ECS-1200 Distributed Control System

Product Line Technical Specifications

Leading the World in DCS Technology

Version 1.1 April 2004

Control System
A powerful, yet scalable system, with superior reliability and flexibility, the ECS-1200 distributed control system (manufactured by HFControls Corporation) is the result of more than five decades of innovation and manufacturing of control systems in hundreds of installations around the world. With scalable architecture to match any size control requirement, each system provides complete, fully integrated network and system control solutions in any application or industrial setting. Encompassing an extensive selection of I/O cards for the simplest to the most complex operations, the ECS1200 control system is fully redundant for confident operation during critical control conditions. Linked through a high-speed, open architecture network, the advanced microprocessor-based control system can perform all sequential and modulating control functions including plantwide data acquisition, monitoring, and display functions with superior integrity and maximum data throughput. With the open architecture network, connection of foreign devices and third-party software applications is easily achieved. Reduced integration time and hardware costs eliminate communications cables and dramatically improve configuration flexibility and maintenance facility. HFC provides a full complement of system engineering and programming services. In addition to the advanced control and monitoring software packages, HFC applications engineers can uniquely configure each control system to significantly improve plant efficiency and profitability. The system can provide a diversity of field interfaces ranging from 420ma analog input modules to remote fieldbus devices. With modular design to allow easy system expansion plus the downward compatibility of features to legacy systems, the end users investment is protected as the system evolves to meet the changing needs of the process. HFCs ISO-registered quality program meets the most rigorous quality requirements. Coupled with full Verification and Validation for software development and rigorous integration testing, the HFC control system is a safe, reliable, and performance-oriented control system with unsurpassed capability. ECS-1200 Reference Installations Power Generation - Thermal Power Generation - Recovery Boiler Control - Burner Management - Steam Generation - Combined Cycle Unit Control - Turbine Control - Total Plant Control - Nuclear Safety Monitoring and Protection Control Industrial - Pulp and Paper Manufacturing - Food Manufacturing - Cement Processing - Chemical Processing - Iron and Steel Production - Coal Handling - General Process Control - Petrochemical Process Control Water Treatment - Freshwater and Wastewater treatment - Feedwater - Desalination - Incinerator - Desulfurization Process Control

Technical innovation, quality products, and excellent customer service have been important trademarks at HFC. We are committed to supplying you with proven, reliable control systems designed in accordance with your needs and specifications, delivered on time at competitive prices. We look forward to working with you to fulfill your process control and automation needs.

A Division of Doosan Heavy Industries & Construction Co. Copyright 2000-2002 HFControls Corporation All rights reserved HFControls Corporation 16650 Westgrove Dr. Suite 500 Addison, TX 75001 USA Toll Free: 866.501.9954 Phone: 972.367.4600 Fax: 972.367.4699 www.HFControls.com customer.care@hfcontrols.com

Communications Network Open architecture coupled with high intensity subsystem links provides an integrated, secure network capable of transmitting thousands of variables per second. To optimize plant production, open architecture allows intelligent, supervisory information and control systems to be located on the network. Control system performance can be continuously tuned without operator intervention. The system architecture allows the addition of new devices to the network without compromising the integrity of the control system. Benefits of open architecture networks include the elimination of various hardware, shortened setup times, reduction in errors often incurred with hardware setup, and improved performance as a result of improved communications between devices. These benefits all translate to a substantial hardware cost savings and more efficient plant control and monitoring system. Local Area Network The 100MB/sec local area network (ECS LAN) is the backbone of the entire information system network. Control systems can communicate on the same network as the customers individual PCs. If necessary, a user can access the control system by remotely connecting to the ECS LAN through an offsite PC. The ECS-1200 control system can be connected to other manufacturers computers and control systems through the use of standard Ethernet LAN and TCP/IP links. Additional interface links to other automation and information systems via Modbus, HART, and Fieldbus are also available. Communications Link The redundant 10 MB/sec, communications link (C-link) ties the communications controllers together. The C-link is continuously checked to prevent system degradation or data loss.

The ECS-1200 distributed control system consists of five major components: Multifunction Controllers, Input/Output (I/O) modules, Applications Software, Industry Standard Communication Networks, and the Advanced Operator Interface Workstations. These components combine to deliver an exceptional process automation solution that not only optimizes plant performance and efficiency, but also is an extension of managements daily decision making tools. Controllers Because scalability is necessary for both small and large systems, HFC offers a variety of controllers that can be intermixed throughout the system to optimize system configuration. With advanced, powerful digital and analog central algorithms, the multifunction controllers can be configured online or offline using a programming utility incorporating simple function blocks for control applications. I/O Modules The control system I/O modules are comprised of a complete family of digital and analog input and output boards. The I/O modules provide a host of advanced technological features offering a secure and dependable interface to field devices. The intelligent I/O supports a multitude of features such as built-in continuity monitoring, motive power, and status feedback for complete plant control and monitoring functions. Other significant features include separate power monitoring, independent manual reset switches, jumperselectable I/O link addresses, and a self-configuring baud rate. Sophisticated diagnostics provide operators with a virtual extension of their senses into the heart of the operation. In addition to the vast array of standard analog and digital I/O modules, specific functions such as thermocouple and sequence of events monitoring, HSIMs (High-Speed Interface Modules), and pulse input-output are available for specialized control and monitoring functions. Control Room Three workstation configurations make up the components of the control room. Efficient plant operation is easily achieved through Microsoft Windows 2000 based workstations: the operator workstation, the engineering workstation, and the historical archiving system. With the Windows 2000 environment, all workstations support interactive color displays, multi-window displays, and a standard library of symbols to allow complete customization. To provide a real-time interactive environment, the control room workstation displays are updated with current values at a rate of once per second. Workstations are connected to the system through industry-standard communication protocols, allowing access to any database point in the system. Each system can be connected to other computers and control systems on the network through the use of a standard Ethernet LAN and TCP/IP link.

I/O Modules

Communications Network

Controllers Applications Software Control Room

The ECS-1200 control system is the result of combining field proven hardware, enhanced network security, and human machine interface (HMI) software to deliver superior optimization and control with exceptional reliability.

Any communications error stays local and does not impact the whole system. Multiple layers allow different media to be located on separate layers, while frequent error checking helps ensure data integrity. Input/Output Interface Link The input/output interface (IOIF) link allows I/O modules to communicate with control modules. The IOIF link can manage up to 8 I/O links (each link can have up to 32 I/O modules). The link is composed of 10-conductor ribbon cable for short distances, and 62.5micron fiber-optic for longer distances. Gateway The gateway connects the C-Link and the LAN to create an advanced intranet, allowing all control system functions to be accessed by the LAN network.

Applications Software HFC incorporates an innovative approach to software design and integration services that allow information obtained from local and remote I/O, data links to other devices, or output variables from controls strategies to be shared by other software applications and devices. Implementing changes to the system logic as well as customizing logic for a specific application is simple and does not require specific programming knowledge or software training. A built-in programmable feature also allows construction of the control system before operational logic is completed, minimizing the cost of field logic changes. These design tools along with the industry standard hardware and open architecture communications result in a high-speed, reliable, and fully integrated system that is capable of meeting any process control requirements. Communications Network The HFC communications network is the most flexible network available today. The network accepts all systems and devices including PLC and CEMS, and can support commercial software in addition to HFC software. The redundant communications links between the controllers provide exceptional data integrity and stability. The redundant 10Mb/sec C-link allows the connection of multiple controller units and distributed control is supported through high-speed fiber optic links to form an extremely well designed and reliable communications network. For interface with our advanced CRT operator and engineering workstations, high-speed, open architecture technology provides a 100Mb/sec TCP/IP local area network (LAN). Communications gateways and hubs enable easy connection to multiple workstations as well as allow access to plant control operation from offsite locations.

Communications Input-Output Interface IO/IF C-link Proprietary Protocol

Features High-speed data transfer rate Repeaters can provide connections greater than 1km in distance Connection of up to 32 I/O modules on one link 10MB/sec high-speed data transfer via thinnet, fiber optic, or CAT5 Fiber optic cables provide electrical isolation from ground faults CAT5 connections provide better signal reliability, current hardware technology, and reduced interference Continuously checked to prevent system degradation or data loss Any communications error stays local and does not impact the whole system Multiple layers allow different media to be located on separate layers, while frequent error checking helps ensure data integrity. 100MB/sec CAT5 connections Open architecture coupled with high intensity subsystem links provides an integrated, secure network capable of transmitting thousands of variables per second. Allows intelligent, supervisory information and control systems to be located on the network. Redundant configuration maximizes plant control and monitoring operability Control system performance can be continuously tuned without operator intervention.

Control Room LAN

ECS-1200 Distributed Control System

EWS Engineering Workstation Printer Remote Access PC OWS Operator Workstation Printer HAS Historical Archiving Station Printer

Redundant 100MBps TCP/IP Super Data Highway High-speed Local Area Network

Redundant 10Mbps Communications Link (C-Link)

To Customer Computers and Other Devices PLC Gateway TCP/IP Device Gateway Supervisor Device WAN

Control Room Each control room component is an industry standard workstation that places plant operations and engineering staff in touch with the plant process. A graphic display package uses various color codes, text messages, and numeric values to indicate current plant conditions. For enhanced safety, graphic displays provide the operator with immediate indications of alarm conditions and rapid access to the display window the operator needs to remedy the situation. Video trends display continuous graphs for system variables over a user-specified time period and sampling frequency. Operator Workstation Operator workstations can be configured with a variety of monitors for enhanced system display. Advanced interface is available through high-resolution touch screen monitors and mouse. The graphics software package includes standardized system graphics that illustrate the overall system status, and process graphics that depict the process and the field equipment under control. The operator uses these displays to control plant functions and monitor system status. A zooming function automatically scales the contents of a display graphic to allow close examination of process parameters. Three-dimensional images can be constructed to realistically portray plant equipment. Graphic files from an existing library or archive can be imported and dynamically translated to enhance equipment diagnostics and provide comprehensive maintenance information. Optional third party HMI software packages also operate on the operator workstation.

Engineering Workstation The engineering workstation allows creation of the software database for a new control system, generate a new control application, edit existing applications, or troubleshoot any component of the control system. Powered with the innovative ONE-STEP software development tool, the engineering workstation is capable of complete control system configuration and tuning functions to maximize plant efficiency. Plant engineers can define a control loop algorithm in the form of a schematic; the ONE-STEP applications editor then translates that schematic into a binary formatted file that can be downloaded directly onto the application firmware on a loop controller. Among the various output files that the ONE-STEP applications editor can generate are diagnostic reports and error reports that contain detailed configuration parameters and critical debug information, which aid in the analysis and troubleshooting of application firmware. Historical Archiving System The historical archiving system (HAS) builds a historical archive of the system status (up to 5,000 real and calculated variables) with a time stamp for each entry. With the HAS software, data is made available for short-term and long-term reports, trending, analysis, and for computing plant performance parameters. The software uses Microsoft Excel as the interface for creating a scan table of monitored points. A Dynamic Database (DDB) program within the system obtains data in real-time from each operating controller. The HAS can also be configured to accommodate third party software such as SQL Server and OSI PI.

PCS#1

PCS#2

PCS#3

PCS#N

ECS-1200 Control System Features Open architecture permits communication with virtually any external host system or existing distributed control system (DCS) Redundant architecture of critical components ensures that no single-point failure can prevent the system from assuming a fail-safe state Modular design permits linking multiple controllers within a single system on a common local area network (LAN) Input/output (I/O) modules include onboard microprocessors and signal conditioning hardware Supports a sequence of events (SOE) logger utility that provides a maximum resolution of 100 microseconds over a 24hour interval for selected events Configurable control operation for fail-inplace and fail-safe control operation Continuously checked redundant fiber optic communication channels prevent system degradation or data loss

Redundant 10Mbps Communications Link (C-link)

Input-Output Interface Redundant (IOIF)

Foreign Device Interface (Serial, MODBUS)

Workstation Operator Workstation

Features High-resolution, flat display touch screen monitors Specialized Flat Panel OIS in rack mount configuration available Available interface to third party HMI software packages Operator Workstation Minimum Specifications: o 19 or larger multiple scan monitor (touch screen optional) o Intel Pentium/Pentium II, 128MB DRAM, 4GB HD, CD-ROM, Floppy o 10/100BaseT Fast Ethernet LAN card (or equivalent LAN board) o AGP slot graphic card o Microsoft Windows 2000 OS with Antivirus software Pentium processor technology delivers supreme performance User-friendly Design, Development, and Documentation Tools ONE-STEP graphical applications improve plant operation efficiency Engineering Workstation Minimum Specifications: o 17 or larger multiple scan monitor o Intel Pentium II, 128MB DRAM, 4GB HD, CD-ROM, Floppy o 10/100BaseT Fast Ethernet LAN card (or equivalent LAN board) o AGP slot graphic card o Microsoft Windows 2000 OS with Antivirus software Integrated tools provide viewing, sorting and data analysis Advanced RAID disk array maximizes data storage capacity Configurable with third party software applications Historical Archiving System Minimum Specifications: o 17 or larger multiple scan monitor o Intel Pentium II, 128MB DRAM, 4GB HD, CD-ROM, Floppy o 10/100BaseT Fast Ethernet LAN card (or equivalent LAN board) o 2 GB internal JAZ drive and one disk pack, AGP slot graphic card o Microsoft Windows 2000 OS with Antivirus software

IOR#1 Engineering Workstation

IOR#8 Historical Archiving System

Field Devices

ECS-07 Control System

EWS Engineering Workstation Printer Remote Access PC OWS Operator Workstation Printer HAS Historical Archiving Station Printer

100MBps TCP/IP Super Data Highway High-speed Local Area Network

HUB

HUB

To Customer Computers and Other Devices PLC Gateway TCP/IP Device Gateway Supervisor Device

PCS#1

PCS#2

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PCS#N

ECS-07 Control System Features Applications Software The ECS-1200 applications software library contains functional analog and digital algorithms designed for process control. A modular, high-level control application editor includes predefined control functions and also supports customized solutions to meet plant needs. The editors are based on the Microsoft Windows operating system. A simulation mode is available for employee training and system testing purposes. Analog and Digital Technologies The ECS-1200 supports the most advanced synergy of regulatory and discrete control available. For example, the variable gain of an analog controller can be scaled directly from digital logic based on whether or not equipment is in service. Similarly, an analog value can be compared with a setpoint to produce a permissive signal for starting a pump with the digital control logic. Complex control is accomplished and represented with ease. Function Blocks Analog applications are constructed from predefined analog algorithms called function blocks. Various blocks are then linked together to produce the composite algorithm for the process, and the resulting output controls the AO channel to the field device. The anti-windup feature in the control blocks provides bumpless transfers when control or operating modes are switched. Because this protection has been built into the block algorithms, the user is not required to setup external feedback and tracking schemes to prevent controller windup. ONE-STEP The ONE-STEP graphical configuration software package enables the use of AUTO_CAD for complete control system configuration. This graphical, icon-based system configuration tool translates CAD drawings and compiles function blocks into executable code. Plant engineers can create and modify control logic application codes of a loop controller in a completely graphical based programming environment. System configuration and maintenance are extremely user-friendly allowing minimal operator intervention and manual configuration. ONE-STEP can create a dynamic data image of a CAD drawing related to the logic inputs and outputs, all while operating online with the loop controller. The data image can be outputted to a high-resolution workstation monitor providing an interactive analysis tool for use by operations staff. Plant-wide TCP/IP 100Mbps open architecture protocol. TCP/IP is highly supportable, with abundant hardware and software support, flexible open architecture Remote I/O is networked via a "star" configuration, assuring that if one remote I/O location fails, it will not disrupt other ongoing processes The ECS-07 uses the same programming tools as a regular ECS-05 multifunction controller and can also drive CRT graphics for enhanced process monitoring The ECS-07 and Q-series I/O module hardware is rugged and easily replaceable at very reasonable cost Available Fiber Optic Transceivers also provide 100Mbps data transfer rates up to distances of 2km (full duplex cabling) TCP/IP plant wide protocol excludes the need for Control Room Gateways, since the ECS-07 connects directly to Control Room workstations through the existing high-speed data highway

Redundant 100Mbps Communications Link

ECS-07

TCP/IP Communications

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Field Devices

Controllers
A high performance Pentium processor can be found at the heart of every ECS-1200 controller. In addition to the advanced CPU, high-speed sequence control and continuous control can be achieved on the same controller, improving handling capacity and speed. For even more fail-safe control functions, HFC offers an optional redundant configuration on all controllers, allowing bumpless transfer of control during any situation for maximizing plant uptime. Each controller also incorporates self-diagnostics on startup and during execution resulting in outstanding reliability. HFC offers the following controllers designed to meet your process control needs: ECS SBC-05 The ECS multifunction controller combines integrated digital and continuous control logic to control an entire system. It can be configured either on or offline using a function-block programming utility. Full access to logic programs, database, and system diagnostics is available online. In full compliance with NFPA criteria, safety system logic functions can be programmed into the nonvolatile flash memory on the ECS05 controllers to preclude any online changes that might cause system disruption. The ECS-05 also has configurable control operation for fail-in-place and failsafe control modes. ECS-06 The ECS-06 Single Board Controller provides complete control function in a compact package. It resides in the same rack assembly with Q-series I/O cards, connects directly to the ECS-1200 Communication Link and can communicate with a variety of external devices. Two serial communication ports can each be connected with up to 32 Q-series I/O cards for a maximum of 64 cards. The Single Board Controller includes redundant connections to the Communication Link and consequently permits direct connection to the high-speed fiber optic data highway. HFC Applications Software resides in the firmware and a dual-ported memory array provides 8Mb of data storage. ECS-07 For small control applications, the ECS-07 controller provides efficient control functions from a remote location. Residing in a standard rack assembly, it features a high-speed embedded processor and multiple communications links which allow direct connection to the high-speed TCP/IP communications network. The ECS-07 delivers enhanced control and monitoring operation with the added flexibility of remote diagnostic facilities. Integrated digital and analog control algorithms provide simple, yet complete plant control solutions for many processes. The ECS-07 also has an additional built-in feature allowing exceptional simulation and control capability that significantly optimizes plant operation and efficiency.

I/O Modules Featuring onboard microprocessors and memory arrays, the ECS-1200 I/O modules are remarkably intelligent. The advanced microprocessors prevent system failure by providing internal fault detection through redundant communications links. Memory, calibration, and communications status are continuously checked and critical diagnostic information about each I/O modules functionality and field device integrity are relayed back to the controller, available for plant operations personnel. This important feature results in speedier resolution of plant process control problems within the system and in the field. Redundant power supplied to each I/O module is diode auctioneered, which maximizes uptime. The onboard regulation of logic power minimizes power dissipation, which enables each process to stay operational even through line losses or momentary power fluctuations.

The I/O modules also feature onboard signal conversion, which permits direct connection to field equipment with a wide range of electrical characteristics. This feature eliminates the need for external interposing relays or other signal conditioning hardware, reducing the overall cost of the control system. Link integrity between controller and I/O is heightened by watchdog timers and sophisticated firmware in the microprocessor. The I/O modules can be configured to predetermined failure modes to protect precious plant assets. Data integrity is completely assured with unique error-checking and communication subroutines. Heavyduty card-edge bezels provide direct connection to field wiring simplifying both system installation and post installation troubleshooting. In addition, all outputs are individually fused and surge suppressed (meeting or exceeding IEEE 472-1972 (ANSI C37.90)) including the main fuse on the loop power input.

I/O Modules ECS-Q102B Analog Output Module 8-channel

Features 100 ms polling cycle for digital image to analog conversion Transparent latch with tri-state output ports isolates the data input ports of the DAC chips from the digital bus, reducing ringing and cross talk. Can be strapped to hold: Last State, Board Failure-Failsafe, Controller Failure-Failsafe for reliability and effortless customization Jumper-selectable thermocouple type, fail up or fail down feature A/D conversion time of only 25 microseconds 90% calibration voltage allows the board to automatically compensate for gain error drift; on-board thermocouple linearization Each TCI channel has associated protection circuitry including: R-F chokes (which limit induced radio noise), Energy absorbing zener diodes, Bipolar low-pass filters Onboard RTD linearization and auto zero functions 90% calibration voltage allows compensation for gain error drift Conversion is performed every 50 milliseconds on all eight input points Each RTD channel has associated protection circuitry including: Energy absorbing zener diodes, Terminals for the RTD signal and its shield, Input protection, Low-pass filters Programmable tuning parameters to detect error conditions Pushbutton RESET switch and series of jumper nodes configures the input interface Firmware verifies that the pulse repetition rate and the pulse duration are within limits supplied by the tuning parameters Common or isolated AC or DC operation Common voltages are isolated from logic power Photo couplers isolate the excitation voltage on the input channels from the logic power LEDs aid troubleshooting; a voltage is used to compare field voltages with the LED status SOE or HSIM functionality, jumper configurable Status of the digital inputs can be transferred to the ECS-Q136 (digital output) board in approximately 2 milliseconds RAM memory can store up to 3000 events Sequence of events can be resolved to 1 millisecond Common voltages are isolated from logic power Additional signal conditioning provides over-range detection and filters output ripple from isolation amplifier, providing unity gain buffering and low-impedance input to the analogto-digital (A/D) converter Isolated inputs allow devices with different ground potentials to interact Microprocessor provides a modular core for processing interrupts and exception conditions High-speed serial isolation of digital data Duplicates the on/off pattern of the 16 digital inputs that it receives from its mated digital input (DI) ECS-Q134 board Properly turns on and off its outputs based on the status of the data received. Sixteen photo couplers isolate the excitation voltage on input channels from logic power Microprocessor can detect input changes quickly and immediately stores the input change and timer contents into RAM, providing the system with a history of events If any input changes state, the comparator output generates an interrupt signal which is sent to the microprocessor through operational amplifiers and inverters

ECS-Q111 Analog Input Module Thermocouple 8-channel

ECS-Q114 Analog Input Module RTD 8-channel ECS-Q121B Digital Pulse Input Module 4-channel ECS-Q122 Digital Input Module 16-channel ECS-Q134 Digital Input Module Sequence of Events HSIM 16-channel ECS-Q135B Analog Input Module 16-channel

Controller ECS-05 Multifunction Controller

I/O Module Support 256

Features A 16-position DIP switch controls a data word that can be used to identify separate system-specific functions An intelligent battery chip supplies emergency backup power for onboard memory Redundant serial communications ports for direct connection to the C-link Control capability of up to 64 ECS Q-series I/O modules or a total of 1024 points The HFC Single Board Controller is housed, with its associated I/O and power supplies, in a compact assembly All HFC Application Tools reside in the Single Board Controller, permitting full function control strategies Control and simulation functional capabilities allow simulation of events and tuning, optimizing plant control Advanced ALU controls up to 64 ECS Q-series I/O modules or a total of 1024 points Communications ports provide direct connection to the high-speed network and to ECS Q-series I/O or TCP/IP I/O

ECS-06 Q-series Rack-mount Controller

64

ECS-07 Industrial PC-Based Multifunction Controller

64

ECS-Q136 Digital Output Module HSIM 16-channel ECS-Q143 Digital Input Module 32-channel