T940X Process Supervisor

Process Supervisor
the redundant DCS solution

Distributed process supervisor supporting both continuous and sequential strategies
Redundant processor option
Large application capacity up to 512 I/O
Live replacement of processor with automatic initialisation
Peer-to-peer control network and supervisory communications
Open I/O network supports Profibus® DP and DPV1 and Modbus® RTU master and slave
Multiple network support
Ability to run two processors independently on the same base

The Process Supervisor is a powerful and configurable strategy engine capable of performing both continuous, logic and sequential control. It has evolved from the successful T103/T102/T100 Unit Controllers and is designed for large applications. Multi-tasking functionality allows user control of strategy execution.

The optional redundancy of processor modules provides high availability solutions for process control. The automatic and seamless changeover of the processors, together with the live replacement of processor modules, prevents any interruption of the process.

The T940X supports peer-to-peer communications using LIN over ARCnet (ALIN) or Ethernet (ELIN) providing a real distributed control system.

The Process Supervisor’s support for Profibus (DP and DPV1) and Modbus™ RTU provides a truly open I/O network allowing connections to the process interface (2500) I/O modules and other third party devices.

Separating the processing from the I/O allows physical distribution of the modules which reduces wiring installation costs.

An extensive function block library is available that includes control, batch, timing, math, logic, conditioning and control modules,while Sequence Function Charts (SFC) can be used for more advanced sequencing.

Online reconfiguration of the database can be tried out and deleted as required - the final modifications can then be applied. All carried out without halting the application or the process.

Features:

Supports continuous and sequential strategies
Supports multiple networking for easy system integration
Compatible with Eurotherm LIN products
Large range of standard applications
Redundant Processor
Modbus™ communications
Profibus communications
Ethernet communications

Modular Hardware

REDUNDANT CONFIGURATION
The Process Supervisor duplex redundant option provides

Two separate processor units
Separate power supply connections for each processor
Dual control network connections (ARCnet and Ethernet)
Dual I/O network connections (Profibus DP, DPV1 and Modbus serial)

In duplex operation, the two processor modules are designated one as primary and the other as secondary. On power-up the primary module runs the control strategy and communications while the secondary tracks the primary operation and status via a high-speed data link. Upon detection of a failure in the primary processor, the changeover form the primary to the secondary will be automatic and bumpless, initiated by watchdog circuits and software checks. All control and I/O communications are also switched transparently from primary to secondary in the event of a failure.
The fascia of each processor gives visualisation of its status via LED and also allows processor synchronisation and manual changeover.

FLEXIBLE COMMUNICATIONS
The Process Supervisor supports a number of different communication ports simultaneously. Connections via RJ45 connectors are provided via the Connect Module allowing the replacement of the Process Module without effecting the cabling LIN communications.

MODULAR HARDWARE
The modular hardware of the Process Supervisor comprise a chassis, a Connect Module and up to two Processor Modules.

CONNECT MODULE
All external connections to the Processor Module are via the Connect Module, allowing the removal of a processor unit without any disturbance to the external cable interface. All the communication connectors and termination plug-ins are RJ45 format. The RJ45 connectors on the front panel can be wired for ALIN, Modbus RTU or Profibus DPV1 use, according to specification at the time of order. The pairs of RJ45 connectors on the left-hand side of the module are assigned to the left-hand processor and the right-hand connectors to the right-hand module. Each pair of connectors is wired in parallel to facilitate easy daisy chaining. Each processor has two 24V-supply connections. Additionally, a separate connector allows external battery, watchdog, and two software configurable alarm relays.

PROCESSOR MODULE
Up to two Processor Modules can be installed on a chassis and can operate either independently (simplex), or in redundant mode. In redundant mode, one of the processors acts as a primary which is backed-up by the secondary in case of failure. All external interfaces to the Processor Modules are via the Connect Module. Processor modules can be supplied by two external 24V-power supplies to ensure operation in the event of power failure. The LEDs on the front panel of the Processor Modules provide comprehensive status indication, allowing for rapid verification and diagnostics. The start-up mode of the module is selected from the front panel switch. Inside the processor, a plug-in memory module holds both control strategies and operating software, enabling their rapid transfer to a spare instrument.

REMOTE I/O
The Process Supervisor is designed to work with EurothermSuite Process Interface (2500) units. Up to 16 Process Interface units may be multi-dropped from the Process Supervisor and it can work with any third party I/O which supports Profibus DPV1 or Modbus RTU. Its open network architecture allows connection to the Process Interface (T2550) I/O modules and the Eycon Visual Supervisor are peer-to-peer

Continuous and Logic control

CONTINUOUS PROGRAMMING - Click for larger view

The T2550 supports the level of block structuring normally only found in advanced DCS systems. The continuous strategy is built up by interconnection of function blocks from a rich library of analog and logic elements.

Sequence control

SEQUENCE PROGRAMMING - Click for larger view

Sequences act in a supervisory role relative to the continuous database and may thus be loaded and unloaded independently. This is increasingly important for batch sequences, which relate to the process rather than the physical equipment, as these must be changed to meet the requirement of flexible plants. The capacity of the local filing system allows storage of a large number of sequences. Their operation is controlled through specialized blocks in the continuous database.

ELIN System Architecture

The ELIN control network is the backbone of the control and data acquisition network that provides peer-to-peer communications between control nodes and seamless access to all data by operator and configuration workstations.

All nodes appear as part of a coherent distributed database. The database in any networked element is accessible to any other network element, allowing complete flexibility in strategy interconnection.

ELIN supports OPC with a readily available server and direct connection of operator, configuration workstations and other Eurotherm control and logging units including the T800 Integrated Loop Processor where standalone or panel-mounted display and control is appropriate.

ALIN networks

Connection to existing networks LIN networks via T225 ELIN – ALIN bridge.

Configuration

At the heart of the system is the LINtools configuration and engineering station. LINtools is a comprehensive set of configuration, test, documentation and commissioning tools for strategy elements distributed over the LIN control backbone.

The LINtools suite includes graphical configuration of block structured continuous control, sequence control SFC’s, ladder and graphics for any LIN based product. VIEW and Online reconfiguration modes allows dynamic monitoring and editing of running databases and flow charts.

LINtools follows the IEC 61131-3 standard for sequence configuration (see below), while adopting a decoupling of continuous and sequential strategy appropriate to complex process control.

Underlying the design of LINtools are the concepts of simplicity and productivity. Online help, free-format text annotation and area editing are just some of the features included not only to make LINtools easy to use in itself but also to make work done understandable and reusable. LINtools runs on a standalone or networked PC.

The T640 supports the level of block structuring normally only found in advanced DCS systems. Each of the four control loops occupies its own task, which may be set to run at a rate appropriate to its function in the strategy. The general purpose blocks can be distributed between these tasks, T640’s internal architecture ensuring data coherence.

All but the M006 Fixed-Function versions are configured by the LINtools package. The Fixed- Function version is set up by simple parameterization which may be achieved either via the front panel, or using the Parameterization tool software (supplied with the controller) on a PC fitted with an ALIN interface. Parameters may also be accessed online from the LINview package.

Up to 250 function blocks can be configured, depending on the size of the blocks and the number of connections. The table below lists the blocks currently supported by T640 and summarises their functions.

IEC 61131

LADDER PROGRAMMING - Click for larger view

Languages appropriate for the I/O type and for the application

Function Block Diagram
Sequence Function Chart
Structured Text
Relay Ladder Logic Control

Continuous control

Continuous strategies are configured graphically on screen using ‘block structured’ techniques implemented across system.

The control configurator supports a comprehensive library of functions together with powerful editing and compound definition facilities. Merging allows the re-use of similar sections of databases avoiding duplication of effort. Free text may be placed on the screen or attached to function blocks, simplifying descriptive documentation. Context-sensitive help reduces the need to keep referring to manuals.

Sequence

Sequences are configured graphically using Sequential Function Charts (SFCs) following the IEC 61131-3 standard. Steps initiate Actions which may be Structured Text statements (ST) or nested SFCs. Transitions determine when control passes from one step to the next. By accessing the continuous control strategy this configurator presents the available points through a menu system, eliminating the need to remember the names of points and reducing the likelihood of typing errors.

Like the control configurator this configurator supports text annotation and context-sensitive help.

Action block

ACTION blocks in the continuous control strategy have their functionality defined in Ladder diagram or Structured Text (ST) within a standard template. These are particularly appropriate for implementation of plant control modules. The configurator is used to generate reusable structured text definitions.

Action functionality can also be configured using ladder logic graphical tools

Specifications

SPECIFICATIONS for T940X (General)
Physical, case dimension and weight
Dimensions	Backplane:	402mm wide x 180mm high x 24mm deep
	Connection Module:	120mm wide x 180mm high x 126mm deep
	Processor Module:	120mm wide x 180mm high x 186mm deep
Backplane fixing centres:		382 horizontal x 125 vertical
Weight	Backplane:	2kg. max (without modules)
	Connection module:	1.1kg max.
	Processor module:	2.4kg max. (each)

Environmental operating ranges, and standards
Temperature	Storage:	–25 to +85°C
	Operation:	0 to + 50°C
Humidity:	Storage/Operation:	5 to 95% RH (non-condensing)
Vibration:		To IEC1131-2 section 2.1.3 (0.075mm peak amplitude10 to 57 Hz; 1g 57 to 150 Hz)

EMC and safety standards
RFI EMC emissions:		BS EN561326 2000-02
EMC immunity:		BS EN561326 2000-02
Electrical Safety:		BS EN61010-1/A2:1993
Installation category:		II
Pollution:		degree 2

Power Requirements
Main supply:		24Vdc nom. (18 to 36Vdc)
Max power requirement:		at 50W per processor module
Supply voltage connector:		DC: Phoenix MSTB 2,5/2-ST-5.08 or equivalent. Two supplies can be connected, to ensure continued operation should one supply fails
Battery options	Internal:	Nickel/metal hydride battery board maintains database and realtime clock for 72 hrs (min)
Backup supplies	External:	2.4 to 5Volt battery
		Typical drain per processor = 3.4mA at 3.4V
Fusing requirement:		No internal fuse
	24V supplies fuse:	3A Type T in each positive supply line
External batteries fuse:		0.5A Type T in each positive supply line

Processor
CPU type:		Pentium MMX 266 MHz
Flash memory:		>8 Mbyte,
Serial Communications		Non-isolated RS232 terminal configuration port (RJ11 connector)

Health Relays
Relays:		One watchdog relay per processor / Two user configurable relays per processor
Contact Format:		Common and normally open
Contact rating (resistive)		30Vac / 60Vdc at 0.5Amps
Isolation		(Contact-to-ground) 30Vac (RMS) or 60Vdc

Panel Indicators
Main supply (24Vdc nom) status
External battery Status
Internal battery status
Alarm relays status
ELIN/ALIN/Profibus/Modbus Master/Modbus Slave comms status
Primary processor status
Standby processor status
Watchdog status
Duplex (redundant mode) status

Control switches
Processor front panel		Push button switches - Watchdog Halt
		Watchdog Restart
		Processor module synchronization/ changeover
		Processor module resynchronization
	Rotary switch	Start-up mode selection
Back plane
Configuration Switches	SW1:	ALIN address
	SW2, segment 1:	Watchdog retry (trip and try again mode)
	SW2, segment 6:	Redundant/non-redundant mode select (duplex/simplex)
	SW2, segment 5:	Modbus select

Other connections
Safety earth connection:		By M4 earth stud on right hand flange of the backplane

Control Specification
Continuous database resources (default max values)
Continuous control database size:		320k Bytes
Number of templates:		50
Number of libraries:		28
Number of EDBs:		32
Number of TEATTs (external attachements):		512
Number of connections:		1024
Control database size:		256k Bytes (max)
SFC database size:		512k Bytes (max)

Sequence Control Resources
Sequence memory Program data:		256k Bytes
SFC Resources:		256k Bytes
Independent sequence tasks simultaneously active:		40
SFC actions:		170, including root SFCs
Steps:		640
Action associations:		2400
Actions:		1200
Transitions:		900

Communications specification
ELIN ports
Connectors:		pairs of shielded RJ45 connectors per processor unit
Network medium:		Ethernet Cat5
Network type:		LIN over Ethernet TCP/IP
Speed:		10/100 TX
Network Topology:		star connection to a hub
Line length (max):		100 metres, extendable by repeater
Allocation of IP address:		Manual / Link-Local / BootP

ALIN ports
Connectors:		Parallel wired pairs of shielded RJ45 connectors per processor unit.
Network medium:		ArcNet (screened twisted pair, 100 Ohm)
Network type:		Token bus
Speed:		2.5 Mbits/sec.
Number of nodes:		8 (max), extendable by repeater
Line length (max):		100 metres (max), extendable by repeater
Isolation:		60Vdc / 30Vac; 5.6kΩ to 0V

Master I/O Comms memory
Profibus:		200k
Modbus:		100k
Note: The comms spreadsheet must be used for the I/O sizing.

Modbus/Jbus (EIA422/485), Slave
Connectors:		Parallel wired pairs of shielded RJ45 connectors per processor unit.
Protocol:		MODBUS/JBUS RTU slave
Data rate:		Selectable between 600 and 38,400 Baud
Data format:		8-bits, 1 or 2 stop bits, selectable parity
MODBUS data tables:		16 tables of 16, configurable as registers or bits
Table length:		200 registers (max) or 999 bits
Memory allocated to tables:		24K Bytes
Isolation:		60Vdc / 30Vac

Modbus (DCM) Master
Connectors:		Parallel wired pairs of shielded RJ45 connectors per processor unit.
Protocol:		MODBUS/JBUS RTU master
Data rate:		Selectable between 600 and 38,400 Baud
Data format:		8-bits, 1 or 2 stop bits, selectable parity
Isolation:		60Vdc / 30Vac

Profibus
Connectors:		Parallel wired pairs of shielded RJ45 connectors per processor unit.
Protocol:		Profibus DP/DPV1
Number of nodes supported:		123 nodes max
Data rate:		Selectable between 9600 and 12M Baud
Isolation:		60Vdc / 30Vac; 1MΩ to Chassis

Documentation

Documentation and file utilities allow the strategy and graphics to be fully documented and transferred across the network.

Hard copy documentation consists of the graphical representation of the control strategy supplemented by a listing of the block parameters and connections. Output can be to a printer or in PostScript or AutoCAD compatible file format. User annotations may be added either directly to graphical screens, or associated with blocks and steps. In this way LINtools provides an electronic documentation environment.