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Summary of Contents for YOKOGAWA ProSafe-COM
- Page 1 System Overview ProSafe-COM Technical ProSafe-COM 3.00 Information TI48J01A00-00E-N Yokogawa Europe Solutions B.V. TI48J01A00-00E-N © Copyright 2010 PO Box 163, 3800 AD, Amersfoort, The Netherlands Tel: (31) 88-464 1000 Fax: (31) 88-464 1111 4th Edition Oct 2010...
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Page 2: Table Of Contents
Engineering ........................... 42 Commissioning, test and maintenance ..................43 I/O emulation tool ..........................45 EmuTool ............................45 Appendix A: Integrating DCS and ProSafe-COM..................46 Abbreviations ............................... 48 Glossary............................... 49 All Rights Reserved. © Copyright Yokogawa Europe Solutions B.V. TI48J01A00-00E Oct 2010... - Page 3 Figure 19: ProSafe-PLC: M-NET, MBX module and CCM modules ............28 Figure 20: ProSafe-SLS: Safety system and matrix panel connections............28 Figure 21: ProSafe-COM as Modbus master in a network with Modbus slaves ......... 29 Figure 22: ProSafe-COM as Modbus/TCP master in a network with Modbus/TCP slaves ......29 Figure 23: Interfacing ProSafe-COM ......................
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Page 4: Preface
Preface Company profile A part of Yokogawa company is active in the field of design and engineering of control and safety systems. The products are worldwide used as emergency shutdown, process shutdown or fire & gas systems in oil and gas exploration, petrochemical and nuclear industries. -
Page 5: About This Manual
Note This System overview describes the maximally possible configurations of ProSafe-COM and the ProSafe safety systems. However, in practice ProSafe-COM and the ProSafe safety systems do not need to have all components described. All Rights Reserved. © Copyright Yokogawa Europe Solutions B.V. - Page 6 The ProSafe-COM Installation, Test & Maintenance manual provides information for hardware and software installation, for maintenance and for trouble shooting. Ordering information The ProSafe-COM 3.0 system documentation can be obtained from any Yokogawa Europe Solutions BV Sales & Marketing department using the volume title and document number: •...
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Page 7: An Introduction To Prosafe-Com
The ProSafe family can be divided into systems with the following functions: • Safeguarding • Communication • Supervising ProSafe-COM ProSafe-RS Figure 1: The ProSafe family members All Rights Reserved. © Copyright Yokogawa Europe Solutions B.V. TI48J01A00-00E Oct 2010... - Page 8 • from ProSafe safety system to ProSafe-COM, and further up to supervisory systems • from supervisory systems down to ProSafe-COM, and further down to the ProSafe safety system The basic function of ProSafe-COM is communication. In addition to this, ProSafe-COM can store events (SOE = sequence of event recorder) and perform logical operations.
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Page 9: Modcom / Mulcom Versus Prosafe-Com
Figure 2: Example of an operator screen on a CENTUM CS3000 1.2 MODCOM / MULCOM versus ProSafe-COM ProSafe-COM supersedes two earlier versions: MODCOM and MULCOM. MODCOM is realised on a DOS platform and the DCS interface is based on the Modbus RTU protocol. -
Page 10: Prosafe-Com Context
OPC runs over TCP/IP Ethernet. Both Data Access and Alarm and Events are supported by the ProSafe-COM OPC servers. ProSafe-COM has up to 10 serial lines that can be used for Modbus communication with DCS or SCADA systems other than CENTUM. For example, Yokogawa’s FAST/TOOLS can provide a SCADA solution. -
Page 11: Figure 4: Prosafe-Plc
ProSafe-COM SET can also be used for remote first-line maintenance, remote control and remote software upgrading of ProSafe-COM. COM SET can be connected to ProSafe-COM via a serial Modbus connection or via a network connection that supports TCP (Modbus/TCP support). -
Page 12: Figure 5: Prosafe-Rs
If required, various other systems can be connected. For example, PLCs other than the ProSafe-PLC can be connected via a serial link. ProSafe-COM can act as a Modbus master station on these serial links. Other equipment can also be connected via the Ethernet link using the Modbus master capability via Modbus/ TCP. -
Page 13: Prosafe-Com And Centum
ProSafe-COM is the central communication link between the ProSafe safety system and other systems. When used with a CENTUM, ProSafe-COM and the ProSafe safety system present itself as one unit. This unit is called a ProSafe Safety Control Station (SCS). The CENTUM is also connected to a Field Control Station (FCS). -
Page 14: Functions Overview
So selections can be made by means of groups of tags. Logical operations ProSafe-COM has the ability to execute non-safety logic. This facility, for example, can be used to provide a cost-effective solution for the implementation of an operator matrix panel. -
Page 15: Hardware Overview
ProSafe-COM is scalable in hardware and software functionality and can easily be tailored according the project’s needs. Status acquisition and event recording are just the two basic facilities. All other ProSafe-COM functionality is based on these two features. Figure 8 gives an overview of the possible functionality. -
Page 16: Interface Overview
System Overview ProSafe-COM 3.00 16 of 49 1.7 Interface overview To communicate with the ProSafe safety system and for external communication, ProSafe-COM has the following interface possibilities: • Printer (maximally 1) • User interface (keyboard / VDU / mouse / LEDs) •... - Page 17 17 of 49 User interface ProSafe-COM can be used without user interface (VDU / keyboard / mouse). The user interface then consists of LEDs on various modules. LEDs give a quick indication of the status and functioning of the system.
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Page 18: Prosafe-Com Functions
18 of 49 ProSafe-COM functions 2.1 Basic function The basic function of ProSafe-COM is to exchange data. The term data covers both events and tag status information. Events are signal changes with the changing time. Events inform about what has happened sequentially. -
Page 19: Status Acquisition
In a DCS system an operator can get status information of the actual situation of the ProSafe safety system. ProSafe-COM retrieves the status of the ProSafe safety system, and sends it to a CS3000 / VP when requested. Event information (time-stamped status changes) is automatically sent to the CS3000 / VP. -
Page 20: Sequence Of Events Recording
ProSafe-COM maintains an event list in memory. All ProSafe safety system events are kept and sorted on time stamp. This list can be printed or made available to the process engineers for thorough process investigations or analysis of process shutdown sequences. -
Page 21: Configuring Prosafe-Com
The latter is more secure and has more possibilities. The logic file of ProSafe-COM can be configured to automatically end overrides after a certain time or in case of a certain condition. The logic file can also limit the number of overrides that can occur simultaneously. -
Page 22: Figure 14: Tag Definition
Moreover, the configuration file defines exactly what the scan rates will be for each PLC (network tuning). Tag file The communication of ProSafe-COM with other systems is based on tags. A tag is a name for a process variable (a status in the ProSafe safety system). ProSafe-COM... -
Page 23: Figure 15: Communication With Tags
Tags can be read but they can also be written (depending on the accessibility attribute in the tag file). A DCS or other external equipment can force the status of a certain tag, or group of tags. ProSafe-COM directly communicates with the appropriate modules via the M-BUS/M-NET, Y-net or Modbus links and sets the outputs of the modules. -
Page 24: Figure 16: Tag File And Event Filtering
Figure 16: Tag file and event filtering Logic program file ProSafe-COM has the ability to execute a logic program, just like a PLC. It reads inputs, performs logic (an application program) and writes outputs. The inputs can be virtually anything. For example the status... -
Page 25: Prosafe-Com Hardware
ProSafe-COM hardware 3.1 Hardware concept ProSafe-COM comes as an industrial PC with flash disk. Use of a desktop PC is not recommended due to worse specifications and short PC’s life cycle. ProSafe-COM can easily be expanded with additional modules to fit any client’s specification. An extensive set of modules is available, ranging from various types of I/ O boards to various interface boards. -
Page 26: Main Board
3.4 V-net interface board The V-net interface board is used to enable communication between the CENTUM CS3000 / VP system and the ProSafe-COM. V-net is a token-bus network and forms the backbone of the CENTUM CS3000 / VP DCS. 3.5 M-BUS/M-NET interface board The M-BUS/M-NET interface is used for communication between ProSafe-COM and ProSafe-PLC. -
Page 27: Prosafe-Com And Prosafe Safety System Modules
Because the functioning of ProSafe-COM strongly depends on these modules, these modules are discussed in this System overview. Note however that these modules are not part of ProSafe-COM itself. ProSafe-COM directly communicates with the following modules in the ProSafe safety system:... -
Page 28: Figure 19: Prosafe-Plc: M-Net, Mbx Module And Ccm Modules
The Critical Control Module (CCM) is the Central Processing Unit of the ProSafe-PLC. It communicates with ProSafe-COM via M-BUS or M-NET. The CCM module performs the actual control in the ProSafe-PLC. Through the PLC I/O modules, it retrieves values from the inputs and sends appropriate signals to the outputs. -
Page 29: Figure 21: Prosafe-Com As Modbus Master In A Network With Modbus Slaves
System Overview ProSafe-COM 3.00 29 of 49 ProSafe-COM Figure 21: ProSafe-COM as Modbus master in a network with Modbus slaves ProSafe-COM Figure 22: ProSafe-COM as Modbus/TCP master in a network with Modbus/TCP slaves All Rights Reserved. © Copyright Yokogawa Europe Solutions B.V. -
Page 30: Prosafe-Com Interfaces
4.1 Access to status map and event list The ProSafe-COM interfaces give access to the status map and event list in ProSafe-COM. Statuses and events can be viewed. Statuses of ProSafe-COM outputs can also be changed, e.g. in case of overrides. Figure 23: Interfacing ProSafe-COM This chapter describes the interfacing of ProSafe-COM. -
Page 31: Printer
Error messages can easily be interpreted and help an operator, engineer or service personnel with fixing problems. • The printer is a local printer, directly connected to ProSafe-COM’s parallel port or to the parallel port of another computer in the network. Only line printers are supported. -
Page 32: M-Bus/M-Net Interface
(e.g. for operator’s display updates and override signals) • V-net/IP has the same characteristics as V-net, but then on a Gigabit Ethernet network 4.5 M-BUS/M-NET interface Function The M-BUS/M-NET interface enables data exchange between ProSafe-COM and the data acquisition modules within ProSafe-PLC. Hardware provisions M-BUS The M-BUS can be extended up to a maximum of 18 meters, across up to 4 Modulracks. -
Page 33: Serial Interfaces
• Supported protocol: Modbus RTU. A serial interface using a Modbus RTU protocol can be used to: - communicate with DCS systems other than CENTUM CS3000 / VP (ProSafe-COM is Modbus slave) - communicate with COM SET for configuring and monitoring (ProSafe-COM is Modbus slave) -
Page 34: Y-Net Interface
System Overview ProSafe-COM 3.00 34 of 49 4.8 Y-net interface Function The Y-net interface enables data exchange between ProSafe-COM and the data acquisition modules within ProSafe-SLS. Furthermore the matrix panel controllers can be connected to the same network. Hardware provisions Y-net The Y-net can support up to 120 I/O modules. -
Page 35: Functions And Hardware Design
The scan time of the ProSafe-COM scanning the ProSafe-PLC systems can be configured to be different for each CCM. Typically the scan time of the ProSafe-COM is equal or greater than the scan-time of each CCM connected. A scan yields a list of changed tags. ProSafe-COM only retrieves status of changed tags to achieve quick access and low network load. -
Page 36: Prosafe-Plc Event Storage
The SOE_REC block stores the events in a circular buffer of its own: a string array variable configured as an input of the SOE_REC block. This string array is read by the ProSafe-COM. After all events have been read the array is cleared. ProSafe-COM Figure 25: ProSafe-PLC event list concept All Rights Reserved. -
Page 37: Prosafe-Plc Forcing Statuses
The Fail-safe enable is typically connected to an input channel of a CDM. This input will typically be linked to logic in the CCM (basically a logical AND gate) to which also the override output from the ProSafe-COM is connected (originating from external communication lines) The CCM is connected to the M-BUS and receives write commands from the ProSafe-COM. -
Page 38: Prosafe-Sls Event Storage
System Overview ProSafe-COM 3.00 38 of 49 The scan time of the ProSafe-COM scanning each Y-net module can be configured to be different for each module. A scan of a full network is typically performed in less than a second. -
Page 39: Redundant Configurations
V-net, OPC or Modbus interfaces. The DCS or SCADA system must decide which ProSafe-COM acts as active and which as back-up. ProSafe-COM has a special tag for redundancy control, which must be written by DCS or SCADA. -
Page 40: Time Distribution And Synchronisation
ProSafe-COM. ProSafe-COM is the time master for ProSafe-PLC and ProSafe-SLS. • When ProSafe-COM is not connected to V-net, the time master for ProSafe-COM is the DCS that is connected via Modbus. Again, ProSafe-COM is the time master for ProSafe-PLC and ProSafe- SLS. -
Page 41: Prosafe-Sls Event Time Stamping
Realisation of the time synchronization pulse mechanism (classical way) All CCMs receive a common trigger at regular time intervals, either from ProSafe-COM or from an external source (GPS system). The resulting time stamped events enable ProSafe-COM to calculate the correction factor per CCM. -
Page 42: Prosafe-Com System Engineering Tool
ProSafe-COM System Engineering Tool 8.1 COM SET COM SET is the engineering tool for ProSafe-COM and MODCOM. COM SET is a powerful tool during engineering, commissioning, test & maintenance of ProSafe-COM. Engineering, monitoring and diagnosing ProSafe-COM can be completely done with COM SET. -
Page 43: Commissioning, Test And Maintenance
Test A ProSafe-COM system can be tested even when it is not yet fully integrated in a DCS system. Using ProSafe-COM SET and the I/O emulation all interfaces with ProSafe-COM can be tested easily and early in project development. - Page 44 Note that it is possible to assign ‘internal ProSafe-COM tags’ to the individual module statuses and to the overall ProSafe-COM status. This status can be queried by the DCS at regular time intervals and present an error indication on the DCS’s operator screen.
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Page 45: O Emulation Tool
Changes in I/O tags and event generation are invoked via the EmuTool. The EmuTool can either run on the ProSafe-COM (provided that VDU and keyboard are connected), or on another PC in the network. -
Page 46: Appendix A: Integrating Dcs And Prosafe-Com
This appendix provides a more detailed description of the way ProSafe-COM communicates with other systems. This appendix is especially useful for the engineer of the DCS system. The communication between DCS system and ProSafe-COM can easily be configured by exporting to, or importing from, the tag file. - Page 47 CENTUM CS3000 / VP. This makes it easy to guard the integrity of tag names used in ProSafe-COM and the CENTUM CS3000 / It is strongly recommended to use the same names for identical entities as much as possible. This applies to both naming within the tag file as to naming across the various systems.
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Page 48: Abbreviations
ProSafe Safety Control Station Sequence of Event Recorder V-net CENTUM CS3000 / VP proprietary network V-net/IP CENTUM CS3000 / VP proprietary network based on Gigabit Ethernet Y-net ProSafe-SLS proprietary communication network All Rights Reserved. © Copyright Yokogawa Europe Solutions B.V. TI48J01A00-00E Oct 2010... -
Page 49: Glossary
Status Specific situation value in a system or in software. A status can be read and written. Identification of a process variable. A tag consists of a ProSafe-COM name, a physical address and 1 up to 5 logical addresses. Y-net Proprietary RS-485 network for the communication between ProSafe-COM and ProSafe-SLS.
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