(with ethernet communication) - apex innovations · software package wonderware intouch v10.5 (64...

07-06-2014 Im329

DCS TRAINER

(With Ethernet communication)

Instruction manual

Contents

1 Description

2 Specifications

3 Installation requirements

4 Installation

5 Experimentation

6 Components used

7 Packing slip

8 Warranty

9 Wiring diagram

Product Code 329

Apex Innovations

The set up is designed to

understand the latest techniques

adopted in process control. The

concepts of DCS, hybrid controller

and SCADA can be well

understood. Set up consists of

Hybrid Controller, a control panel

for simulating inputs as well as

connecting real time process,

software package for configuring

the controller and a SCADA

package.

Easy to use Windows based Hybrid

control designer software,

operable over Ethernet, an RS232

port or modem connection,

simplifies controller and operator

interface configuration. It provides

advanced monitoring functions for

debug, allows run-mode

configuration changes while limiting process interruption

uploads the complete, annotated graphic controller and

operator interface configuration, plus supplies an array of

printouts for enhanced documentation. The components

are assembled in a control panel designed for standalone

mounting.

I/O

I/O

I/O

I/O

HC900-C30 CONTROLLER

Control panel

Digital outputs

Analog outputs

Digital inputs

Analog inputs

Description

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Product DCS trainer

Product code 329

Control unit Hybrid controller, Make Honeywell, Model HC900 – C30, AI

8, AO4, DI 16, DO16, Control loops 8 with Hybrid Control

Designer software

Communication RS232, RS485, Ethernet

Software package Wonderware Intouch V10.5 (64 Tag) development/runtime

system

Control panel Rotary selector switch for simulated AI

Potentiometer for AI simulation

Analog Input indicator for AI

Push button for DI simulation

Power supply(24VDC) for powering transmitters

Relays 24 VDC, 4nos, for DO application

Banana plug connectors for each field input and output

connections

Overall dimensions 600Wx430Dx1400H mm

Shipping details

Gross volume 0.65m3, Gross weight 160kg, Net weight 95 kg

Specifications

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Electric supply

Provide 230 +/- 10 VAC, 50 Hz, single phase electric supply with proper earthing. (Neutral –

Earth voltage less than 5 VAC)

5A, three pin socket with switch (3 No.)

Computer

IBM compatible with standard configuration

IBM compatible with standard configuration with USB port for Hardware lock.

RAM: 4 GB min. OS: Windows 7 + SP1. NTFS format, Microsoft office 2007

Installation requirements

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INSTALLATION Unpack the box(s) received and ensure that all material is received as per packing slip

(provided in instruction manual). In case of short supply or breakage contact Apex

Innovations / your supplier for further actions.

Place the set up assembly near computer table.

Connect the electric supply to DCS trainer.

SOFTWARE INSTALLATION

Refer document “Software329”

Installation Commissioning

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1. Study of Hybrid control designer

1 Study the files provided in “Study guide” folder on “Apex Innovations” CD in following

sequence

Study guide intro 1217

SSTUDY1-HC900

SSTUDY2-HC900

SSTUDY3-HC900

SSTUDY4-HC900

SSTUDY5-HC900

SSTUDY6-HC900

SSTUDY7-HC900

SSTUDY8-HC900

SSTUDY9-HC900

SSTUDY10-HC900

2 Study “HC900 Hybrid Control Designer User Guide”.

3 Study “HC900 Hybrid Control Designer Function block Reference Guide”.

Experimentation

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2. Understanding control panel

(Refer wiring diagram No. 329002)

Analog Input:

Potentiometer provided for simulation of analog input of 4-20mA.

Power supply 24VDC is provided for analog inputs. Two wire transmitter can be connected

without external powering at the banana plugs of CH.1, 2, 3,4,6,7 & 8.

RTD/ Thermocouple can be connected at the banana plugs of CH.5.

Sample softwares are supplied for control of single loop processes. For executing these

softwares with existing process control loops, connect RTD of Temperature control process

to CH.5, Flow transmitter(sq rooted) of Flow control process to CH.6, Level transmitter of

Level control process to CH.7 and Pressure Transmitter of Pressure control process to CH.8

without external powering.

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Analog Input Indicator:

Analog input value (in %) of selected channel is displayed on the analog input indicator.

Analog Output:

Analog output can be directly connected to final control element.

For sample softwares of single loop controls, connect Analog output CH.1 to control element

of Temperature control trainer (SSR), CH.2 to control element of Flow control trainer(I/P

converter), CH.3 to control element of Level control trainer(I/P converter), & CH.4 to control

element of Pressure control trainer(I/P converter),

Digital Input:

Push button is provided for simulation of Digital input.

Power supply 24VDC is inbuilt for all digital inputs and outputs.

Digital inputs like float switch / microswitch etc can be connected at the banana plugs

provided for DI1 – DI8.

Digital Outputs:

Outputs of Channel no. 1,2,3 & 4 are connected to Relays and 230VAC relay output is

provided on connectors inside the panel.

Output of channel no. 5,6,7 & 8 are on the front panel.

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3. Executing Hybrid controller project

A) Connecting existing “Process control trainers” to the hybrid controller

Disconnect the process from the local controllers and connect it to the connector from DCS

trainer/panel.

Each process trainer is to be connected to specific predefined input/output channels of the

DSC trainer. The channels number are as follows:

Process trainer AI Channel No. AO Channel No.

Temperature 5 (RTD) 1

Flow 6 (4-20mA) 2

Level 7 (4-20mA) 3

Pressure 8 (4-20mA) 4

Ensure Ethernet cable is connected to HC900.

B) Executing Hybrid Control Designer

Open Hybrid control Designer.

Open – C:\Programe files\Hybrid control Designer \Apex process control Trainers

Switch on power supply of DCS trainer. Wait for about 1 minute.

In Current PC to Controller Connection Settings select Port “Network”.

In Current PC to Controller Connection Settings select Port “Network”.

Click Loop back button. On message “Instrument responded correctly” click on Send and

close.

Click on File| Download.

In “Download file” Window Select port as “NETWORK” port. Then click Start

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Click “Cold Start” in “Download complete” window for First time start and then click Close.

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Click on set, ok & close

Click on tab “Function block” and click on File| Download.

In “Download file” Window Select port as “NETWORK” port. Then click Start

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Click “Cold Start“ in “Download complete” window for First time start and then click Close.

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Click yes in “Hybrid control Designer” window.

Click on “Simulation” tab

On the control panel: Connect “Simulated Analog Input” to “Analog input Ch1” by using test

lids.

Click on Monitor | Monitor mode

Click on Analog Input1 Block

Vary the Potentiometer provided for AI simulation and observe the values on the screen.

Repeat above steps to check Analog Input Channel nos 2,3 and 4.

On the control panel: Connect “Simulated Digital Input “ to “Digital input Ch1” by using test

lids.


Click on Digital Input1 Block

Operate the Push button for Simulated digital input and observe the ON-OFF values on the

screen.

Repeat above steps to check Digital Input Channel nos 2 thr 8.

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Click on “Temperature” tab in “Apex Process control trainers”.


Click on Analog Input Block, you will get input value on the blocks.

Similarly Click on PID Loop Block and Analog output block to see other values.

For assistance refer Help.

C) Executing Wonderware In-touch

Click on Start|All programs|Wonderware|InTouch

Click” InTouch”.

Select and click “Yes” under “User account control”

Execute Programs | Wonderware | InTouch for “DCS Trainer”.

Select All in “Windows to open” and Click “Runtime to view following screen

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Select desired process by clicking on the respective process tab

You can control all the processes simultaneously by changing tuning parameters like PID

values, set point and Auto/Man selection for each loop.

Instead of simultaneous running of all process, single process can be independently run by

selecting the process. E.g. For executing Temperature control trainer select Programs |

Wonderware | InTouch for “Temperature ontrol trainer_HC900”. Similarly for Flow, Level or

Pressure.

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Detailed experimentation can be carried out by pressing “Change Expt” and selecting

desired “Experiment”.

Flow control trainer, Level control Trainer and pressure control trainer screens are as

follows:

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Flow Control Trainer

Level control trainer:

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Pressure control trainer:

Data logging, Viewing, Editing and deleting

Click on “DataLog” select “LogOn” or “Logoff” for data logging On or Off.

Click on “Histdata” button to go to Histdata window.

Click on “Showdata” button to view recorded data.

Click on “Export to Excel” button to export the data in excel. You will find the recorded

data in D:\ Temperature control trainer _HC900 Temphistory.Xls (or Flow, Level,

Pressure, DCS as the case may be.

Click on “Print & Export to Excel” button to export the data in excel as well as to print

the data stored in Excel file.

To view data in Microsoft office Access, open Access, go to D:\ Temperature control

trainer _HC900\Temphistory.mbd and double click on Table1. You can Edit/delete the

recorded data. If data is deleted from Access data file, data will not be viewed in

Histdata window. (or Flow, Level, Pressure, DCS as the case may be)

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4. Building new project with Hybrid control designer and WonderWare.

A) Configuring single loop PID control system on Hybrid control designer.

Open Hybrid control designer

Select file New.

Set controller configuration file as

Controller type: HC900-C30

Controller Revision: Rev4.2x

Click OK.

Select Analog input from I/O blocks of Function Blocks and pull it to worksheet.

Double click on Analog Block, when prompted for Analog input properties,

Select Input type and range: Click on RTD and select pt100 -185 316 C

Set Address as: Rack: 1, Module: 1, Channel: 1

Bad Channel Detection: select, Burnout check: enable.

Click OK.

Select PID from Loop block of Function Blocks and pull it to worksheet below Analog input

block.

Double click on PID Block, when prompted for PID function block properties,

Set following

General: Tag Name: PID 102, Description: Temperature pid

Algorithm: PIDA, Direction: Reverse, SP Tracking: None

Start / restart: select following

For Manual, Automatic and Local SP: select Permitted,

For Automatic, Local SP: select Initial Mode

For Automatic, Power up mode select: Retain last mode,

For Local SP, Power up mode select: LSP

RSP: Remote set point source and units: select Use RSP input (EU)

Ratio/Bias: select No ratio or Bias.

Range / Limit: Ranging: PV high range: 100, PV low range: 0,

Display: Decimal places:0, Units: Deg C

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Limiting: SP high limit: 100, SP low Limit: 0, Out High limit: 100, Out Low Limit: 0,

Sp rate Down: 0, Sp rate Up: 0.

Tuning: Tuning Constants: select proportional band : set1:10, set2:10

Reset (Minutes): set1: 5, set2: 5

Rate (Minutes): set1: 1, set2: 1

Forward Gain: 0

Manual Reset: 0

Accutune: Accutune Type: select Disabled

Alarms: Alarm1: Setpoint1 90 Type PVHigh

Click OK

Select Analog output from I/O blocks of Function Blocks and pull it to worksheet below PID

block.

Double click on Analog output Block, when prompted for Analog output properties,

Input range: Range Hi: 100, Range Lo: 0

Output range: mA at Range Hi: 20, mA at Range Lo: 4

Output limits: mA at High limit: 20, mA at Low limit: 0

Set Address as: Rack: 1, Module: 2, Channel: 1

Click OK.

Connect Analog input block to PID function block by soft wire.

Connect PID function block to Analog Output block by soft wire.

Save File with required file Name. When prompted for warning for

Unconnected block inputs click NO.

Switch ON controller HC900

Download the file to controller by clicking Download button, When prompted for Download

file click Start. When prompted for download complete click Hot Start. After completion

Click Close.

Click on Monitor tab, When prompted for Enter monitor mode Click OK.

Click on Analog input, PID, Output Blocks, You will get all values.

For further developments refer Manual and on line help.

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B) Create an InTouch application on Server using Modicon MODBUS I/O Server

MODBUS I/O Server

It is assumed that “communication port settings” are done as below.

In Topic Definition window Click on Configure, click New.

In Modbus Topic Definition window, Topic name = HC900, Com port = (As above), Slave ID = 1,

slave device type = micro 84PLC, other settings = keep as default, click OK then click done.

C) Creating application in In-touch Application manager:

1. Click on Start| All programs | Wonderware| InTouch | Yes to open InTouch-Application

Manager.

2. In InTouch-Application Manager click on File |New to open Create New Application

wizard.

Click on Browse, select D drive click OK

Click Next

Check “Set As Default Directory”

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In window write Apex Demo Application as the directory where you want the

application to be created.

Click “Next”.

Enter name as Apexdemo and description of Intouch application as Apex Demo

application. Click Finish.

3. In Intouch application manager window double click on Apexdemo.

4. In InTouch windowmaker Click on File - New Window.

In Window Properties window; Type name as Temperature. Keep all other parameters

unchanged. Click OK.

5. Inserting Symbol (Graphics from library): Click on Wizards tool.

In Wizards Selection select Symbol Factory, double click on Symbol and click on

Temperature Window to open Symbol Factory by Reichard Software.

Select Category Sensors

Select Symbol Sensor1 and click OK.

Click on T located at toolbar and click on window and write PV near sensor symbol

Click on T located at toolbar and click on window and type ###.# for display of values.

6. Adding Access Name

Click on Special |Access Names.

In Access names window click ADD. Type Access Name HC900, Node name: keep blank,

Type Application Name MODBUS, Topic name HC900.

Click OK, Click Close.

7. Creating Tag for Process value PV

Click on Special |Tagname Dictionary

In Tagname Dictionary Click New and Type Tagname PV

Click Type and select Tag Type I/O real. Click OK

Set MinEU=0, MaxEU=100, Min Raw=0, Max Raw= 1000

Click Access Name, select HC900, Click Close.

Set Item = 40065 F (This is modbus address for PV of Honeywell controller which

is found as explained below)

Click Save Click close

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Creating Tag for Set point SP


In Tagname Dictionary Click New and Type Tagname SP




Set Item = 40069 F (This is modbus address for SP of Honeywell controller)


Creating Tag for Output OP


In Tagname Dictionary Click New and Type Tagname OP




Set Item = 40071 F (This is modbus address for OP of Honeywell controller)


Creating Tag for Proportional Band PB


In Tagname Dictionary Click New and Type Tagname PB




Set Item = 40077 F (This is modbus address for PB of Honeywell controller)


Creating Tag for Reset IT


In Tagname Dictionary Click New and Type Tagname IT




Set Item = 40081 F (This is modbus address for Reset of Honeywell controller)

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Creating Tag for Rate DT


In Tagname Dictionary Click New and Type Tagname DT




Set Item = 40083 F (This is modbus address for Rate value of Honeywell

controller)


8. Click on T located at toolbar and click on window and write SP; Click on T located at

toolbar and click on window and type ### for display of Set point.

Click on T located at toolbar and click on window and write OP; Click on T located at

toolbar and click on window and type ### for display of Output.

Click on T located at toolbar and click on window and write PB; Click on T located at

toolbar and click on window and type ### for display of Proportional band.

Click on T located at toolbar and click on window and write IT; Click on T located at

toolbar and click on window and type ### for display of reset time.

Click on T located at toolbar and click on window and write DT; Click on T located at

toolbar and click on window and type ### for display of rate time.

9. Connecting Tags

Double click on ###.# of PV,

In value display select Analog, double click on Analog, Write expression PV

Doubleclick on PV, Click on Save and Close.

Double click on ### of SP,

In Touch links select Analog, double click on Analog, Write expression SP, double click on

SP, Click on Save and Close.

Similarly connect OP, PB, IT and DT to respective tags.

10. In WindowMaker click on Runtime.

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Creating Data logging file using Microsoft Office Access

1. Click on Start, All programs, Microsoft Office, Microsoft Office Access. In Microsoft

Access click File, New, Blank database, In File select “D:\Apex Demo Application” folder.

Type File name = HistoryData, click Create. In “HistoryData: Database” window click

“Create Table In Design View”. In Table1 type Field Name: ProcessValue (same as

defined in Bind List Configuration for column name), Data Type: Number and save as

Table1. (do not define / create primary key).

2. Click on Start, Control Panel, Performance & Maintenance, Administrative Tools, Data

Source (ODBC). In ODBC Data Source Administrator select System DSN, click Add. In

Create New Data Source select “Microsoft Access Driver (*.mdb)” click “Finish”. In ODBC

Microsoft Access Setup “Data source name”: ApexDemo & click “Select”. In Select

Database select drive “D:\” and directory “Apex Demo Application” and select Database

Name: “HistoryData.mdb” & click OK.

3. Open “Apexdemo” Application in InTouch. Click Special, SQL Access Manager, Bind list,

click Yes, Click New. In Bind List Configuration Bind List Name: ApexBindList. Click

Tagname & select PV Tagname, click OK. Type Column Name: ProcessValue, click Add

Item. Click OK.

4. Create ResultCode as Tagname & Type: Memory Integer.

5. Create ConnectionID as Tagname & Type: Memory Integer

6. Create ErrorMessage as Tagname & Type: Memory Message.

7. Create DT as Tagname & Type: Memory Message.

8. On Apex Demo Application window right click and click on Window Scripts. In Window

Script for “Apex Demo Application” select Condition Type: While showing, on every

5000 msec. Type following script and Click OK

ResultCode=SQLConnect(ConnectionId, "DSN=Apexdemo;DB=HistoryData" );

ErrorMsg=SQLErrorMsg(ResultCode);

SQLInsert( ConnectionId, "Table1", "ApexBindList");

SQLEnd( ConnectionId );

9. In WindowMaker click on File, WindowViewer and in Windows to View select window

and click OK to see the application in Runtime mode. (Use Runtime! Button located at

right hand upper corner of WindowMaker to run opened window.)

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10. Open Microsoft Office Access, file HistoryData and Table1. You will find data stored in

ProcessValue column.

11. In WindowViewer click on File, WindowMaker and in Windows to Edit select window

and click OK to see the application in Development mode. (Use Development! Button

located at right hand upper corner of WindowViewer to edit opened window.)

Creating Data logging file using Microsoft Office Excel

1. Open Apex Demo Application in InTouch.

2. Click on Special, Tagname Dictionary. In Tagname Dictionary click New. Type Tagname:

Name1, Click Type and select Memory message, click Ok, Click Save

3. Create Name2 as Tagname & Type: Memory Message.

4. Create Name3 as Tagname & Type: Memory Message.

5. Create Filename as Tagname & Type: Memory Message.

6. Create Result as Tagname & Type: Memory Integer.

7. Script to create Excel File (Script for new file opening after date is changed): Click

Special, Scripts, Data Change Scripts. In Data Change Scripts type Tagname (Field:) :

$Day and type following script and click Save.

Name1="Date";

Name2="Time";

Name3="PV";

Filename=Text($Day,"#")+"_"+ Text($Month,"#") +"_" + Text($Year,"#");

Result=FileWriteFields ("D:\Apex Demo Application\"+Filename+".CSV",-1, "Name1", 3);

8. Create Column1 as Tagname & Type: Memory Message.

9. Create Column2 as Tagname & Type: Memory Message.

10. Create Column3 as Tagname & Type: Memory Integer.

11. Script to create data logging (Script for storing data after every One second): Click

Special, Scripts, Data Change Scripts. In Data Change Scripts type Tagname (Field:) :

$Second and type following script and click Save.

Column1=DT;

Column2=Time;

Column3= PV;

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Result=FileWriteFields ("D:\Apex Demo Application\"+Filename+".CSV",-1, "Column1",

3);

12. On Apex Demo Application window right click and click on Window Scripts. In Window

Script for “Apex Demo Application” select Condition Type: While showing, on every

5000 msec. Type following script and Click OK

DT=$Datestring;

Time=$Timestring;

13. In WindowMaker click on File, WindowViewer and in Windows to View select window

and click OK to see the application in Runtime mode. (Use Runtime! Button located at

right hand upper corner of WindowMaker to run opened window.)

14. Change computer system date for storing data under same date name file.

15. Open Microsoft Office Excel and open date name file as created above. You will find

data stored in respective column.

In WindowViewer click on File, WindowMaker and in Windows to Edit select window and click

OK to see the application in Development mode. (Use Development! Button located at right

hand upper corner of WindowViewer to edit opened window.)

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Components Details

Control unit Hybrid controller, Make Honeywell, Model HC900 – C30, AI

8, AO4, DI 16, DO16, Control loops 8 with Hybrid Control

Designer software

Power supply Make Meanwell, model S-15-24, O/P 24 V, 0.7 A

Contact relay Make Leone, Model P30FC – 2C, Supply – 24V DC, DC24V –

350 ohms, Contact 25A, 250VAC

Analog Input/Output

indicator

Make Selectron, Model PIC 101

Computer Model Compaq 3143, P4, DC 1.6, 512 MB RAM, 80GB HD,

DVD Writer, 17” TFT Monitor

Components used

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Shipping details : Gross volume 0.52m3, Gross weight 88kg, Net weight 37kg

Box

No.1/2

Size W1700xD575xH525 mm; Volume:0.51m3 Gross weight: 65 kg

Net weight:25 kg

1 Set up assembly 1 No

Box

No.2/2

Size W725xD350xH330 mm; Volume:0.01m3 Gross weight: 23kg

Net weight: 12kg

1 Hybrid controller assembly 1 No

2 Tool kit 1 No

3 SCADA software package set of CDs (6 Nos)

-Plant scape R400 application software

-Plantscape R400 knowledge builder

-Plantscape Vista R400 supplemental

-Plantscape R 400 service pack

-HC900 Hybrid control designer

-Honeywell Experion PKS

-Apex Innovations(329), Instruction manual and

product software

1 Set

4 Set of cables and other hardware:

Ethernet cable (1 no)

Communication cable (1 no)

LAN card (1 No.)

Software protection key (1 no.)

1 Set

5 Set of Instruction manuals

-HC900 hybrid controller Ethernet Modbus /TCP

communications user manual

-HC900 hybrid controller Installation and user guide

-HC900 hybrid controller designer user guide

-HC900 hybrid controller designer function block

reference guide

1 Set

Packing slip

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This product is warranted for a period of 12 months from the date of supply against

manufacturing defects. You shall inform us in writing any defect in the system noticed during

the warranty period. On receipt of your written notice, Apex at its option either repairs or

replaces the product if proved to be defective as stated above. You shall not return any part of

the system to us before receiving our confirmation to this effect.

The foregoing warranty shall not apply to defects resulting from:

Buyer/ User shall not have subjected the system to unauthorized alterations/ additions/

modifications.

Unauthorized use of external software/interfacing.

Unauthorized maintenance by third party not authorized by Apex.

Improper site utilities and/or maintenance.

We do not take any responsibility for accidental injuries caused while working with the set up.

Apex Innovations Pvt. Ltd.

E9/1, MIDC, Kupwad, Sangli-416436 (Maharashtra) India

Telefax:0233-2644098, 2644398

Email: support @apexinnovations.co.in Web: www.apexinnovations.co.in

Warranty

http://support%[email protected]/

http://www.apexinnovations.co.in/

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Wiring diagram

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(with ethernet communication) - apex innovations · software package wonderware intouch v10.5 (64...

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