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. CA
 Outline of Presentation
• Preface
• Course objective
• Learning
• Definition of DCS (Foxboro)
• DCS (Foxboro) architecture
• Overview of DCS (Foxboro)
• Summary

CA
 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.
CA
 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.
CA
 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.
CA
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 results
COMPUTER - CPU
INPUT OUTPUT
(Processes)
 Foxboro I/A Series Distributed Control System
WinNT PC WinNT PC UNIX W/station Terminal
File
Ethernet, Decnet , Server Management
Novell, TCP/IP,
X.25, OSI, etc. Computer

Main Control Room Workstations Workstation

Production
CBLAN IEEE 802.4

Distributed Node Distributed Node DistributedNode

AW AW Workstation
Nodebus CP CP
WP PLC
IEEE 802.3 WP
GW GW
Cmp Cmp

Mass Flowmeters
Fieldbus Field Field Process GLCs
IEEE 1118 devices devices Workstation Field

Overview of Foxboro DCS CA

 Introduction To Foxboro DCS
Architecture:

A DCS is a collection of microprocessor-

based modules that work together
through a real-time communication
system to control & monitor the process
operation.

CA
 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.

CA
 Foxboro Distributed Control System

OPERATOR
CONSOLE CP, AW, WP, GW, CP,
CBLI, FDG, NBI, DNBI,
FBM, FBI.

REMOTE REMOTE REMOTE

CONTROL CONTROL CONTROL
UNIT UNIT UNIT

SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR

FINAL FINAL FINAL FINAL FINAL FINAL

CONTROL CONTROL CONTROL CONTROL CONTROL CONTROL
ELEMENT ELEMENT ELEMENT ELEMENT ELEMENT ELEMENT

CA
 Introduction To Foxboro DCS
A DCS consists of:

01. Dual Nodebus interface (DNBI)

02. Communication modules (Com10/15)
03. Data highway (Nodebus/Fieldbus)
04. Application Workstations (AW51D)
05. Workstation Processors (WP51D)
06. Control Processors (CP30/40/60)
07. Gateways (GW)
08. Fieldbus Modules (FBMs)
09. Transmitters
10. Valves, fans, motors, switches, etc.
CA
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.
CA
 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.

CA
 Workstation Processor 51
19”Monitor 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

CA
Distributed Control System

Fieldbus
Modules

IPM2
Industrial Power supply (IPM2) & Fieldbus Modules (FBM)
 Gateway Processors(GW)
Other
CLI I/A WP AW CP
Nodes

Nodebus

Spectrum Spectrum Info Foreign

PLC Instr
Master Slave Network Device
GW GW
GW GW GW GW

Spectrum Spectrum ABB, DEC VAX

760/761
Master Control & FGS, IPS IBM GLC
Triconex PLC Control
Stations I/O devices HP
I/A I/A Modicon
Master Slave PLC
CA
 Control Processor (CP)

Nodebus

CB CP WP AW51 ComP GW

Fieldbus

FBM01 FBM02 FBM03 FBM04 FBM18

CA
 Foxboro DCS I/A Series System
Nodebus IEEE 802.3

Link
to other
nodes CBI DNBI DNBI CP ComP GW

AW51 WP51

User’s interface User’s interface Terminal

Operator’s Workstation Operator’s Workstation VT100

Application Workstation 51(AW/WP51)

CA
 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.

CA
 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.
CA
 Signal Loop Diagram

Foxboro DCS I/A Series System

CA
 Foxboro DCS I/A
Series System
AIN PID AOUT

COMMONLY USED BLOCKS

FBM4 ECB
BLOCK CHARACTERISTICS:
AIN (Analog Input)
PID (Proportional Integral Deviation)
PNT AOUT (Analog Output)
7
ECB (Electronic Control Block)
PNT FBM (Field Bus Module)
4 FBM4
Tank
Level PNT
Out to valve
7
AI0001

LT T7101

CA
 Foxboro DCS I/A Series System

Modem

Modem

XTerminal
XTerminal VT100

2nd 1st 1st 2nd

AW Com WP Com
CRT CRT CRT CRT
Nodebus VT100
To other
CP GW PLC CLI
Distributed
Node
Fieldbus

FBM FBM FBM FBM FBM FBM

01 02 03 04 18 39
Other means of
communications
Final element
CA
FE-Field Enclosure
IE-Industrial Enclosure

Example of an FE8 Enclosure

(FE4&8, IE16 & IE32)
 SYSTEM MANAGEMENT OVERVIEW

WORKSTATION PW
(WP,AW)

TAPE

D
N
A HARDDISK
N P G
B B A W
SYSTEM I I W
MANAGEMENT PLC, BN,
SUBSYSTEM NON DCS EQUIP
C PW
C O
P M
M
NODEBUS

AUTOMATIC:
IE32
•MONITOR SYSTEM HEALTH ENCLOSURE
•GENERATE SYSTEM ALARMS PRINTER
•DOCUMENT SYSTEM EVENTS

F F
OPERATOR INITIATED:
FIELDBUS B B
•ACKNOWLEDGE SYSTEM ALARMS
M M
•VIEW HARDWARE STATUS INFO
•CHANGE HARDWARE STATUS
•SET SYSTEM DATE/TIME
HLD’s 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 FA 1 2 3 4 5 6 7 8 F A 1 2 3 4 5 6 7 8 F A 1 2 3 4 5 6 7 8 FA1 2345 678

FA1 2345 678 FA 1 2 3 4 5 6 7 8 F A1 2345 678 F A1 2345 678 FA 1 2 3 4 5 6 7 8

GE Fanuc B1 2345 678 B 1 2 3 4 5 6 7 8 B1 2 3 4 5 6 7 8 B1 2345 678 B1 2345 678

IPS, FGS, WESTLOCK,

GE Fanuc P
B1 2345 678 B1 2345 678 B1 2 3 4 5 6 7 8 B1 2345 678 B1 2345 678 SERIES 90-30
POWER SUPPLY
P
W
SERIES 90-30
W R
POWER SUPPLY R
O
O K
K
R
R U
U N
N
B
B A
A
PROGRAMMABLET
T
CONTROLLER T
PROGRAMMABLE T
CONTROLLER

TRICONEX, PANAMETRICS,
100-240
VAC 40A
50/60HZ
100-240
VAC 40A
50/60HZ

HONEYWELL, SOLAR
+
24VDC
OUTPUT
-
+
24VDC
OUTPUT
-

YOKOGAWA B
A
T
T
E
R
Y
B
A
T
T
E
R
Y

FIELD FIELD

Gateways
 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 drop-outs.
IPM-Industrial Power Module
 FBMs

IPM2-240VAC
To 110DCV

FBIs Power supply input

to FBIs and FBMs
is 110VDC

Power supply input to FBIs & FBMs

FBM-
Fieldbus
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
FIELD CCR
DCS screen

H/W S/W

0 - 10000 kPa

AIN 0 - 10000 kPa

4 - 20 mA
 DCS Control Loop
FIELD CCR
DCS screen

0 - 10000 kPa

H/W S/W

0 - 10000 kPa
FBM AIN
4 - 20 mA

PIDA

FBM AOUT
4 - 20 mA
 Problem areas

AW51 WP51

NODE BUS 1

C G
P W

IPS

FBM

X-MIT
NON DCS
FBM
AREA
FIELD BUS or
FIELD
FBM
DEVICES
I/O
MODULE
 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
 BSP LAN DCS ARCHITECTURE

HUMAN INTERFACE AND FILE SERVERS

AW51 WP51

NODE BUS 1 DATA HIWAY

INTERCONNECTING BUS STRUCTURE
C G
P W
CONTROL PROCESSORS
GATEWAYS TO NON-DCS EQUIPMENT
FIELD BUS SAFEGUARDING, F&G SYSTEMS, COMPRESSOR,
IPS CONTROL

FBM FBM

NON DCS FIELD INTERFACE MODULES

FBM AREA FIELD TRANSMITTERS, CONTROL VALVES
or
I/O FIELD
MODULE DEVICES
 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.

CA
Thank you
and
all the best