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Gas Control Manager Program User Manual (ROC800-Series)
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Remote Automation Solutions Gas Control Manager Program User Manual (ROC800-Series) Manuals & Guides

Part D301748X012
August 2014
Gas Control Manager Program User Manual (for the ROC800-Series)
Remote Automation Solutions
Page
Revision
Initial release
Aug-14
Revision Tracking Sheet
August 2014
This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover. Listed below is the revision date of each page (if applicable):
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Contents
Chapter 1 – Introduction 1
1.1. Scope and Organization ................................................................................................................. 1
1.2. Product Overview ........................................................................................................................... 2
1.2.1. EFM Applications ............................................................................................................. 2
1.2.2. Cause and Effect .............................................................................................................. 2
1.3. Program Requirements .................................................................................................................. 2
Chapter 2 – Installation 5
2.1. Installing the License Key ............................................................................................................... 5
2.1.1 Verifying the License Key Installation .............................................................................. 6
2.2. Downloading the Program .............................................................................................................. 6
Chapter 3 – Configuration 11
3.1. EFM Applications .......................................................................................................................... 11
3.1.1. Run Switching – Run Switch Tab: Station Settings ....................................................... 12
3.1.2. Run Switching – Run Switch Tab: Tube Settings .......................................................... 17
3.1.3. Run Switching – Run Switch Operate Tab ..................................................................... 20
3.1.4. Run Switching – Proportional Output Tab ...................................................................... 21
3.1.5. Run Switching – Total Accum Tab ................................................................................. 22
3.1.6. About Open and Close DO ............................................................................................ 23
3.2. Cause and Effect .......................................................................................................................... 23
3.2.1. Effect Configuration Settings .......................................................................................... 25
3.2.2. Cause Configuration Settings ........................................................................................ 27
3.2.3. Cause and Effect Operate Display ................................................................................. 32
3.2.4. Configuration Examples ................................................................................................. 33
Chapter 4 – Reference 43
4.1. Point Type 73: Run Switching ..................................................................................................... 44
4.2. Point Type 71: Cause Configuration ............................................................................................ 54
4.3. Point Type 72: Effect Configuration .............................................................................................. 59
Appendix A – Sample Cause and Effect Diagram 63
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Chapter 1 – Introduction

Caution
When implementing control using this product, observe best industry practices as suggested by applicable and appropriate environmental, health, and safety organizations. While this product can be used as A safety component in a system, it is NOT intended or designed to be the ONLY safety mechanism in that system.
This chapter describes the structure of this manual and presents an overview and installation instructions of the Gas Control Manager Program for the ROC800-Series Remote Operations Controller (ROC800).

1.1. Scope and Organization

This document is the user manual for the Gas Control Manager Program for use in the ROC800.
This manual describes how to download and configure this program (referred to as the “Gas Control Manager Program” or “the program” throughout the rest of this manual). You access and configure this program using ROCLINK™ 800 Configuration Software (version 2.20 or greater) loaded on a personal computer (PC) running Windows Service Pack 2), Windows XP (with Service Pack 3), Windows Vista (32­bit), or Windows 7 (32-bit).
®
2000 (with
The sections in this manual provide information in a sequence appropriate for first-time users. Once you become familiar with the procedures and the software running in a ROC800, the manual becomes a reference tool.
This manual has the following major sections:
Chapter 1 – Introduction Chapter 2 – Installation Chapter 3 – Configuration Chapter 4 – Reference
This manual assumes that you are familiar with the ROC800 and its configuration. For more information, refer to the following manuals:
ROC800-Series Remote Operations Controller Instruction Manual
(Form A6175).
ROCLINK 800 Configuration Software User Manual (for ROC800-
Series) (Form A6218).
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1.2. Product Overview

The Gas Control Manager Program contains two parts: EFM Applications and Cause and Effect. This manual describes both parts of the program, in two sections. The first section covers the EFM Applications, and the second section covers Cause and Effect.

1.2.1. EFM Applications

The EFM Applications User Program is designed to allow you to configure the Emerson Process Management ROC and ROC800 products to do common gas measurement functions such as station emergency shutdown, outputting a 4-20mA signal proportional to an input or calculation, resettable total meter accumulators for volume/energy and run switching. Normally, a user would have to write FSTs to accomplish these tasks.

1.2.2. Cause and Effect

The Gas Control Manager User Program supports 16 causes and 8 effects. The program is designed to allow you to configure the Emerson Process Management ROC and ROC800 products to do logical operations without writing FSTs. A Cause would typically monitor a selected point that would be logically evaluated against a user defined set-point. Any tripped Cause linked to an Effect will force the action defined in that Effect. The layout of the configuration screens is such that you can configure logic by inputting entries from a Cause and Effect matrix. In many cases you can input the effects and causes line by line through the entire matrix. Each Cause configuration screen and Effect configuration screen will apply to a tag line in the user’s Cause & Effect matrix.

1.3. Program Requirements

You download the Gas Control Manager Program to the Flash and RAM memory on the ROC800 with firmware version 3.50 (or greater). Download and configure the program using ROCLINK 800 Configuration software version 2.20 (or greater).
The downloadable program is:
File Name
GasControlMgrv
305_01.tar
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Target Unit/
Version
ROC800 3.50 71, 72, 73 128845 114688 2.20 20, 21, 22, 23
User Defined Points (UDP)
Note: You must connect a PC to the ROC800’s LOI port before starting
Flash Used
(in bytes)
DRAM Used
(in bytes)
ROCLINK 800
Version
Display
Number
the download.
For information on viewing the memory allocation of user programs, refer to the ROCLINK 800 Configuration Software User Manual (for ROC800­Series) (Form A6218).
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Failure to exercise proper electrostatic discharge precautions, such as

Chapter 2 – Installation

This section provides instructions for installing the Gas Control Manager program into the ROC800. Read Section 1.3 of this manual for program requirements.
Notes:
The computer running ROCLINK 800 must be connected to the Local
Operator Interface (LOI) port before you begin the download.
The program and license key can be installed in any order. The manual
shows the installation of the license key first.
The installation process and functionality is the same for all versions
of the Gas Control Manager program.

2.1. Installing the License Key

If you order the Gas Control Manager program for a new ROC800, your ROC800 is delivered with the license key installed. Go to Section 2.2. If you order the program for an existing ROC800, you must install the license key yourself.
Caution
wearing a grounded wrist strap may reset the processor or damage electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive gases may be present), make sure the area is in a non-hazardous state before performing these procedures. Performing these procedures in a hazardous area could result in personal injury or property damage.
To install a license key:
1. Remove power from the ROC800.
2. Remove the wire channel cover.
3. Unscrew the screws from the Central Processing Unit (CPU) faceplate.
4. Remove the CPU faceplate.
5. Place the license key in the appropriate terminal slot (P4 or P6) in the
CPU.
Figure 2-1. License Key Installation
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Note: When using a single license key, install it in slot P4.
6. Press the license key into the terminal until it is firmly seated (refer to
Figure 2–1).
7. Replace the CPU faceplate.
8. Replace the screws on the CPU faceplate.
9. Replace the wire channel cover.
10. Restore power to the ROC800.

2.1.1 Verifying the License Key Installation

After you install the license key, you can verify whether the ROC800 recognizes the key. From the ROCLINK 800 screen, select Utilities > License Key Administrator. The License Key Administrator screen displays:
Figure 2-2. License Key Administrator
Gas Control Mgr appears in the Application Name column. [For further information on the License Key Administrator screen, refer to Section 2.4 of the ROCLINK 800 Configuration Software User Manual (for ROC800- Series) (Form A6218).]
After you verify that the license key is correctly installed and recognized, proceed to Section 2.2 to download the user programs.

2.2. Downloading the Program

This section provides instructions for installing the user program into ROC800 memory.
Note: Connect a PC to the ROC800’s LOI port before starting the
download.
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To download the user program:
1. Start and logon to ROCLINK 800.
2. Select ROC > Direct Connect to connect to the ROC800 unit.
3. Select Utilities > User Program Administrator from the ROCLINK
menu bar. The User Program Administrator screen displays (see
Figure 3):
Figure 3. User Program Administrator
4. Click Browse in the Download User Program File frame. The Select
User Program File screen displays (see Figure 4).
5. Select the path and user program file to download from the CD-ROM.
(Program files are typically located in the Program Files folder on the CD-ROM). As Figure 4 shows, the screen lists all valid user program files with the .TAR extension:
Figure 4. Select User Program File
6. Click Open to select the program file. The User Program
Administrator screen displays. As shown in Figure 5, note that the
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Download User Program File frame identifies the selected program and that the Download & Start button is active:
Figure 5. User Program Administrator
7. Click Download & Start to begin loading the selected program. The
following message displays:
Figure 6. Confirm Download
8. Click Yes to begin the download. During the download, the program
performs a warm start, creates an event in the event log, and—when the download completes—displays the following message:
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Figure 7. ROCLINK 800 Download Confirmation
9. Click OK. The User Program Administrator screen displays (see
Figure 8). Note that:
The User Programs Installed in Device frame identifies the loaded
program.
The Status field indicates that the program is running.
Figure 8. User Program Administrator
10. Click Close and proceed to Chapter 3 to configure the program
Note: Installing a user program without a license key allows you only
to view the program screens (that is, the program outputs no data). Installing the license key enables the program to read from the meter and output data.
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Chapter 3 – Configuration

After you download and start the Gas Control Manager Program, configure the program using ROCLINK 800 software. To do this, use the program-specific Gas Control Manager Program screen.

3.1. EFM Applications

Once you have successfully loaded the Gas Control Manager program into the ROC800, you can access the Gas Control Manager screens. To start the EFM Applications:
1. Double-click an ROC800 device or click the Direct Connect icon in
2. The device window opens. Select User Program > Gas Control Mgr
3. Double-click Display #23, Run Switching.
4. You will see a display for each station. Double-click a station to see
Figure 9. ROCLINK 800
the toolbar.
in the ROCLINK configuration tree.
the Run Switching window for that station.
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Figure 10. Run Switch tab – Run Switching screen
The Run Switch tab is divided into two main sections: Station Configuration and Tube Configuration:
Station Configuration. Use this section to configure global settings
that affect all tubes in the station. Four run switching stations are available.
Tube Configuration. Use this section to configure switching for up to
four runs. You define your input and output points, set high and low points, and choose when to open and close runs.

3.1.1. Run Switching – Run Switch Tab: Station Settings

Use this section to configure global settings that affect all tubes in the station. Four run switching stations are available.
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Field
Description
Figure 11. Station settings of the Run Switch tab
1. Review the values in the following fields:
Station Tag
Status
Status Message Display
Use this field to name your station. The default value is Station1.
The first number reflects the total number of runs (flow tubes) that the program believes is currently open. The next four fields show the status of each of the four tubes. The values are 1 (open) or 0 (closed). The blue box frames the tube that is in focus or control.
Provides information for the following run switching conditions. The code number is available in Run Switching Parameter 81:
0 = Status OK 1 = Station ESD
2 = PV Type Not Selected
3 = Invalid Open DO Type
4 = Invalid Open DO Param
5 = Invalid Close DO Type 6 = Invalid Close DO Param
7 = Invalid Open DI Type
8 = Invalid Open DI Param
9 = Invalid Close DI Type
10 = Invalid Close DI Param
11 = Illegal Flow Tube 1 12 = Illegal Flow Tube 2
13 = Illegal Flow Tube 3
14 = Illegal Flow Tube 4
15 = Illegal DI Tube 1
16 = Illegal DI Tube 2
17 = Illegal DI Tube 3 18 = Illegal DI Tube 4
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Delays
Use the Spike and Settling delays to set how long the system waits before taking action.
Field
Description
Spike Delay
Settling Delay
Switch Mode
Solenoid Mode
Delay time in seconds. The program examines this field whenever a run’s Input TLP value goes above or below its high or low set point. The condition must remain in effect for the number of seconds specified in this field before any run-switching executes. The delay provides a filter for the process variables. The Spike Delay time is also used when switching down to a lower tube that has been closed or up from a lower tube that will be closed (this happens when “Leave Open After Opening Next Tube” is unchecked). Before the program closes that tube, it must see flow (a PV value greater than the PV Cutoff Value) for the tube just opened, for the amount of time specified in the Spike Delay. Maximum value is 255 seconds.
Delay time in seconds. This delay goes into effect immediately after a run switches. During the delay, the new focus run remains in focus, so no comparisons occur for any more possible switching. This allows process conditions to stabilize after the previous change before any more decisions are made. Maximum value is 255 seconds.
Indicates how the tubes are monitored.
Monitor All
Monitor Last Opened
Selects a method for controlling the run switching valve activations. The selected mode applies to all valves, and impacts status messages that notify whether relevant selections for digital outputs and digital inputs have been made. Valid values are:
Single Solenoid Latch
Monitor all passed switch points. For example, if all four tubes had been opened, choosing this option causes the system to monitor the switch points in all four tubes.
Monitor only the switch point that was last activated. For example, if all four tubes had been opened, choosing this option causes the system to monitor the switch points in tube 4 only.
The Open DO selection is defined for each valve used which opens and closes the valve by energizing or de­energizing a solenoid. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
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Field
Description
Focus Run Verification
PV Cutoff Value
Dual Solenoid Latch
Dual Solenoid Latch with DI Reset
Dual Solenoid Momentary
Verifies the focus (control) tube by continually monitoring the verification method of each enabled tube. The highest number tube that is verified to be flowing is set as the focus tube. This feedback causes the proper DO state to be asserted to establish proper focus. Valid values are:
Disable
PV Flow Sensing
DI State
The low flow cutoff value that defines a threshold for a valid flow sensing condition. The program also uses this value to establish a valid flow for the Action On Failure mode Illegal PV Flow.
The Open DO selection defines the output signal to open the valve. The program will hold this state until a signal to close is issued. The Close DO selection will define the output signal to close the valve. One or the other solenoids will always be on. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
In this mode the outputs behave as a Dual Solenoid Latch, but the solenoid resets or releases after the valve travels and the valve DI limit switches detect that valve position.
In this mode, selections are made for an open and close DO that turn on momentarily while the valve travels and then turn off. The ROC800 Point I/O Time On setting for that DO determines the duration of the momentary pulse. The Open and Close DI selections can be defined and monitored to verify valve travel if needed.
No Run Verification
Compares Input PV to the PV Cutoff Value to determine whether a flow condition exists for that tube. The highest number tube that is flowing becomes the focus tube.
Examines the state of the digital inputs for each tube to determine the focus tube. The highest number tube with its digital inputs indicating “valve open” becomes the focus tube. If these DI points are “Undefined,” this evaluation is not made.
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Field
Description
Station ESD
ESD TLP
Action On Failure
Failure Delay (Sec)
Configures the Emergency Shutdown feature. If you leave this field “Undefined” the ESD is not activated. This feature can also be used for routine station shut-in. When tripped, an ESD closes all run switching valves to provide positive shut-in. A Set condition is logged to the alarm log. The program restores the run switching function when the ESD condition clears, and sends a Clear condition to the alarm log.
Defines the TLP the program monitors for emergency shutdown.
Verifies tube flowing conditions or DI states relative to the focus tube depending on the selected Failure Type. Various actions are possible based on the selection. No evaluations are made until after the Failure Delay counter to allow run switching to stabilize before applying any actions are applied. Valid values are:
Type: None
Type: Illegal PV Flow
Type: Illegal DI State
Action: Status Only
Action: Alarm Log
Action: Disable Tube & Alarm Log
All Action On Failures are performed after the Settling Delay plus the Failure Delay setting in seconds. Maximum value is 255 seconds.
Disables any failure evaluation.
Evaluates valid tube flow by using the PV Cutoff Value in the Focus Run Verification section, which determines if a tube is actually open or closed.
Uses digital input states to determine if a tube is actually open or closed.
Generates a status message code to indicate a Failure condition.
Sends a Failure condition to the alarm log that contains the status message code number.
Disables the tube where the Failure condition is identified and logs that tube as OFF in the alarm log. If this tube was not the last tube enabled, run switching skips the disabled tube and uses the next tube for control.
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2. Click Apply to save your changes.
3. Proceed to Section 3.1.2, Run Switching – Run Switch Tab: Tube
Settings.
Focus Run Verification methods can be used to assure the run switching program’s focus tube is what is actually happening. An example of this is a valve with momentary solenoids that do not change state when the output is pulsed. If this were to occur, the program would switch focus and lose sight of the actual valve states. This may be most useful for dual
Field
Description
solenoids that do not hold their states such as Momentary or DI Reset modes.
An example of what happens in the event of a valve switch failure: Tube 3 has just pulsed to close because of low DP. Ordinarily tube 2 becomes the focus run. But as long as flow is still sensed in tube 3, it remains the focus run. After the settling time expires (default 30 seconds), if tube 3 still has low DP, the program will pulse to close tube 3 again and wait another settling period.

3.1.2. Run Switching – Run Switch Tab: Tube Settings

Use this section to configure switching for up to four runs. You define your input and output points, set high and low points, and choose when to open and close runs.
In the Run Switching section, you can configure switching for up to four runs, using various types of input and output points. The program supports both non-latching and latching (such as Versa® Valve or Magna-Latch) solenoids and has configurable high and low switch points, and the option of closing the previous run when opening another.
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Figure 12. Station settings of the Run Switch tab
Notice that the Run 1 configuration has no Lo SwitchPt field. This is because the Lo SwitchPt field triggers a run to be closed and closing Run 1 would result in no flow at the station. Conversely, notice that the Run 4 configuration has no Hi SwitchPt or Leave Open fields. This is because there is no Run 5 to be opened after Run 4.
1. Review the values in the following fields:
Tag
A 10-character field that identifies the meters that makes up the run-switching scheme. This tag is useful for documentation purposes (screen prints, etc.).
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