DCS

DCS
DIGITAL CONTROL
SYSTEM
or

DISTRIBUTED CONTROL
SYSTEM

Foxboro DCS I/A Series System

This course describes the physical and
functional characteristics of the I/A Series
System. The system processor modules, I/O
modules, storage and peripheral devices
are described as well as;
(1)

the relationship of the physical layers

with the system's mounting structures,
enclosures, adapters,

(2)

the functional relationship of the System

bus Network, System Stations, System
Integrators and Gateways, Fieldbus
Modules, and System Interface.
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Outline of Presentation
Preface
Course objective
Learning
Definition of DCS (Foxboro)
DCS (Foxboro) architecture
Overview of DCS (Foxboro)
Summary

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Objectives
The objective of the course is to give
participants the basic building blocks of the
Distributed
Control
System
and
an
understanding of the architecture of the
system.
This course targets Instrument technician
with no previous DCS (Foxboro) experience but
who are likely to be attending courses in the
near future.
At the end of this course, participants should
be able to identify the hardware & understand
the operation / function of each components.

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Learning
Skill development can be undertaken by
residential training or directed self-study
(i.e to overcome knowledge-base
weakness-basic knowledge of DCS.)
Effective training:
depends upon identifying the key skill of jobs.
exercising their performance.
to sharpen as well as to broaden the human
capability.
competences.

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Introduction To Foxboro DCS

Definition of DCS:
I/A Series: Intelligent Automation Series is
a state-of-art, cost effective plant automation
system provided by the Foxboro Company.
functions are distributed not centralize.
consist of microprocessors that work together.
is a computer network.
does a real-time computing by scanning its
inputs & updating its data several times a
second.

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What are computers?

A computer is an electronic machine for
receiving data (INPUT). It stores this data as
well as carries out any instruction concerning
the data (PROCESSING). Finally, it produces
the results (OUTPUT).
data
INPUT

COMPUTER - CPU

(Processes)

results
OUTPUT

Foxboro I/A Series Distributed Control System

WinNT PC WinNT PC

UNIX W/station

Terminal
File
Server

Ethernet, Decnet ,
Novell, TCP/IP,
X.25, OSI, etc.

Management

Computer

Workstation

Main Control Room Workstations

Production

CBLAN IEEE 802.4

Distributed Node

AW
CP
WP
GW
Cmp

Nodebus
IEEE 802.3

Fieldbus
IEEE 1118

Distributed Node

Field
devices

PLC

Field
devices

DistributedNode
AW
CP
WP
GW
Cmp

Workstation

Mass Flowmeters
Process GLCs

Workstation

Overview of Foxboro DCS

Field

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Introduction To Foxboro DCS

Architecture:
A DCS is a collection of microprocessorbased modules that work together
through a real-time communication
system to control & monitor the process
operation.
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Data Highway & Local I/O bus

backbone of the system.

pass the system messages & file transfers.
constantly updates the consoles, gateway,
etc.
If highway fails, loss of communications.
Very critical element, has a redundant
highway.
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Foxboro Distributed Control System

OPERATOR
CONSOLE

REMOTE
CONTROL
UNIT

SENSOR

SENSOR

FINAL
CONTROL
ELEMENT

FINAL
CONTROL
ELEMENT

REMOTE
CONTROL
UNIT

SENSOR

SENSOR

FINAL
CONTROL
ELEMENT

FINAL
CONTROL
ELEMENT

CP, AW, WP, GW, CP,

CBLI, FDG, NBI, DNBI,
FBM, FBI.

REMOTE
CONTROL
UNIT

SENSOR

SENSOR

FINAL
CONTROL
ELEMENT

FINAL
CONTROL
ELEMENT

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Introduction To Foxboro DCS

A DCS consists of:
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.

Dual Nodebus interface (DNBI)

Communication modules (Com10/15)
Data highway (Nodebus/Fieldbus)
Application Workstations (AW51D)
Workstation Processors (WP51D)
Control Processors (CP30/40/60)
Gateways (GW)
Fieldbus Modules (FBMs)
Transmitters
Valves, fans, motors, switches, etc.

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Industrial Eclosure 32
or IE32
32 slots for hardware modules

Control Processors,
Application Workstation,
Workstation Processors,
Gateways, Communication
Processors, Carrierband LAN
Interface, Intergrators,
Foreign Device Gateways,
Nodebus Interface, Dual
Nodebus Interface, Fieldbus
Modules, Fieldbus Isolators.

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Foxboro DCS I/A Series System

User Interfaces
Display monitor or CRT based console or
WP51 (workstation processor 51).
Also known as VDU (video display unit) or
VDT (video display terminal).
These CRT comes in a 19 display screen.

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Workstation Processor 51
19Monitor Workstation

Trackball or Mouse

Numeric Keyboard

Annunciator Keypad

Industrial Power Module 2

Normally installed in non-stop
uninterupted Power supply
configurations
Convert Input power supply
of 240 VAC to 110 VDC to
FBIs and FBMs.
FBMs
IPM2
FBIs

Power supply input

to FBIs and FBMs
is 110VDC

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Distributed Control System

Fieldbus
Modules

IPM2
Industrial Power supply (IPM2) & Fieldbus Modules (FBM)

Gateway Processors(GW)
CLI

Other
I/A
Nodes

WP

AW

CP

Nodebus

Spectrum Spectrum
Master
Slave
GW
GW
Spectrum
Spectrum
Master
Control &
Stations I/O devices
I/A
Master

I/A
Slave

PLC
GW

ABB,
FGS, IPS
Triconex PLC

Modicon
PLC

Info
Network
GW

Instr
GW

Foreign
Device
GW

DEC VAX
IBM
HP

760/761
Control

GLC

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Control Processor (CP)

Nodebus

CB

CP

WP

AW51

ComP

GW

Fieldbus

FBM01

FBM02

FBM03

FBM04

FBM18

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Foxboro DCS I/A Series System

Nodebus IEEE 802.3

Link
to other
nodes

CBI

DNBI

AW51

Users interface
Operators Workstation

DNBI

CP

ComP

GW

WP51
Users interface
Operators Workstation

Application Workstation 51(AW/WP51)

Terminal
VT100

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Foxboro DCS I/A Series System

(Control Processor)

continuously updates information from the

I/O modules.
perform regulatory, complex logic, timing &
sequential control and loop calculations.
Communicates directly with fieldbus modules.
The only processor module which connects to
FBMs.

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Foxboro DCS I/A Series System

(Fieldbus Module)

able to read and writes both digital as well as

analogues signals.
Can be used as both input and output devices to
control a process.
4 basic I/O modules are: analogue input and
output, digital input & output.
The input modules for example convert
information from the process instruments into
digital form, filter & signal characterizing.
The FBMs communications path, the Fieldbus, is
redundant.

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Signal Loop Diagram

Foxboro DCS I/A Series System

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AIN

PID

AOUT

Foxboro DCS I/A

Series System

COMMONLY USED BLOCKS

FBM4 ECB
BLOCK CHARACTERISTICS:
AIN (Analog Input)
PID (Proportional Integral Deviation)
AOUT (Analog Output)

PNT
7

PNT
4

Tank
Level

ECB (Electronic Control Block)

FBM (Field Bus Module)

FBM4

AI0001

PNT
7

Out to valve

LT

T7101

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Foxboro DCS I/A Series System

Modem

Modem
XTerminal

VT100

XTerminal
2nd
CRT

1st
CRT

AW

WP

Com

1st
CRT

2nd
CRT

Com

Nodebus

VT100
CP

GW

FBM
02

FBM
03

PLC

CLI

Fieldbus
FBM
01

FBM
04

FBM
18

FBM
39

Final element

To other
Distributed
Node

Other means of
communications

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FE-Field Enclosure
IE-Industrial Enclosure

Example of an FE8 Enclosure

(FE4&8, IE16 & IE32)

SYSTEM MANAGEMENT OVERVIEW

WORKSTATION
(WP,AW)

PW
TAPE

SYSTEM
MANAGEMENT
SUBSYSTEM

NODEBUS

D
N
B
I

N
B
I

A
P
A
W

HARDDISK
G
W

C
O
M
M

C
P

IE32
MONITOR SYSTEM HEALTHENCLOSURE

PW

PLC, BN,
NON DCS EQUIP

AUTOMATIC:

GENERATE SYSTEM ALARMS

DOCUMENT SYSTEM EVENTS
FIELDBUS

F
B
M

F
B
M

PRINTER
OPERATOR INITIATED:
ACKNOWLEDGE SYSTEM ALARMS
VIEW HARDWARE STATUS INFO
CHANGE HARDWARE STATUS
SET SYSTEM DATE/TIME

HLDs Foxboro I/A Series System

Training Simulator

DCS Operator Workstation

DNBI or DNBT
(Dual Nodebus Interface)

Control Processor

CP/30/60

FIELDBUS

FBM-200 Series

FBM

FIELD

Control Processors
with FBMs

GW/30
MODBUS
FA 1 2 3 4 5 6 7 8

IPS, FGS,
TRICONEX,
HONEYWELL,
YOKOGAWA

GE Fanuc PWR
SERIES 90-30

POWER SUPPLY

F A123 45678

FA 1 2 3 4 5 6 7 8

F A12 34567 8

B123 45678

B1 23456 78

B1 2 3 4 5 6 7 8

F A123 45678

FA 1 2 3 4 5 6 7 8

B123 45678

B 1234 5678

GE Fanuc

B 12345 678

FA 1 2 3 4 5 6 7 8 F A 1 2 3 4 5 6 7 8 FA 1 2 3 4 5 6 7 8
B12 34567 8

B1 2 3 4 5 6 7 8

B 12345 678

F A12 34567 8
B123 45678

PWR
SERIES 90-30
POWER SUPPLY
OK

OK

RUN

RUN

BATT

BATT

PROGRAMMABLE
CONTROLLER

PROGRAMMABLE
CONTROLLER

100-240
VAC 40A
50/60HZ
100-240
VAC 40A
50/60HZ

+
24VDC
OUTPUT
+
24VDC
OUTPUT
-

BATTERY

BATTERY

FIELD

FIELD

Gateways

WESTLOCK,
PANAMETRICS,
SOLAR

IPM02
Industrial Power Module2
supply 110VDC to hardware
modules.
System extended 100 ms
ride-through (ac) input to
(dc) output current mode
switching primary only type.
It accepts any standard ac
input and is used when
wave-crest or power factor is
critical. This module is
preferred in applications with
frequent ac line voltage
IPM-Industrial
Power Module
drop-outs.

FBMs

IPM2-240VAC
To 110DCV
FBIs

Power supply input

to FBIs and FBMs
is 110VDC

Power supply input to FBIs & FBMs

FBMFieldbus
Modules

Example of an FBMs
(nest in an IE32 Enclosure)

TCA on fault-tolerant Nodebus

200 Series Products

200 Series FBM (Field Bus Modules)

200 Series Fieldbus Modules

FBM 220 & FBM 224

200 Series Fieldbus TCAs for

FBM 220 & FBM 224

Fieldbus Control Module

(FCM)-200 Series

Fieldbus Module (FBM)

Fault Tolerant Control processor (CP)

Internal view of a module processor

Control loops & problems

DCS Indicators
CCR
DCS screen

FIELD

H/W

S/W

0 - 10000 kPa
AIN

4 - 20 mA

0 - 10000 kPa

DCS Control Loop

FIELD

CCR
DCS screen
0 - 10000 kPa
H/W

S/W

0 - 10000 kPa
FBM

AIN

4 - 20 mA
PIDA

4 - 20 mA

FBM

AOUT

Problem areas

AW51

WP51

NODE BUS 1
G
W

C
P

IPS
FBM
X-MIT
FBM

FIELD BUS
FBM

I/O
MODULE

NON DCS
AREA
or
FIELD
DEVICES

Distributed Control System

Coming up next

Distributed Control System

Redundant Fieldbus Modules with Fault Tolerant Control Processors

WP51D, AW51D

AW51E Set-up
I/A Series System

AW70 Layout

AW70 Set-up
I/A Series System

DCS ARCHITECTURE

BSP LAN

HUMAN INTERFACE AND FILE SERVERS

AW51

WP51

DATA HIWAY
INTERCONNECTING BUS STRUCTURE

NODE BUS 1
C
P

G
W

FIELD BUS
IPS

FBM

CONTROL PROCESSORS
GATEWAYS TO NON-DCS EQUIPMENT
SAFEGUARDING, F&G SYSTEMS, COMPRESSOR,
CONTROL

FBM

FBM

I/O
MODULE

NON DCS
AREA
or
FIELD
DEVICES

FIELD INTERFACE MODULES

FIELD TRANSMITTERS, CONTROL VALVES

Foxboro DCS I/A Series System

Summarised
A DCS is made up of many control modules
that can operate simultaneously and
independently.
It has the ability to carry out rapid
communications between these and other
modules by means of a communications link
called a real-time data highway.

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Thank you
and
all the best