Application Module

L
Specification and
Technical Data
AM03-400
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TDC 3000 Specification and

Application Module Technical Data

Introduction different Local Control Networks. single process-connected box.

This publication defines the
significant functions of the
TDC 3000 Application Module.
The Application Module is one of
the modules on the Local Control
Network (LCN). As Figure 1
indicates, it communicates with
other modules on the same or
other Local Control Networks and
with process-connected devices
on the Universal Control
Networks and Data Hiways.
Because of its position in the
system architecture, the
Application Module can accept
inputs from multiple process-
connected devices, as well as
from other modules on the
It can also provide control outputs The Application Module features
to control elements in the a full complement of control
process or to other data points in algorithms. The Control
modules on the different Local Language that executes in the
Control Networks, including itself. Application Module makes it easy
For more information on the role to develop custom point
of the Application Module in the processing and special
TDC 3000 System, refer to the algorithms. The Application
System Technical Data. Module provides full cascade
functionality between an AM
With at least one Application point and any process data point
Module present in a TDC 3000 resident in modules on different
System, more advanced LCNs.
calculations and control strategies
can be implemented. Each
Application Module data point can Functional Description
have multiple inputs and outputs
from many devices, and a single The relationships of the major
Application Module can handle functions of the Application
many more data points than a Module are shown in Figure 2.

Universal Stations Universal

Fiber Archive Replay Application History Plant Plant Network Work Station
Optics Module Module Module Information Module
Additional Network
LCN Modules Network Network
Gateway Gateway

LOCAL CONTROL NETWORK NO. 1 LOCAL CONTROL NETWORK NO. 2

LCN Hiway Network Network

Extenders Gateway Interface Interface
Module Module
Process
Manager UNIVERSAL
Logic
CONTROL
Manager
DATA Advanced NETWORKS
HIWAY Data Process
Advanced
Hiway Manager
Process
Boxes
Advanced Manager
Process
Manager

Remote I/O
Subsystem

Smartline 3000

11808

Figure 1 — TDC 3000 Architecture with Application Module

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Data Points
BUILT-IN
The Application Module contains CONTROL
ALGORITHMS
a process database made up of LANGUAGE
data points that the process EXECUTION
engineer builds and assigns to it
during configuration. Each data
point is a collection of fixed and
dynamic parameters that performs
a specific function and is INTERNETW0RK
identified by a point name. Data- FAST SLOW BACKGROUND
POINT
point processing can use either PROCESSOR PROCESSOR CL
PROCESSOR
preprogrammed or custom
algorithms to calculate required
information and/or initiate specific
control action.

In addition to regulatory data PROCESS DATABASE

points that represent continuous
variables in or related to the
process, the Application Module
also offers several utility data-
point types. These include the LOCAL CONTROL NETWORK
following: 11809

• Timers—provide timing Figure 2 — Application Module Functions

functions.
• Counters—process counter
inputs.
• Flags—boolean variables.
• Numeric—numeric variables.
During configuration, the user
defines the data-point name,
point type, selected algorithms (if
applicable), input sources (up to
16, from multiple sources), output
destinations (up to 8), alarm trip
points, and the processing
schedule. Other information
pertinent to the type of data point
may also be entered, or standard
default values may be used.
Data Point Scheduling
Each data point in an Application
Module is processed according to
a schedule defined by the
process engineer during
configuration. The engineer may
assign a data point to a "fast"
processor, a "slow" processor, or
an internetwork point processor,
and may choose from a variety of
time intervals from 1 second to 24
hours. The fast processor has a
higher priority, so data points
assigned to it are processed at
more regular intervals. Generally,
noncritical, low-frequency data
points are assigned to the slow
processor, so that they do not
interfere with the processing of
data points assigned to the fast
processor. The internetwork
point processor provides for
closed loop control across the
Network Gateway.
The user can also schedule data
points to be processed before or
after another data point, on
demand, or when some user-
defined process event occurs.
When a regulatory data point in an
Application Module is processed,
it goes through most or all of the
steps in the sequence shown in
Figure 3.
Regulatory Control
General Input Processing—At the
user's option, a regulatory data
point can fetch values from the
process database and update
designated parameters within the
data point before proceeding with
the remainder of its processing.
PV Processing —A regulatory
data point that uses PV
processing fetches the
designated PV inputs from a
process-connected box or
module on the Local Control
Network before executing the
specified PV algorithm (see Table
1), or custom algorithm (see the
"Custom Control" description
FUNCTIONS
• Scheduling of Data Point
Processing
• Regulatory Control
– PV Processing
– Control Processing
– Control Output
Processing
• Custom Control
– Control Language
Execution
– Custom Data Point
Processing
– Custom Data Segments
– Multipoint Strategies
(Switch Data Point)
• Alarming
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PV PROCESSING CONTROL PROCESSING

*

GENERAL INITIAL GENERAL

INPUT CONTROL OUTPUT
PROCESSING PROCESSING PROCESSING

*
PV CONTROL
INPUT INPUT *
PROCESSING PROCESSING

* *
PV SET POINT ALARM
ALGORITHM AND TARGET DISTRIBUTION
PROCESSING PROCESSING PROCESSING

*
DEVIATION
PV
ALARM
FILTERING
PROCESSING * CL Block
Insertion
* * points
PV SOURCE CONTROL
SELECTION AND ALGORITHM
RANGE CHECK PROCESSING

* *
PV CONTROL
ALARM OUTPUT
PROCESSING PROCESSING

* * 1173

Figure 3 — Processing Sequence for Regulatory Data Point

below). The PV is calculated,
checks are made to determine if
limits have been violated, and a
value status (good, bad, or
uncertain) is assigned.
Control Processing — A
regulatory data point that uses
control processing obtains the
designated control inputs from
PV processing, or elsewhere,
before executing the selected
control algorithm (see Table 2), or
custom algorithm (see "Custom
Control"). When configured to do
so, such a data point can also
store the output in other data
points in the same or another
Application Module or in some
other LCN-based module or
process-connected device.
Multiloop control schemes are
normally configured to provide
bumpless transfers from one
mode of operation to another.
Control Output Processing —
Control output processing stores
a whole value appropriate to the
units of the destination
parameter. It also accommodates
any control constraints, including
any output high/low limits, output
increment limits, and integral
high/low limits, as well as handling
initialization, mode change, and
antiwindup conditions.
Alarming — Alarms for regulatory
data points can be selected by
the user from the types of
conditions listed below. If an
alarm is detected as a data point is
processed, that event is
journaled, annunciated, and
displayed in the same way as an
alarm detected by a process-
connected device.
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• High/low deviations Table 1 — PV Algorithms Table 2 — Regulatory Control

• High/low PV Algorithms
• High high/low low PV Algorithm Name
• PV rate of change Algorithm Name
• PV significant change Null
Data Acquisition Null
Flow Compensation Auto Manual
Custom Control Middle-of-Three Selector PID With Options, Including
Hi/Lo Average Selector – GAP
In addition to the built-in PV and Summer – Nonlinear Gain
control algorithms, the engineer Multiplier/Divider – Auto-Ratio
may use the Control Language Sum of Products – Auto-Bias
(CL/AM) to define his own Variable Deadtime With PID-External Reset Feedback
algorithms and processing Lead-Lag PID-With Feedforward
routines. Control Language can Totalizer Incremental Summer
be written at a TDC 3000 General Linearization Lead/Lag
Universal Station/Universal Work Control Language PV Summer
Station, or at a personal computer Algorithm Multiplier/Divider
using an optional software Ratio
package called Workbook, that Override Selector
runs under MS-DOS/PC-DOS.™ Switch
when the segment is defined.
Programs are compiled at a Ramp Soak
Once defined, and attached to
Universal Station or Universal Control Language Control
specific data points, the custom
Work Station. Control Language Algorithms
segment data is automatically
algorithms and routines are
available for displays and other
inserted at specified points in the
functions.
Application Module processing execute in either the foreground
order. or background mode. For
Foreground and Background
CL — Control Language foreground execution, insertion
Control Language — Control points are defined where blocks
programs can be assigned to
Language is designed specifically
for the Process Engineer to use
in implementing custom control Table 3 — Control Language for the AM
schemes. This easy-to-use
language employs a variety of Data Types
general and process-oriented
statements (see Table 3 and Number Discrete (Logical, Enumeration)
Figure 4) and provides a Data Points Time
significant improvement in both Arrays Strings
security and throughput over
previous customization Statements
techniques.
set state change call
Security features include checks go to if/else send
to make sure that parameters and loop repeat end
storage destinations are valid, exit abort
and to protect against customer-
coded infinite loops. Operators
Custom Data Segments — Arithmetic -, +, *, /, mod, **
Custom Data Segments (CDS) Logic and, or, not, xor
are parts of a data point used for Relational <, +, >, <+, >+, <>
storing data that is to be used by
Control Language programs. For Functions and Subroutines
example, the name of each
parameter and its type, units, and Sin, Cos, Tan, Atan, Ln, Log 10, Exp, Sqrt
change authority are included Abs, Max, Min, Ave, Sum

™ MS-DOS and PC-DOS are Badval Set bad Allow bad

registered trademarks of Exists Now Self
Microsoft Corporation. Comm Error Date time Round Int
AM03-400
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BLOCK dual_oxy (point CAI1515;

& at pv alg)

—This block of CL code selects the higher of two recycle oxygen readings from
—dual oxygen analyzers and places that value as the PV of point CAI1515. If
—one of the analyzers is off scale, out of limits, or out of service, the
—other analyzer is selected. Also, if one of the analyzers is bad or out of
—service, the PV source for another loop in the control scheme is set to
—MANUAL.

—These statements define the variables.

local aval, bval
external AAR1515A, AAR1515B —the analyzers
external CAA1515 —the other control loop

—These statements check out Analyzer A.

if AAR1515A.PVHIFL or AAR1515A.PVLOFL or —If the limits have been violated
& badval(AAR1515A.PV) or —or the value is bad
& not (AAR1515A.PTEXECST = active) —or the analyzer not active
& then (set CAA1515.PVSOURCE = MAN; set aval = 0) —set source to manual
else set aval = AAR1515A.PV —otherwise use the PV

—These statements check out Analyzer B.

if AAR1515B.PVHIFL or AAR1515B.PVLOFL or —If the limits have been violated
& badval(AAR1515B.PV) or —or the value is bad
& not (AAR1515B.PTEXECST = active) —or the analyzer not active
& then (set CAA1515.PVSOURCE = MAN; set bval = 0) —set source to manual
else set bval = AAR1515B.PV —otherwise use the PV

—These statements select the higher analyzer reading and end the CL block.
set PVCALC = MAX (aval, bval)
end dual_oxy

Note: "—" indicates a comment line included to help in understanding the program.
All other lines are program statements.

Figure 4 — Sample Control Language Program

of CL code can be executed available. Consequently Custom Multipoint Switch

during the standard processing
sequence (see Figure 3).
Execution of a block might be
triggered by a specific event,
such as crossing an alarm
threshold or when it becomes
necessary to initialize a control
loop.
Background CL programs are
attached to a data point and
execute whenever CPU time is
background routines do not slow
down point processing
execution.
Control Language Algorithms —
The standard sets of both PV and
control algorithms have "Control
Language algorithm" as one of
the choices, making it easy for the
user to substitute his own
algorithm in the standard point-
processing scheme.
Strategies — A Control Language
switch data point can be used
with user-written Control
Language routines to monitor
and direct control of strategies
that involve different sets of data
points. The multipoint Control
Language routines respond to
strategy changes requested by
the process operator through a
Universal Station.

Control Language Extensions
Accessing History — Control
Language Extensions provide for
history access by reading
historized data from the History
Module. Up to 262 history values
can be obtained with one call.
Data being retrieved can be
Absolute Snapshots, Relative
Snapshots, or Absolute
Averages of any historized
point.parameter. The extensions
can determine the collection rate
for a specific point.parameter.
Values can be specified in either
ASCII or internal Form. The data
can be used by CL programs
and/or displayed on a Universal
Station.
Math Library — A set of math
subroutines are available for
those AMs that are equipped with
a high performance processor
module with math coprocessor.
The subroutines provide the
following features:
• Standard deviation of an array
• Generate random numbers with
both uniform (0 - 1) and
pseudo-Gaussian distribution
• Create single-dimension CDS
array from two-dimension local
matrix
• Create a two-dimensional local
matrix from a single-dimension
CDS array
• Matrix multiply, add, subtract,
and transpose
• Matrix inversion and solution
with right-hand/left-hand
division options
• Maintenance of matrix work
areas
• CPU usage calculations.
Options
Hardware Options
The Application Module is
available in a 5-card electronics
module and a dual node
electronics package. The 5-card
module can be equipped with
cards that use Motorola 68000
microprocessors and have a
memory capacity of 2 Mw, or with
cards that provide higher
throughput using Motorola
68020s. The 68020 option is
available with 2, 3, 4, 6, or 8* Mw
of memory. The dual node
package can also be supplied
with 2, 3, 4, 6, or 8* Mw memory
capacity. For additional
information about the two types
of enclosures, see the System
Technical Data.
Redundant 68020 AMs,
including special software, can be
provided for those applications
where availability of the advanced
AM functions is a prime
consideration. Upon primary
failure, the secondary will take
over with a minimal delay (within 5
seconds) and without loss of
alarms or messages. Redundant
AMs are available in 5-card
modules only. These are
mounted adjacently in the same
cabinet and are separately
powered. Maximum memory that
can be installed is 7* Mw.
Multiple Application Modules can
be connected to the Local
Control Network to increase the
point-processing capacity and/or
for dedicated process unit
applications.
Application Programs
Several powerful software
application programs are available
that take advantage of the AM
custom programming capabilities.
Included are:
• LOOPTUNE II ™ — optimally
tunes PID control loops.
• HORIZON MULTIVARIABLE
PREDICTIVE CONTROL™ — a
multiple input/ multiple output
control algorithm capable of
controlling loops that cannot be
* The maximum memory that can be
addressed by software is 6 3/4 Mw.
AM03-400
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adequately controlled with PID
algorithms.
• Real Time SPQC-II ™ — uses
statistical control methods and a
full range of control charting
functions for early detection of
quality problems.
Your Honeywell representative
will be pleased to provide you
with details about these and other
available applications packages.
Physical Description
When packaged as a 5-card
module, the Application Module
contains a Local Control Network
Interface board,
microprocessor/memory board(s),
a power supply, and a fan
assembly. If the AM is a member
of a redundant pair, there is also a
redundancy board. The dual
node version of the Application
Module contains a high-density
K2LCN board, a power supply,
and fan assembly. The boards
and power supply are Optimum
Replaceable Units** for
maintenance.
Both types of electronics
modules mount in a standard 19”
(48 cm) RETMA rack and are
typically mounted in a standard
TDC 3000 system cabinet.
The Local Control Network
connects to the module through
coaxial connectors.
™ LOOPTUNE II, HORIZON
MULTIVARIABLE PREDICTIVE
CONTROL, and Real Time
SPQC-II are trademarks of
Honeywell Inc.
* * Optimum Replaceable Units
(ORUs) are replaceable
assemblies that provide the best
trade-off between the cost of the
ORU and the cost of attempting to
isolate troubles to a smaller part
of that ORU. Examples of ORUs
include printed-circuit boards,
power supplies, printers, and
Winchester disk drives.
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Application Module Specifications

Physical Characteristics

Approximate Dimensions
(5 Card and Dual Node) Approximate Weight

Height 18.8 cm (7") 5-Card File 21 kg (46 lb)

Width 48.3 cm (19") Dual-Node File with
Depth 53.3 cm (21") Single Node 14.6 kg (32 lb)
Two Nodes 18 kg (40 lb)

Power Options

Strap-Selected Ac-Voltage Options

120, 220, 240 Vac +10%, -15%

Frequency options
50 Hz or 60 Hz, +3%, -6%

The Application Module operates without disruption through an interruption in the input ac voltage of up to 40
ms duration.

Operating Characteristics

Point Processing Capacity AMI (68000 microprocessor):

Up to 60 data points per second, depending on point-type
mix and model of HG

AMII (68020 microprocessor):

Up to 90 data points per second, depending on point-type
mix and model of HG

Data Point Capacity Varies widely with point-type mix and memory usage; for details,
see Application Module Implementation Guidelines.

Point Scheduling Capability Fast Processing: 1 sec, 2 sec, 5 sec, 10 sec, 15 sec, 30 sec,
1 min, 2 min, and On Demand

Slow Processing: 1 min, 2 min, 5 min, 10 min, 15 min, 30 min,

1 hr, 8 hr, 12 hr, 24 hr, and On Demand

Internetwork Point Processor: 5 sec, 10 sec, 15 sec, 30 sec,

1 min, 2 min, 5 min, 10 min, 15 min, 30 min, 1 hr, 8 hr, 12 hr,
24 hr, and On Demand

Configuration Capability

Maximum Number of Nonredundant AMs per LCN = 20

Maximum Number of Redundant AMs per LCN = 10

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and
makes no express warranties except as may be stated in its written agreement with and for its customer.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without
notice.

Printed in U.S.A. — © Copyright 1992 - Honeywell Inc.