnished by the subsystem vendor for mapping of subsystem into DCS.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 4 of 34
1.4 Definitions, Abbreviations and Terminology
AI Analog Input
AI/O Analog Input/Output
ALR121 Serial Communication Interface Module in DCS
AO Analog Output
DCS Process Control System
DI Digital Input
DI/O Digital Input/Output
DO Digital Output
ESB Bus Extended SB Bus (Internal Communication Bus) in a FCS
FCS Field Control Station
FIO Field Input/Output
HIS Human Interface Station
I/O Input/Output
IOP-/+ Input Low (open)/High (overshoot)
LAN Local Area Network
LED Light Emitting Diode
LSB Least Significant Bit
MAN Manual
MSB Most Significant Bit
MV Manipulated Value (Output Variable)
NU Node Unit
PLC Programmable Logic Controller
PV Process Variable
RTU Remote Termination Unit
SEBOL Sequence and Batch Oriented Language
SFC Sequence Function Chart
TBA To Be Assign
VNET/IP Yokogawa DCS Network
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 5 of 34
2 Subsystem Overview
The DCS communication with the various Third party subsystems shall be realized as following.
SubsystemModbus-RTU
RS-485
Vnet/IP Bus 1
Vnet/IP Bus 2
Ethernet
Operator Station [HIS]
Controller [FCS]
Higher level System
For Monitoring / Control Applications
Subsystem communication: By Modbus – RTU protocol
The Subsystems, which require the Monitoring & Control operations from the DCS system, shall be based on MODBUS –RTU protocol & the communication links shall be RS485.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 6 of 34
3 DCS Subsystem Communication: MODBUS – RTU
The following sections describe the General Specification for the Subsystem communication implementation by using Modbus RTU protocol.
3.1 Philosophy
The Control System configuration involves communication with Sub-Systems.
Interface module ALR121 is to be housed in one of the node units (NU) in the Field Control Station (FCS). If a redundant communication required, the first (MASTER) communication module should be installed in an odd numbered slot, and it’s redundant (SLAVE) in the next contiguous even slot.
This communication link performs the following functions:
• Exchange of all necessary process data for monitoring and control (if applicable).
• Time Synchronization between DCS and sub-system (wherever applicable).
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 7 of 34
ALR121
RS485 ModbusPLC
ModbusPLC
ModbusPLC
FCS
Note: All the subsystem communication interface shall be standardized to RS422/RS485 Modbus RTU interface. This is required to overcome the Cable length limitation posed by RS232C links.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 8 of 34
3.2 Communication Function
3.2.1 Communication Function – Outline
The Block Diagram below shows the communication I/O data flow for ALR121 communication module in CS 3000 DCS when interfaced with subsystems.
SUBSYSTEM ALR121 CommunicationPackage
Comm. I/O DataStorage
ControlFunctions
The Communication Package is a program downloaded to the ALR121 module; its main function is to convert the information to be exchanged with the subsystem in accordance with the Communication Protocol used.
Comm. I/O data storage area, also called the I/O image table, gathers the communication data and makes it available for control functions. In case of a redundant configuration, two ALR121 Modules will be required and an additional program to control the switching functions between the two communication modules.
The figure (Read Function & Write Function) shows configuration of Redundant Communication Function implemented in the FCS and ALR121 communication program using special software.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 9 of 34
1. Read Function
The two ALR121 cards will be executing asynchronously, accessing the sub-system. Sub-system data read by each ALR121 card will be stored in its own I/O image in the FCS. The redundant function monitors the condition of the two ALR121 cards and the communication. If the master side fails, the redundant function will copy the backup I/O image into the master I/O image of the FCS.
ALR121 ALR121
CONTROL SIDE(MASTER)
STAND-BYSIDE
Data OverWrite
SWITCH INSTRUMENT
SEQUENCE TABLE
CONTINOUS CONTROL INSTRUMENT
Read
REDUNDANTFUNCTION
SUB-SYSTEM
MASTER I/OIMAGE AREA
BACKUP I/OIMAGE AREA
Comm.Card
Comm.Card
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 10 of 34
2. Write Function
Each function block must write the I/O image to the master side only which in turn writes to the sub-system through the ALR121 communication program. The I/O will be copied to the backup side when the master side fails. The Changes in I/O information are set to I/O image area via the redundant function.
CommCard
CommCard
ALR121 ALR121
CONTROLSIDE
STAND-BYSIDE
DataOverwrite
SWITCH INSTRUMENT
SEQUENCE TABLE
CONTINOUS CONTROL INSTRUMENT
Write
REDUNDANTFUNCTION
SUB-SYSTEM
Changinginformation
MASTER I/OIMAGE AREA
BACKUPI/OIMAGE AREA
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 11 of 34
3.2.2 Redundancy
For a redundant link two ALR121 cards are used as control and stand-by respectively. In case of read communication, both cards will read data from the sub-system independently, but only control side data will be delivered.
In case of write communication, only the control side will communicate. Incase of malfunctioning, control switching will take place as follows:
Initially, the master ALR121 card is the controlling side, and the backup card is standby side.
1. When the master ALR121 card detects abnormal condition or sub-system communication
error occurs, and if the backup ALR121 card and sub-system communication is normal, switching will take place.
2. When both ports on the stand-by card are normal and the communication on the master card is abnormal.
3.3 DCS Communication Capacities
The capacity specific to Modbus when performing subsystem communication with a Modbus-RTU PLC is indicated below:
Item Capacity
No. Of ALR121 cards per FCS Max 16 nos. (8 Redundant)
Sub-system connectable per FCS 4 types (4 different Communication Protocols)
Amount of data handled by one ALR121 card Max 1000 words (16bits = 1 word)
No. Of Communication I/O data per FCS Max 4000 words
Number of DI/DO’s configurable per card Max 1000 tags
Number of DI/DO’s configurable per FCS Max 1000 tags
No of Words per transmission Max 125 Words (A I/O)
Max 8 Words (D I/O)
No. Of ports in one ALR121 card 2 (Same Protocol for both)
No. Of stations that can be handled by one port 30 Stations
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 12 of 34
3.4 Communication Performance
The Communication performance over the MODBUS –RTU protocol is dependent on the following factors
a. No of words per transmission frame.
b. Subsystem Communication data shall be with contiguous addresses & packed in units of words, so as to minimize the number of data to be acquired and set by the FCS.
3.5 Communication Interface
The ALR121 are serial communication modules that are installed to the node unit for ESB bus (ANB10S, ANB10D).
• ALR121: 10 pole terminal block for two RS-422 or RS-485 ports (5 poles/port)
The following diagram indicates the external views of Serial communication modules.
LED Display Indications: • STATUS : This LED turns on (green
colour)when the self-diagnosis has been completed normally and the hardware is ready, otherwise it is turned off.
• ACT : When the module is operating normal, LED is ON(green colour) otherwise it is turned off.
• DX : This LED turns on(green colour) when module is configured for dual-redundant operation.
• SND-1 & 2: This LED turns on (green colour)during data transmission, otherwise it is turned off. The status is as per the Communication port basis.
• RCV-1 & 2: This LED turns on (green colour) during data reception, otherwise it is turned off. The status is as per the Communication port basis.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 13 of 34
3.6 Cable connection specification for ALR121
The following cable connection methodology shall be considered while using ALR121 cards as follows;
• RS-422: [Point- to –Point communication]: 4 wire connection
• RS-485: [Point to Point or Multipoint communication]: 2 wire connection
The following table shows the connector specification of the ALR121 card.
The ALR121 card can be either used for a 4-wire or 2-wire type of connection. The default connection type is 4-wire mode.
Cable connection when ALR121 is used with RS422 for Point-to-Point Communication [ 1:1 ], 4-wire connection is as follows,
ALR121 SUB-SYSTEM
SDA
SDB
RDA
RDB
SG
TX+
TX-
RX+
RX-
SG
120 120
120
Requirement of Termination resistance at the Sub-system end varies for each subsystem. Subsystem vendor to confirm.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 14 of 34
Cable connection when ALR121 is used with RS485 for Point-to-Point Communication [1:1 ], 2-wire connection is as follows,
ALR121 SUB-SYSTEM
SDA
SDB
RDA
RDB
SG
TX+
TX-
RX+
RX-
SG
120 120
Cable connection when ALR121 is used with RS485 with Multipoint Communication [ 1:N ], 2-wire connection is as follows,
ALR121 Subsystem-1 Subsystem-2 Subsystem-n
SDA
SDB
RDA
RDB
SG
SDA
SDB
RDA
RDB
SG
TX+
TX-
RX+
RX-
SG
120
SDA
SDB
RDA
RDB
SG
120
Different Models of MODBUS PLC require different wiring for cables, the user’s manual for MODBUS PLC must be referred to for individual subsystem connections.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 15 of 34
3.6.1 Cable Specifications for RS-422/RS-485 Communication Links
The standard length for the Communication cable is limited to 100 Meters or less, for the CENTUM systems to allow for the faulty communication caused by noise in the field. However the communicable cable lengths can be extended till 1200 meters, as per the following recommended cable specifications.
Recommended Specifications of Connection Cables:
• Cable type: Shielded twist pair • Number of pairs: 3 • Insulation resistance (at 20°C): 10,000 M ohm·km or greater • Withstanding voltage: 500 V DC for 1 minute • Capacitance (at 1 kHz): 60 pF/m or less • Characteristic impedance (at 1 MHz): 100 ± 10 ohm • Conductor resistance (at 20°C)
Connection of 100 m or less: 54.5 ohm/km or less Connection of 500 m or less: 36 ohm/km or less Connection of 1200 m or less: 17.2 ohm/km or less
3.7 Transmission specifications
Item Description Project Default Settings
Remark
Interface RS-422 / RS485 RS422 or RS485 Transmission method Half Duplex Half Duplex
Synchronization method Asynchronous (Start –Stop Synchronization)
Asynchronous (Start –Stop
Synchronization)
Baud rate 1200, 2400, 4800, 9600, 19200 bps
19200 (*1)
Transmission procedure Modbus protocol (RTU mode)
Modbus Protocol (RTU)
Binary Binary
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 16 of 34
Data type
Start bit 1 1
Data bit 8 8
Parity bit None, Even, Odd Even (*1)
Stop bit 1 1
Time monitoring
Transmission enable monitoring time
1000 ms 1000 ms
Reception character interval monitoring time
10 ms 10 ms
Text frame
Start of text None None
End of text None None
XON/XOFF flow control No No
RS control No No (*1)
DR check Yes Yes (*1)
CD check No No (*1)
No response time 0 to 99 seconds 4 (*1)
Number of communication retries upon error
0 to 99 times 4 (*1)
Recovery communication time interval
0 to 999 seconds 30 (*1)
Transmission wait time 1 second 1 second
Note: *1 This can be changed using the ALR121 card -property dialog box from CS3000 System
Builder
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
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3.8 CS3000: Setting items for ALR121
• Connection Device – Set [MODBUS] as the type of connection device (subsystem).
• Baud Rate – This sets the baud rate between the communication module and MODBUS
PC. The recommended setting for baud rate is [19200 bps].
• Parity – This sets the method for checking the parity of the subsystem data to be transmitted. The recommended setting for the parity is [Even].
• Data Bits – This sets the data bit length of the subsystem data to be transmitted. When using MODBUS PLC, select [8 bits] for the data bit length.
• Stop Bits – This sets the stop bit of the subsystem data to be transmitted. When using the MODBUS PLC, select [1 bit] for the stop bit.
• RS Control – This sets whether or not RS control is performed during subsystem data transmission. When using MODBUS PLC, disable [RS Control] by leaving the [RS Control] check box unchecked.
• DR Check – This sets whether or not DR check is performed during subsystem data transmission. For MODBUS PLC, it is required to enable the DR check by checking [DR check] check box.
• CD Check – This sets whether or not CD check is performed during subsystem data transmission. When using MODBUS PLC, disable [CD Check] by leaving the [CD Check] check box unchecked.
Note: The following figure shows all the above settings as it appears on the ALR121 Module properties.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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3.9 Subsystem Addressing and Function Codes
“Device & Address” and “Data size” are designated on the Communication I/O Builder to access devices. In the case of a Modbus PLC, addresses have the following structure:
<Function code> + <device type> + <address of the device>
For example, when designating input relay 10012 to 10015 on the Communication I/O Builder, A10012 is set as the “Device & Address” and 1 is specified as the “Data size,” Where the “A” of “A10012” corresponds to the function code, “1” to the device type and “0012” to the address of the device.
The range of device address and Modbus protocol function codes for the accessible devices are listed in the following table.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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Page: 19 of 34
Meaning of the function code is indicated below:
• A: Read: Read a packet of data designated on the Communication I/O Builder in word units.
Write: Write a packet of data designated on the Communication I/O Builder. With read back.
• B: Read: Read a packet of data designated on the Communication I/O Builder in word units.
Write: Only write the changed single bit device or single word device to the subsystem. With read back.
• X: Write: Write a packet of data designated on the Communication I/O Builder only once when the change occurs. No read back.
• Y: Write: Only write the changed single bit device or single word device once when the change occurs. No read back.
3.10 Time Synchronization With Subsystem
Time Synchronization between CS3000 System and Subsystem shall be achieved as follows.
1. DCS as Master.
At a preconfigured time say at 00:00 Hrs A DO is raised (pulse duration is for minimum 3 second) through SEBOL Program. This DO is hardwired to the DI of the subsystem. 2. Sub-System as Slave.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 20 of 34
When the Sub-System receives the DI (Hardwired pulse of minimum 3 second duration) from the DCS, it resets its time appropriately.
The CS3000 HIS and FCS are connected by Vnet and there is a hardwiring of DO between the subsystem and CS3000 for this purpose.
SEBOL program shall be running always. The program will be checking the time and at specified time, the DO will be set (a 3 second pulse).
V- NET Cable
HIS
FCS Hard Wired DO
Subsystem
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3.11 Setting Items on Communication I/O Builder
Element- With respect to the address of the subsystem data buffer, the element numbers are displayed on Communication I/O Builder. The element number is not for set, only for display.
Buffer- This sets the buffer for the communicated data. This is a required setting item of the Communication I/O Builder.
Program Name- Set the unit number, slot number and MODBUS as program name in the following format:
u-s: Program Name
u: Unit number
s: Slot number
Program Name: MODBUS
Size -This item sets the data size (data length) from the head address set in “Device & Address.”
For MODBUS PLC the setting ranges are limited as follows, the unit is in Word.
For analog input and analog output: 1 to 124 words
For discrete input and discrete output: 1 to 8 words
Station-This sets the station number of the MODBUS PLC. The station numbers that can be set are 1 to 255.
Note: The Subsystem Supplier shall identify the MODBUS Station Numbers.
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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Device & Address- Set the head address of MODBUS PLC data.
The addresses can be set using 3 to 7 alphanumeric characters in the formats given below: There is no default setting.
• Coil: A0xxxx, B0xxxx
• Input relay: A1xxxx
• Input register: A3xxxx
• Holding register: A4xxxx, B4xxxx,
“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.
Data Type-This sets data type of the subsystem data. The data type can be selected from the following:
• Input (16-Bit Signed)
• Input (32-Bit Signed)
• Input (16-Bit Unsigned)
• Input (32-Bit Unsigned)
• Input (32-Bit Floating)
• Output (16-Bit Signed)
• Output (32-Bit Signed)
• Output (16-Bit Unsigned)
• Output (32-Bit Unsigned)
• Output (32-Bit Floating)
• Input (Discrete)
• Output (Discrete)
Reverse- This sets whether or not to make the bit arrangement in FCS in reverse order of the subsystem data. The following settings can be selected:
• Bits [ Yes/ No]
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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Scan- Set whether to read the communication I/O Analog data into the communication I/O data buffer at the beginning of high-speed scan of the FCS.
The default value Scan setting is 1 Second.
Service Comment -A text comment can be set.
Label- The name of the function block I/O terminal can be set as a user-defined label.
3.12 System Alarm Message
This section explains system alarm messages that are specific to the communication module (ALR111, ALR121) as well as those that occur when downloading a sub-system program into the communication module.
3.12.1 System Alarm Messages
System Alarm Messages when the Communication Module is Abnormal:
When the communication module is abnormal, the system alarm message shown below is displayed on the HIS.
FCSxxxx IOM Fail FIOmm NODEnn SLOTyy
FCSxxxx IOM Configuration Error FIOmm NODEnn SLOTyy
• FCSxxxx : FCS name
• mm : FIO number
• nn : Node number
• yy : Slot number
System Alarm Message when the Communication Module Returns to Normal:
When the communication module returns to the normal state, the system alarm message shown below is displayed on the HIS:
FCSxxxx IOM Recover FIOmm NODEnn SLOTyy
• FCSxxxx : FCS name
• mm : FIO number
• nn : Node number
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 24 of 34
• yy : Slot number
Message when Downloading Starts:
When the subsystem program begins downloading to the communication module, the system alarm message shown below is displayed on the HIS:
FCSxxxx IOM Load Start FIOmm NODEnn SLOTyy
• FCSxxxx : FCS name
• mm : FIO number
• nn : Node number
• yy : Slot number
Message when Downloading Ends Normally:
When downloading of the subsystem program to the communication module is completed normally, the system alarm message shown below is displayed on the HIS:
FCSxxxx IOM Load Complete FIOmm NODEnn SLOTyy
• FCSxxxx : FCS name
• mm : FIO number
• nn : Node number
• yy : Slot number
Message when Downloading Ends Abnormally:
When downloading of the subsystem program to the communication module is completed abnormally, the system alarm message shown below is sent to HIS:
FCSxxxx IOM Load Error FIOmm NODEnn SLOTyy Error= ####
• FCSxxxx: FCS name
• mm : FIO number
• nn : Node number
• yy : Slot number
• ####: Error code
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
Consultant: M/s AKER SOLUTIONS End-user: PETROQUIMICASUAPE CO. LTD
Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
Job Name: DCS & ESD SYSTEMS FOR PQS
PTA PROJECT Revision: 2
Page: 25 of 34
3.12.2 Communication Error Codes
The following are the error code types for the communication error code of Modbus,
Note: *1: ALR121’s definition check error. If this error occurs, no communication can be performed to the Modbus Subsystem.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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Note: *2: This is error when an error message is received from the Modbus PLC. Refer to Third party PLC supplier error message table.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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3.13 Subsystem I/O mapping
3.13.1 I/O Mapping Principle
Exchanging data between the DCS and a subsystem is done in a MASTER/SLAVE relationship, whereby the DCS is always the master.
The number of communication commands messages that can be sent by the DCS is limited to 30, and the total number of words of these messages may not exceed the limit of 1000 words (refer to section 3.3 DCS Communication Capacities).
Each message command transfers a sequential part of memory either from the subsystem to the DCS or the other way around. Please refer the following figure
The total number of words per command message that can be sent depends on the type of message used, as described in section 3.3 DCS Communication Capacities. To optimize for the maximum amount of data to be transferred, it is advisable to use the maximum amount of possible words per command. This approach will limit the amount of command messages and the total overhead time needed for each command message transfer.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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To improve speed it is advisable to keep the data for each call in a contiguous range.
3.13.2 Accessing Subsystem Data from a Function Block
Subsystem data can be acquired from the regulatory control block, sequence control block, SFC block and other function blocks using the subsystem communication package. Also, data can be set into the subsystem from function blocks by using the subsystem communication package.
3.13.3 Overview of Accessing Subsystem Data
Accessing subsystem data varies according to the type of communication module used.
The figure below shows the flow of data between function blocks and subsystem.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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The method for accessing subsystem data from a function block will vary depending on the subsystem data I/O type as follows:
3.13.4 Access in case of Analog input from subsystem
The subsystem data can be treated as analog input signal just like with an analog input module, by specifying the subsystem data address in the format %WWnnnn and assigning it to the input terminal of a regulatory control block. The Input Signal conversion is required to set to “Subsystem Conversion “ in the function block detail definition builder.
TAG_1
PVI
%WW0001
IN
Subsystem[Analog Input]
16 Bit data
The signal conversion follows the equation: PV (fcs) = PV (Subsys.)* GAIN + BIAS PV (fcs): Data after input conversion (PV value of the function block) PV (Subsys.): Raw data from the Subsystem. GAIN: Data conversion gain (7 digits including sign and decimal, 1.000 as the default) BIAS: Data conversion bias (7 digits including sign and decimal, 0.000 as the default) For more illustration on the above, please see the example below,
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Example: The input scale range used for Analog input from a subsystem is as follows: Subsystem Serial Link DCS (100%) SH 4096 4096 SH (100%) (0%) SL 819 819 SL (0%)
• SH/SL: Engineering Scale High/Low Gain/Bias calculation:
For correct indication on the DCS block, the Subsystem inputs have to be corrected as follows:
100 = 4096 * GAIN + BIAS 0 = 819* GAIN + BIAS
Therefore, GAIN = 100 / (4096 - 819) = 0.030516 BIAS = -(0.030516 * 819) = -24.9924
3.13.5 Access in case of Analog output to the subsystem
The subsystem data can be output to the subsystem as a manipulated output vale (MV) of the regulatory block just like with the analog output module by specifying the data in the format %WWnnnn and assigning it to the output terminal of a regulatory block.
TAG_2
MLD
%WW0033
OUT
Subsystem[Analog Output]
16 Bit Data
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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In this case, the function block performs the conversion according to the following equation for the communication output data. This is referred to as the communication output conversion:
MV(Subsys.) = (MV(fcs) – BIAS) / GAIN Where, MV(Subsys) = value to be set in the subsystem MV(fcs) = value output from the function block (the MV value of the function block) GAIN = gain for data conversion (7 digits including sign and decimal ,1.000 as the default) BIAS = bias for data conversion (7 digits including sign and decimal , 0.000 as the default)
3.13.6 Access in cases of discrete input and output to and from the subsystem
The subsystem data is specified in the format %WBnnnnbb, as each word of (16 bits) can be assigned to discrete inputs or discrete outputs. I/O number identifies the subsystem data. The DI number is the I/O number for discrete input and DO number is the I/O number for discrete output. In this case, MSB (Most significant bit) corresponds to the smaller DI or DO number and LSB (Least significant bit) corresponds to the larger DI or DO number.
In some cases, depending on the subsystem, this correlation is reversed. Because of this, it is possible to set LSB and MSB reversal via communication IO builder.
If bit reversal is specified in the communication IO builder, when the data obtained via communication is stored in the communication IO data storage area, the order of data reverses in 16-bit units so that at the connection destination, what was the MSB becomes the LSB. The figure below illustrates bit reversal:
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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4 Sub-Systems used in the Project. Sub-systems in the “DCS & ESD SYSTEMS FOR PQA PTA PROJECT” are listed below along with their slave addresses.
Baud Rate: 19200 bps.
SUBSYSTEM SLAVE
ADDRESSPackage Package Name TBA TBA 1 TBA TBA 2 TBA TBA 3 TBA TBA 4 TBA TBA 5 TBA TBA 6 TBA TBA 7 TBA TBA 8 TBA TBA 9 TBA TBA 10 TBA TBA 11 TBA TBA 12 TBA TBA 13 TBA TBA 14 TBA TBA 15 TBA TBA 16 TBA TBA 17 TBA TBA 18 TBA TBA 19 TBA TBA 20 TBA TBA 21 TBA TBA 22 TBA TBA 23 TBA TBA 24
Note: The subsystem package list is to be furnished by the client.
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FUNCTIONAL DESIGN SPECIFICATION FOR SUB-SYSTEM COMMUNICATION
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Proj Doc No : AU2103-K06-006 YIL Document No.: MP17-DS1-SCS
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5 Sub-System Mapping Format The Sub-System Vendor has to provide the sub-system tags database as per the following sample format for mapping in DCS:
SL. No.
PLC Tag
Description
Subsystem (PLC) Range
Engg Unit
(PLC)
DCS Tag No.
DCS Range
Engg Unit
(DCS)
Data Type
Subsystem.
station No.
Subsystem
Address
Bit Reversal
LO HI LO HI
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