Participant Guide

Foxboro Control Systems – Configuartion

Essentials
Course No. 5001

Revision A – March 9th 2012

Copyright

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 Participant Guide Contents

Participant Guide Contents

Course Introduction................................................................................ 1

Using this Guide ................................................................................................... 4

Hello Activity ....................................................................................................... 5

Purpose .................................................................................................................. 5

Structure and Rules................................................................................................ 5

Course Objectives ................................................................................................ 6

Course Overview .................................................................................................. 7

Course Documentation ........................................................................................ 8

Hardware Overview ............................................................................... 1

Module Objectives ............................................................................................... 8

Module Overview ................................................................................................ 8

Reference Documentation ..................................................................................... 8

Intelligent Automation (I/A) Series System ......................................................... 10

Distributive Control Systems Features ................................................................ 10

I/A Series Evolution History ................................................................................. 11

I/A Series Hardware Basic Components .............................................................. 14

Modules ............................................................................................................ 15

Module Types ...................................................................................................... 15

Workstations and Servers .................................................................................. 17

Workstations ........................................................................................................ 17

Servers ................................................................................................................. 18

Workstation/Server Naming Conventions ........................................................... 19

Determining the Workstation/Server Configuration ........................................... 20

Workstation and Server Types ............................................................................. 27

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P90 Server ............................................................................................................ 27

P91 Server ............................................................................................................ 29

P92 Workstation .................................................................................................. 33

Control Processors Modules ................................................................................ 44

Fieldbus Modules ................................................................................................. 76

I/A Series Modular Baseplates ............................................................................. 87

I/A Series Letterbug Configurator ....................................................................... 97

Configuring Module Identifier ............................................................................. 99

Termination Assembly (TA) Unit ....................................................................... 101

Termination Assembly Wiring Connections....................................................... 104

MESH Control Network .................................................................................... 106

MESH Control Network Features ....................................................................... 107

Hubs Versus Switches ........................................................................................ 108

MESH Control Network Topologies ................................................................... 111

Convergence ...................................................................................................... 121

MESH Control Network Specifications............................................................... 122

MESH Control Network Ethernet Switches........................................................ 125

Interoperability with Legacy I/A Networks ........................................................ 126

LAB – Identifying the I/A Series Hardware Components .................................... 129

Introduction ....................................................................................................... 129

Objectives .......................................................................................................... 129

Instructions ........................................................................................................ 129

I/A Series Hardware System Worksheet ............................................................ 131

Hardware Components Worksheet ................................................................... 133

Summary ............................................................................................................ 139

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Review Questions ............................................................................................ 140

FCS Software Overview .......................................................................... 1

Module Objectives ............................................................................................... 6

Module Overview ................................................................................................ 6

Reference Documentation ..................................................................................... 6

Basis for FCS ........................................................................................................ 7

Purdue 5-Layer Automation Model ....................................................................... 8

ArchestrA ............................................................................................................. 10

Functional Areas .................................................................................................. 12

Hardware Versus Functional Areas...................................................................... 16

Objects ................................................................................................................. 18

Control Configuration ........................................................................................ 21

FCS Configuration Tools Process Strategy ........................................................... 21

Visualization ...................................................................................................... 23

FCS InTouch Application Software ....................................................................... 23

FCS InTouch Application Viewer .......................................................................... 25

Contents of WindowMaker Process Graphic ....................................................... 26

FCS InTouch Application Versus FoxView ............................................................ 29

Wonderware Historian ....................................................................................... 31

Wonderware Historian Client Trend .................................................................... 32

System Manager ................................................................................................ 33

Security ............................................................................................................. 34

Alarming ............................................................................................................ 35

LAB – Using FCS.................................................................................................. 36

Introduction ......................................................................................................... 36

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Objectives ............................................................................................................ 36

Lab Procedure ...................................................................................................... 38

Summary .............................................................................................................. 52

Review Questions .............................................................................................. 53

Continuous Control Concepts ................................................................. 1

Module Objective ................................................................................................ 6

Module Overview ................................................................................................ 6

Reference Documentation ..................................................................................... 6

Process Control Database ..................................................................................... 7

Continuous Control Domain .................................................................................. 9

Ladder Logic Control Domain............................................................................... 12

Sequence Logic Control Domain .......................................................................... 14

Compound Overview ......................................................................................... 15

Compound Concept ............................................................................................. 15

Compound Rules .................................................................................................. 15

Default Compounds ............................................................................................. 16

Block Overview .................................................................................................. 19

Specific Block Functions ....................................................................................... 19

Block Rules ........................................................................................................... 23

Parameters Connectability and Settability .......................................................... 25

Parameters........................................................................................................... 25

Connectability ...................................................................................................... 28

Settability ............................................................................................................. 30

Compound Parameters ...................................................................................... 32

Input Parameters ................................................................................................. 33

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Output Parameters .............................................................................................. 36

Block Parameters ............................................................................................... 37

Block Initialization ................................................................................................ 37

Feedback/Back Calculation Parameters .............................................................. 38

FBM Access Parameters....................................................................................... 39

Signal Conditioning Parameters........................................................................... 41

Range Parameters ................................................................................................ 42

Delta Value Parameters ....................................................................................... 44

Manual/Automatic Parameters ........................................................................... 46

PID Control Parameters ....................................................................................... 48

Additional Parameters ....................................................................................... 53

LAB – Using Block Select ..................................................................................... 54

Review Questions .............................................................................................. 63

Process Control Faceplate Windows ....................................................... 1

Module Objectives ............................................................................................... 6

Module Overview ................................................................................................ 6

Reference Documentation ..................................................................................... 6

FCS InTouch Application Block Select .................................................................... 7

Station View ........................................................................................................... 8

Report Views ........................................................................................................ 14

Interfacing with FCS InTouch Application ............................................................ 16

FCS InTouch Application Block Select Window and Dialog Boxes ......................... 17

FCS InTouch Application Block Select Window.................................................... 17

Dialog Boxes ......................................................................................................... 28

Lab 1 – Using Block Select................................................................................... 41

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Faceplate Overlays ............................................................................................. 50

Faceplate Overlay Locations ................................................................................ 50

Faceplate Overlay Features ................................................................................. 52

Changing Parameter Values ................................................................................. 60

Data Quality Indication ........................................................................................ 64

Detail View Navigation......................................................................................... 66

Faceplate Overlay Alarms .................................................................................... 72

Faceplate Overlay Trends .................................................................................... 74

Lab 2 – Working with Faceplate Windows ........................................................... 77

Review Questions .............................................................................................. 83

Control Configuration for FCS ................................................................. 1

Module Objectives ............................................................................................. 10

Module Overview .............................................................................................. 10

Reference Documentation ................................................................................... 11

Control Configuration ........................................................................................ 12

Hardware Architecture ........................................................................................ 12

Objective of Control Configuration ...................................................................... 13

New Terms ........................................................................................................... 13

Foxboro I/A Series Configuration Tools Database Hierarchy ................................ 18

Database Structure .............................................................................................. 18

ArchestrA Pathname versus I/A Pathname ......................................................... 20

Foxboro I/A Series Configuration Tools Components ........................................... 21

Opening Foxboro I/A Series Configuration Tools from HMI ................................ 22

Foxboro I/A Series Configuration Tools Initial Display......................................... 23

Creating Your Own Toolset .................................................................................. 28

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Building a Control Strategy ................................................................................. 32

Building a Strategy ............................................................................................... 32

Check In – Check Out ........................................................................................... 33

Object Properties ................................................................................................. 35

Appearance Object Editor.................................................................................... 36

Locking and Inheritance ....................................................................................... 38

IO ASSIGNMENT ................................................................................................... 40

Various Utilities and Functions ........................................................................... 41

Deployment Utilities ............................................................................................ 41

Galaxy Status........................................................................................................ 42

Find Function ....................................................................................................... 43

Live Action Update ............................................................................................... 44

Instances ........................................................................................................... 45

Creating a New Strategy Using Menu .................................................................. 45

Creating a New Strategy Using Drag-and-Drop ................................................... 46

Renaming a New Strategy.................................................................................... 47

Creating a Compound .......................................................................................... 50

Strategy Editor Window ....................................................................................... 51

Making an On-screen Connection ....................................................................... 56

WinForm Editing .................................................................................................. 57

Specifying Configured Values and Connections................................................... 59

Simplifying Connection Lines ............................................................................... 63

Adding an Off-page Connection........................................................................... 65

Changing Order of Block Execution ..................................................................... 72

Changing Execution Order in a Strategy .............................................................. 72

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Displaying Execution Order within Strategy ........................................................ 73

Displaying Execution Order within CP and Compound ........................................ 75

Deployment ....................................................................................................... 76

Deployment View ................................................................................................ 77

Packaging the Strategy ....................................................................................... 82

Equipment Unit .................................................................................................... 82

Control Processor................................................................................................. 83

Compound ........................................................................................................... 83

Strategy ................................................................................................................ 83

Order of Building and Assigning........................................................................... 83

Creating a Derived Template for a Strategy ......................................................... 84

Standard Versus Derived Objects ........................................................................ 84

Creating New Toolset........................................................................................... 85

Creating a Derived Strategy Template ................................................................. 86

Import/Export Application Objects ...................................................................... 90

Database Backup and Restore ............................................................................. 90

Remedying Galaxy/CP Mismatches ..................................................................... 92

Selective Upload/Deploy ..................................................................................... 98

Update CP/Update Galaxy ................................................................................. 101

Bulk Generate .................................................................................................. 103

Lab 1 – Create a Compound from a Base Template. ........................................... 104

Lab 2 – Create a Compound from a Derived Template ....................................... 112

Lab 3 – Create Blocks from Base Templates....................................................... 129

Lab 4 – Create Blocks from Derived Templates .................................................. 154

Lab 5 – Make Connections Between Blocks ....................................................... 170

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Lab 6 – Create a PID Loop using the IDE ............................................................ 181

Review Questions ............................................................................................ 198

Building and Configuring Process Displays with WindowMaker for FCS ... 1

Module Objectives ............................................................................................... 6

Module Overview ................................................................................................ 8

Reference Documentation ..................................................................................... 9

Foxboro I/A Series InTouch Application Versus FoxView ..................................... 10

WindowMaker Versus FoxDraw ......................................................................... 12

InTouch Application Directory ............................................................................ 12

Window Properties .............................................................................................. 13

Window Construction Overview ......................................................................... 19

Calling WindowMaker.......................................................................................... 20

Windows to Open… ............................................................................................. 20

WindowMaker Screen Basics ............................................................................... 21

Create a New Window ......................................................................................... 21

Lab 1 – Build a Custom InTouch Window ............................................................ 26

Object Selection ................................................................................................. 36

Selecting Objects Individually .............................................................................. 36

Selecting Objects in a Group ................................................................................ 38

Selected Object Steps .......................................................................................... 39

Symbols and Cells .............................................................................................. 39

Making Symbols and Cells.................................................................................... 40

Making and Breaking Symbols and Cells.............................................................. 41

Status Toolbar ................................................................................................... 41

WindowMaker Properties Configuration ............................................................ 42

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Export Windows ................................................................................................... 43

Wizards/ActiveX Toolbar .................................................................................... 43

Wizards Selection................................................................................................. 45

Wizards Type........................................................................................................ 45

Lab 2 – Creating Animation ................................................................................ 50

Entering an I/A Compound Block Parameter (CBP) .............................................. 79

CBP Number Extensions....................................................................................... 79

Animation Links ................................................................................................. 86

Animation Links Types ......................................................................................... 87

Touch Pushbuttons ............................................................................................ 107

Accessing Foxboro I/A Series InTouch Application Framer ................................. 114

Create New Configuration ................................................................................. 115

Labeling the Navigation Keys ............................................................................. 116

Assign Window to Key ....................................................................................... 117

Framer Properties .............................................................................................. 119

Foxboro I/A Series InTouch Application Viewer................................................. 119

Use Browse ........................................................................................................ 120

Use Configuring Favorites .................................................................................. 120

Use Recent ......................................................................................................... 124

Foxboro I/A Series InTouch Application Security ............................................... 125

Security .............................................................................................................. 125

Authentication Modes ....................................................................................... 126

Security Groups.................................................................................................. 129

Roles................................................................................................................... 130

Users .................................................................................................................. 131

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Review Questions ............................................................................................ 132

Trending for FCS ..................................................................................... 1

Module Objectives ............................................................................................... 4

Module Overview ................................................................................................ 4

Reference Documentation ..................................................................................... 4

Trending Components .......................................................................................... 5

Trending Versus Historization ................................................................................ 5

Types of Trends ...................................................................................................... 5

Available Trends..................................................................................................... 7

Adding a 16-Pen Trend to a Foxboro I/A Series InTouch Application Window ...... 11

Configuring Historical Data Collection ................................................................. 14

Configuring the Block ........................................................................................... 16

Configuring the Compound.................................................................................. 18

Configuring the History Object’s AppEngine ....................................................... 19

Wonderware Historian Server ............................................................................ 21

System Management Console (SMC) .................................................................. 21

Displaying Historical Trends ............................................................................... 28

Operating the Historian Client Trend Application ............................................... 29

Lab 1 – FCS Trending and Logging ....................................................................... 31

How can I view logged data? .................................................................40

Review Questions .............................................................................................. 45

Process Alarming for FCS, Configuration and Notification ....................... 1

Module Objectives ............................................................................................... 6

Module Overview ................................................................................................ 6

Reference Documentation ..................................................................................... 6

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Alarming Hardware Architecture .......................................................................... 7

Process Alarms .................................................................................................... 8

Process Alarm Data Flow ....................................................................................... 8

Alarm Handling .................................................................................................... 11

InTouch Distributed Alarm System ...................................................................... 13

Alarm Types in I/A ............................................................................................. 14

Alarm Parameters in General ............................................................................. 15

H/L and HH/LL Absolute Alarm ............................................................................ 16

H/L Deviation Alarm............................................................................................. 18

Deviation Alarm Key Parameters (PID) ................................................................ 19

Output Alarm ....................................................................................................... 19

H/L Out-of-Range Alarm ...................................................................................... 20

Out-of-Range Alarm Key parameters (AIN Block) ................................................ 20

BAD Alarm ............................................................................................................ 21

BAD Alarm, Clamping, and Last Good Value ........................................................ 22

Nuisance Alarm Suppression ............................................................................... 24

Alarm Regeneration ............................................................................................. 25

Alarm Processing.................................................................................................. 25

Group Alarm Devices ......................................................................................... 28

Compound Group Alarm Devices ........................................................................ 29

STATION Block Group Alarm Devices................................................................... 30

Process Alarm Notification and Acknowledgement ............................................. 40

Alarm Notification................................................................................................ 40

Alarm Indication and Acknowledgement the Faceplate Windows ..................... 40

Acknowledging Alarms......................................................................................... 44

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Alarm Indicator .................................................................................................... 45

Alarm Panel .......................................................................................................... 45

Annunciator Keyboard LEDs ................................................................................ 52

LAB – Process Alarming for FCS, Configuration and Notification .......................... 55

Introduction ......................................................................................................... 55

Objectives ............................................................................................................ 55

Lab Procedure ...................................................................................................... 55

Summary .............................................................................................................. 68

Review Questions .............................................................................................. 69

Network Definition for FCS ..................................................................... 1

Module Objectives ............................................................................................... 5

Module Overview ................................................................................................ 5

Reference Documentation ..................................................................................... 6

Hardware Architecture for Foxboro Control Systems Network .............................. 7

Overview of Procedures ....................................................................................... 8

General Workflow .................................................................................................. 9

Device Summary .................................................................................................. 11

Network Definition as a Part of Foxboro I/A Series Configuration Tools ............... 11

Network View ...................................................................................................... 12

Constructing the Hardware Configuration ........................................................... 13

General Workflow of Equipment Units................................................................ 13

Processing the Configuration ............................................................................... 36

Network Options.................................................................................................. 40

Bulk Create ........................................................................................................... 42

Reporting .......................................................................................................... 44

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Review Questions .............................................................................................. 48

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