Rockwell Automation T6200 User Manual

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T6200

Ics triple

User’s Guide

__________________________________________________________________________ ___________________________

T6200

Compressor Anti-Surge and Capacity Controller

Issue 1

May 2004

Contents of this manual may not be reproduced

in any form without the written permission of ICS Triplex.

Printed in the United States of America.

Specifications are subject to change without notice.

A/S VIEW MOPS, and T6200 are trademarks of ICS Triplex,

Information furnished by ICS TRIPLEX is believed to be

accurate and reliable. However, no responsibility

is assumed by ICS TRIPLEX for its use.

T6200

USER’S GUIDE

ICS Triplex p/n 9001-0220

Issued May 2004

ICS Triplex, Inc.

4325 West Sam Houston Pkwy. North

Suite 100

Houston, Texas 77043-1219 USA

Phone: 713-353-2400 Fax: 713-353-2401

www.icstriplextmc.com

T6200

User’s Guide

TABLE OF CONTENTS

SECTION 1 – PRODUCT OVERVIEW

Design Structure.............................................................. ................................................................................1-3

Analog and Discrete Input/Output.................................. ................................................................................1-4

Line Power and Transmitter Power................................ ................................................................................1-5

System Security .............................................................. ................................................................................1-5

On Line Diagnostics........................................................ ................................................................................1-6

Configuration Security..................................................... ................................................................................1-6

Controller Redundancy................................................... ................................................................................1-6

Dual Non-Redundant Controller………………………………………………………………………………….1-6

SECTION 2 – INPUT/OUTPUT CIRCUIT DESCRIPTION

Analog Voltage Inputs..................................................... ................................................................................2-3

Analog Current Inputs..................................................... ................................................................................2-4

Analog Current Outputs .................................................. ....................................................... .........................2-4

Isolated Discrete Inputs .................................................. ................................................................................2-6

Discrete Inputs with Excitation from Controller.............. ................................................................................2-6

Discrete Outputs.............................................................. ................................................................................2-8

Discrete Outputs with Internal Power............................. ................................................................................2-8

Discrete Outputs with External Power............................ ................................................................................2-9

Active/Standby Logic....................................................... ................................................................................2-9

SECTION 3 – HARDWARE INSTALLATION/MAINTENANCE

Site Selection Considerations......................................... ................................................................................3-3

Access Considerations ................................................... ................................................................................3-3

T6200 Controller Mounting ............................................. ......................................................... .......................3-4

T6200 Controller Electrical Power Wiring...................... ................................................................................3-6

T6200R Subrack Electrical Power Connection ............. ................................................................................3-8

Input/Output Hardware Configuration ............................ ................................................................................3-9

Signal Wiring.................................................................... ...............................................................................3-10

Wiring and Jumper Placement for T6200C Channels 1-8............................................................................3-12

Wiring and Jumper Placement for T6200C Channels 9-16..........................................................................3-13

Wiring and Jumper Placement for T6200C Channels 17-22, 31, and 32.................................................... 3-14

Wiring and Jumper Placement for T6200C Channels 23-26 .......................................................................3-16

Wiring for T6200C Channels 27-30................................ ...............................................................................3-17

Wiring and Jumper Placement for T6200D Channels 1-26, 31, and 32 ......................................................3-17

Wiring for T6200D Channels 27-30................................ ...............................................................................3-19

Ethernet Communication Network ................................. ...............................................................................3-19

Network Security ............................................................. .................................................. .............................3-19

Ethernet Network Connectors………………………………………………………… ....................................3-19

Network Cabling.............................................................. ...............................................................................3-20

Non-Redundant Network................................................ ...............................................................................3-20

Redundant Network………………………………………………………………………………………………3-21

T6200R Subrack Ethernet…… .....................................................................................................................3-23

Operator Interface Installation ........................................ ...............................................................................3-24

Firmware Changes.......................................................... ...............................................................................3-27

Serial Communication Connection................................. ...............................................................................3-28

T6200

User’s Guide

SECTION 4 - SOFTWARE INSTALLANTION

The Micon OPC Server Compact Disc .......................... ................................................................................4-2

Install the Packet Driver Software .................................. ........................................................... .....................4-2

Install the Micon OPC Server and Related Components...............................................................................4-5

Ethernet Addresses......................................................... ................................................................................4-7

SECTION 5 - T6200 CONTROLLER OPERATION

Push to Activate Switch .................................................. ................................................................................5-5

System Start-up............................................................... ................................................................................5-6

Replacing Control Boards............................................... ................................................................................5-6

Loading Controller Configuration.................................... ................................................................................5-8

Watchdog Timer.............................................................. ................................................................................5-8

SECTION 6 – HMI-6200 OPERATOR INTERFACE

Preface............................................................................. ................................................................................6-2

Overview of HMI-6200 Features .................................... ................................................................................6-4

Event Information Processing......................................... ................................................................................6-6

Display Layout................................................................. ...............................................................................6-15

General Display Description........................................... ...............................................................................6-18

Graphic Displays Configuration...................................... ...............................................................................6-21

HMI Example – Single Stage Compressor.................... ...............................................................................6-22

Adaptation of Pre-Defined Displays ............................... .............................................................. .................6-25

Surge Curve Screens...................................................... ...............................................................................6-29

Custom Graphic Screens................................................ ...............................................................................6-30

Configuring the Security System.................................... ...............................................................................6-31

Communications.............................................................. ...............................................................................6-34

Downloading the Updated Application........................... ...............................................................................6-38

SECTION 7 – CONTROL PRIMER

Proportional (P) Action.................................................... ................................................................................7-4

Integral (I) Action… ......................................................... ................................................................................7-8

Derivative (D) Action ....................................................... ................................................................................7-8

Proportional-Plus-Integral (PI) Action……………………………………………………………………………7-9 Proportional-Plus-Derivative (PD) Action………………………………………………………………………..7-10 Proportional-Plus-Integral-Plus-Derivative (PID) Action………………………………………………………..7-11 Interactive and Non-Interactive Control………………………………………………………………………….7-12 Deadtime……………………………………………………………………………………………………………7-13

Cascade Control.............................................................. ................................................................................7-14

Ratio Control.................................................................... ................................................................................7-16

Damping........................................................................... ................................................................................7-16

T6200

User’s Guide

SECTION 8 – CONFIGURATION

Preface............................................................................. ................................................................................8-3

Configuration Studio........................................................ ................................................................................8-4

Running the FBD Configurator Workbench................... ................................................................................8-4

Function Block Diagram (FBD) Editor............................ ...............................................................................8-10

Miscellaneous Workbench Features.............................. ...............................................................................8-16

Adaptation of Pre-Defined Configuration....................... ...............................................................................8-22

MICON OPC Server Start-up........................................................................................................................8-39

SECTION 9 – SPECIFICATIONS

APPENDIX A – DATA STRUCTURES AND EXPRESSIONS

Tags................................................................................. ................................................................................A-3

Reserved Words.............................................................. ................................................................................A-6

Labels............................................................................... ................................................................................A-7

Data Types ...................................................................... ................................................................................A-7

Logical Operations .......................................................... ................................................... .............................A-7

Arithmetic Operations...................................................... ................................................................................A-8

Relational Operations...................................................... ................................................................................A-8

Unary Operations............................................................ ................................................................................A-8

Expression....................................................................... ................................................................................A-9

Truth Tables..................................................................... ...............................................................................A-11

Logic Evaluation Rules ................................................... ...............................................................................A-11

Boolean Logic Rules ......................................................................................................................................A-11

APPENDIX B – MODBUS INTERFACE – RS-232

Preface............................................................................. ................................................................................B-2

T6200 MODBUS Functions Supported………………………………………………………………………….B-2 T6200 MODBUS Configuration…………………………………………………………………………………..B-3

T6200

User’s Guide

Product Overview

Section One

Product Overview

Design Structure 3 Analog and Discrete Input/Output 4 Line Power and Transmitter Power 5 System Security 5 On Line Diagnostics 6 Configuration Security 6 Controller Redundancy 6 Dual Non-Redundant Controller 6

1-1

Product Overview

1-2

Product Overview

PRODUCT OVERVIEW

The T6200 Controller is made up of two parts: The Operator Interface and the T6200 Controller. The Operator Interface with the Windows CE platform enables complete interaction with the T6200 Controller. Through the touch screen and LCD display users can change setpoints, outputs, start/stop devices, scroll through trends, or acknowledge alarms. The T6200 Controller functions as a multiapplication Controller or intelligent RTU capable of performing all data acquisition, continuous control, batch control, logic control and RTU requirements. Each T6200 Controller includes 999 function blocks in which control/logic functions can reside. The integral input/output (I/O) section of each T6200 Controller accommodates 32 I/O points. The large library of functions (over 100) and the practically unlimited number of blocks allow for pre-configuration of a wide variety of strategies by the factory and permits field application optim izat ion.

Design Structure

The Operator Interface is an embedded PC. It is independent of the T6200 Controller and it communicates with the T6200 Controller via Ethernet.

The T6200 Controller consists of three physical parts: the control board/s (single or redundant), the controller housing, and the termination panel. Refer to Figure 1-1. The termination panel may also include a remote termination panel for the I/O connections.

The control boards are a single printed circuit board design. The board contains the microprocessor circuitry, the memory chips, the communication interfaces, and the input/output conditioning components. Primary and backup control boards are identical.

1-3

FIGURE 1-1.

T6200 Unit Controller

Product Overview

Analog and Discrete Input/Output

Analog inputs can be either current or voltage. High common mode (200 Volts) amplifiers are utilized. Each input has a separate input amplifier. Also, each two wire transmitter input (4-20mA) is provided with a separate internal 24 volt regulator. Analog outputs source up to 20 milliamperes to the user’s receiver (load).

Most discrete inputs are opto-isolated (refer to specifications). The sample rate resolution of one millisecond provides for first out sequence of events capability. Three of these inputs can be

1-4

TABLE 1-1 .

TABLE 1-1.

Input/Output Channel Assignments

Product Overview

configured as frequency/pulse inputs. Discrete outputs are transistor configurations. A separate internal 24 volt regulator is supplied for each input/output.

The internal I/O section of the Controller accommodates 32 I/O points. Refer to Table 1-1 for I/O channel assignment information.

I/O Channel Numbers

Type

T6200C

T6200D

1 - 8 9 – 16 17 - 22 23-26 27 - 30 31 - 32

Analog

Input

Analog

Discrete

I/O *

Analog

I/O

Analog Output

Discr

I/O*

Input

Discrete I/O

Discrete

Input

Discr

I/O*

* Channels 22, 31 and 32 can also be configured as a frequency/pulse input. C hannel 32 can also be configured as a frequency/pulse output.

The process signals supported by the T6200 Controllers are:

• Analog Inputs (4-20 mA, ±20 mA, ±10 Vdc) internally or ext ernally powered

• Analog Outputs (4-20 mA, 0-20 mA)

 Discrete Inputs (On-Off contacts) internally or externally powered  Discrete Outputs - internally or externally powered  Pulse Inputs (up to 25 kHz)

Line Power and Transmitter Power

The T6200 Controllers operate on 26 Vdc power. The T6200R subrack supplies redundant AC to DC power supplies or the 26 Vdc can be obtained from any other reliable power source. Terminal blocks are provided on the termination panel for primary and secondary (redundant) 26 Vdc power input. Power for field transmitters, I/Ps, field switches, etc., is distributed through the T6200 Controller eliminating separate input/output power supplies and circuitry.

Both power supplies operate continuously. If one unit fails, it is not necessary to switch to the other power supply. Both of the 26 Vdc sources are diode-isolated in the T6200 Controller to prevent the failure of one from affecting the other. The supplies feed redundant power distribution traces on the termination panel.

System Security

The Controller maximizes its reliability and availability by a design incorporating complete redundancy of memory, intelligence, communication, and power. The redundancy includes total process input/output circuitry backup. And, since each termination panel can accommodate both the primary and backup control boards, the architecture allows for simple plug-in of the redundant control board. No wiring or cabling is required for redunda nt confi gurati ons.

The integral backup communication link of each unit assures that both control boards (primary and backup) maintain the same data base. Each control board has its own on-line, sophisticated

1-5

diagnostics and also monitors the status of the other control board which provides for a reliable transfer and redundancy scheme.

On Line Diagnostics

The T6200 Controller has on-line diagnostics designed to identify failures quickly. On all (primary and backup) operator interfaces, highways, local communications, the Controller run diagnostics on a continuous basis. These routines continuously check the status of critical device functi ons t o det ect failures.

If a failure is detected an alarm is activated to inform the operator and the backup unit is enable d.

Configuration Security

The T6200 Controllers maintain identical configuration at all times. At startup, when both control boards are powered up, the backup control board’s memory is always cleared, and the active control board transfers the configuration to the backup control board through the backup serial link, if it has a backup control board.

During operation (runtime), if new configuration is downloaded (to active control board), it automatically goes to both the primary and the backup control board. Thus configuration integrity is achieved and there are no mismatches.

Uninterrupted communication and control is provided by automatically transferring all configuration and communications of the active control board to the backup redundant control board. There is a complete transparency in the redundant control board. Apart from notification of failure, there is no change in the operator interface.

Product Overview

Controller Redundancy

The T6200 Controller redundancy concept allows the user to simply plug-in a backup control board side-by-side with the primary control board. The user has no installation or cable connection requirements. Termination panel data links enable the backup to copy the input/output and control configuration of the primary control board and to assume virtually immediately the input/output and control functions in case of a primary malfunction.

Each control board contains, in addition to the input/output functions, an extensive library of control algorithms. Thus, the T6200 Controllers can be configured as totally stand-alone intelligent controllers or RTUs. This minimizes dependency on communications, resulting i n high reliabi lity.

Dual Non-Redundant Controller

The T6200 Dual Non-Redundant Controller concept allows the user to have two independent controllers (a primary and a second controller) in one chassis thereby reducing the required panel space by half. With this option, two T6200-C Controller cards or two T6200-D Controller cards or a T6200-C and a T6200-D Controller card may be plugged into a single chassis. Two Rem ote I/O Termination Panels (one for the primary controller and one for the second controller) are requi red with this concept. The Dual Non-Redundant Controller option should onl y be used when c ontrol le r redundancy is not foreseen as a requirement.

1-6

Input/Output Circuit Description

Section Two

Analog Voltage Inputs 3 Analog Current Inputs 4 Analog Current Outputs 4 Isolated Discrete Inputs 6 Discrete Inputs with Excitation from Controller 6 Discrete Outputs 8 Discrete Outputs with Internal Power 8 Discrete Outputs with External Power 9 Active/Standby Logic 9

Input/Output Circuit Description

2-1

Input/Output Circuit Description

2-2

Input/Output Circuit Description

INPUT/OUTPUT CIRCUIT

DESCRIPTION

Each control board in the T6200 Controller incorporates the µP, memory, communicat ions and I/O circuitry. Separate I/O modules are not required.

Analog Voltage Inputs

Up to 20 channels in the T6200-C Controller can be configured with field changeable jumpers for voltage inputs. In reference to Figure 2-1, the input amplifier does not have galvanic isolation but it appears to have it in most applications because of its high common-mode voltage and its high input resistance. The 100 volt transient absorbers on each input will allow up to 100 volts dc or 75 volts ac (rms, sine wave) continuously or up to 104 volts impulse voltage to enter the amplifier. The amplifier will continue to operate with up to 200 volt s on it s inputs.

Each input has a separate input amplifier. The output of each of these amplifiers passes to the analog switch. Only one of these inputs is selected at one time. The selected signal continues to the programmable gain amplifier (PGA). The microprocessor selects the optimum gain setting for the PGA. The possible input full scale ranges that can be selected are 0.625, 1.25, 2.5, 5, and 10 volts. Inputs may be either polarity.

The voltage input configuration can be used as a current input by putting a resistor between the “+” and “-” input terminals. Use a 250 ohm resistor for a 4 to 20 milliampere loop and a 100 ohm resistor for a 10 to 50 milliampere loop.

2-3

Input/Output Circuit Description

Primary Control Board

To ADC

FIGURE 2-1

Analog Voltage Input

Analog

Voltage

Input

Termination

Panel

100V

200 Volt Common-mode Amplifier

Analog Switch

Programmable Gain Amplifier

Analog Current Inputs

The current input is similar to the voltage input with 250 ohm resistor across the amplifier inputs. Field changeable jumpers are used to select between voltage or current input. The maximum continuous input current is 20 mA and 40 mA momentary. Refer to Figure 2-2. Also the gain is increased in the PGA by a factor of two when a backup control board is present, to compensate for the decrease in voltage that the additional 250 ohm resistor will cause.

When an isolated two-wire 4 to 20 milliampere transmitter is used, the circuit shown in Figure 2-3 m ay be used. In this configuration a separate internal +24 volt voltage regulator is used for each transmitter. Each voltage regulator has thermal, reverse voltage, and short-circuit protection. In this arrangement, one end of the 250 ohm resistor is connected to circuit common. The two-wire 4-20 mA represents the standard analog input jumper selection.

100V

200 Volt Common-mode Amplifier

Analog Switch

Programmable Gain Amplifier

Backup Control Board

To ADC

Analog Current Outputs

The T6200 Controller can be configured from four to eight current out put s. The current out put will source from 0 to 20 milliamperes to the user's receiver (load). The receiver must share the same circuit common as the T6200 Controller. The maximum receiver resistance is 1000 ohms.

In reference to Figure 2-4, the digital to analog converter (DAC) receives a digital value from the microprocessor and converts it to an analog voltage. The voltage to the current converter, combined with transistor Q1 and the 50 ohm resistor, converts the voltage to a current signal.

The output of the primary and backup control boards are connected together on the Controller termination panel. The output is only enabled in the active control board. The diode is used to block the current from the active control board.

2-4

Input/Output Circuit Description

FIGURE 2- 2

Analog Current Input

4-20 MA Input

Termination

Panel

200 Volt Common-mode Amplifier

Analog Switch

Primary Control Board

Program mable Gain Amplifier

To AD C

FIGURE 2- 3

Two-Wire Transmitter Input

200 Volt Common-mode Amplifier

Analog Switch

Backup Control Board

Program mable Gain Amplifier

To AD C

Primary Control Board

Voltage

Regulator with

short-circuit

protection

Programmable Gain Amplifier

Backup Control Board

Voltage

Regulator with

short-circuit

protection

Gain Amplifier

To ADC

Two-Wire

Transmitter

Input

Termination

Panel

100V

24 VDC

250

OHM

24 VDC

250

OHM

Analog Switch

Analog Switch Programmable

2-5

Input/Output Circuit Description

FIGURE 2-4.

Analog Current Output

Analog Current

Output

Termination

Panel

125mA

+25.2V

OHM

Voltag e to Current Converter

DAC

Reset

Active from Figure 2-9

Voltag e to Current Converter

DAC

Reset

Active from Figure 2-9

Primary Control Board

From Microprocessor

Inhibit from Figure 2-9

Primary Control Board

From Microprocessor

Inhibit from Figure 2-9

Isolated Discrete Inputs

The T6200-C Controller can be configured for up to 16 isolated discrete inputs. The T6200-D Controller can be configured for up to 28 isolated discrete inputs in addition to the four internally power discrete inputs. The resistor, in series with the input, is used to limit the maximum current to less than 6.5 milliamperes. In reference to Figure 2-5, the resistor across the opto-isolator is used to increase the minimum input current to greater than one milliampere.

The opto-isolator provides electrical isolation between inputs and other circuits. Each input is protected with fuses. A 100 volt transient absorber is provided on each input terminal to prevent arcing between conductors on the circuit board. The maximum voltage that can be applied continuously is 38 volts dc or 30 volts ac (rms, sine wave). Discrete input channels 22, 31, and 32 can be used as frequency inputs, with input frequencies up to 25 kHz. Other discrete inputs can be used as frequency inputs with input frequencies up to 500 Hz.

Discrete Inputs with Excitation from Controller

The discrete input is similar to the isolated discrete input above, without the isolation. The input is internally powered. In this configuration a separate internal +24 volt regulator is provided for each dry contact input. Each voltage regulator has thermal, reverse voltage, and short circuit protection. The regulator supplies up to five milliamperes.

A contact closure between + and – terminals will activate the input. Refer to Figure 2-6. The internally powered discrete input represents the standard discrete input jumper selection. The T6200 Controller has a minimum of four internally powered discrete inputs.

2-6

Input/Output Circuit Description

FIGURE 2- 5.

Isolated Discrete Input

Power

Termination

Panel

100V

1.8K

4.7K

1.8K

4.7K

Primary Control Board

Input to Microprocessor

Backup ControlBoard

Input to Microprocessor

FIGURE 2-6.

Discrete Input with Excitation from Controller

Termination

Panel

100V

Voltage Regulator

24 VDC

1.8K

4.7K

24 VDC

1.8K

4.7K

Primary Control Board

Input to Microprocessor

Backup Control Board

Input to Microprocessor

2-7

Input/Output Circuit Description

Discrete Outputs

The T6200-C Controller can be configured for up to eight discrete outputs. The T6200-D Controller can be configured for up to 28 discrete outputs. A 100 volt transient absorber is connected on each terminal to protect the output transistor and to prevent arching between conductors on the circuit board. Each terminal is protected with a one ampere fuse.

The output transistor in the standby (not ACTIVE) control board is alway s open.

Discrete output 32 can be used as frequency output, with output frequencies up to 10 kHz. Other discrete outputs can be used as frequency outputs with output frequencies up to 100 Hz.

Discrete Outputs with Internal Power

In reference to Figure 2-7, a separate internal +24 volt voltage regulator is provided for each output. Each voltage regulator has thermal, reverse voltage, and short-circuit protection. The regulator can supply 24 Vdc power for a load up to 20 milliamperes continuously and 100 mill iam peres momentarily .

FIGURE 2-7

Discrete Output with Internal Power

LOAD

<20 mA

Termination

Panel

100V

24 VDC

Voltage

Regulator with

short-circuit

protection

Active from Figure 2-9

Latch

Primary Control Board

Output from Microprocessor

Inhibit from Figure 2-9

100V

24 VDC

Voltage

Regulator with

short-circuit

protection

Active from Figure 2-9 Latch

Backup Control Board

Output from Microprocessor

Inhibit from Figure 2-9

2-8

Input/Output Circuit Description

Discrete Outputs with External Power

In reference to Figure 2-8, the discrete transistor output with an external power source can sink up to 0.25 amperes continuously and one ampere momentarily. The maximum voltage that can be applied continuously is 38 volts DC. The return (-) of the external power source must be connected to the “-” input or “-” power terminal of the T6200 Controller.

Primary Control Board

Output fr om Microprocessor

Inhibit from Figure 2-9

Backup Contr ol Board

Output fr om Microprocessor

Inhibit from Figure 2-9

FIGURE 2-8.

Discrete Output with External Power

Load

<0.25A

T e rmination

Panel

100V

Active from Figure 2-9

Latch

Active from Figure 2-9

Latch

Active/Standby Logic

The active/standby logic determines which control board (primary or backup) is active and if the outputs are active. Only one control board can assume the active role at any given time. Refer to Figure 2-9.

The inhibit signal is true when the control board is not active and the system fail signal is true. The inhibit signal when true will reset the analog outputs to zero and reset the discrete output latches causing the output transistors to open.

The only time the inhibit signal can be true, in a primary control board that does not have a good control board in its backup position, is the first 0.2 second after power is first applied. This will allow the outputs to reset on power up and to freeze the outputs if the system fail signal should become true when the control board is active and must remain active.

2-9

Input/Output Circuit Description

FIGURE 2-9

Termination

Panel

Primary Control B oard

Active/Standby Logic

Active

Inhibit

Active

Inhibit

ACT LED

OUT LED

ACT LED

OUT LED

Power Up Reset

System Fail Activate

switch

Backup Control Board

Power Up Reset

System Fail Activate

switch

2-10

Section Three

Site Selection Considerations 3 Access Considerations 3 T6200 Unit Automating System Mounting 4 T6200 Controller Electrical Power Wiring 6 T6200R Subrack Electrical Power Connection 8 Input/Output Hardware Configuration 9 Signal Wiring 10 Wiring and Jumper Placement for T6200-C Channels 1-8 12 Wiring and Jumper Placement for T6200-C Channels 9-16 13 Wiring and Jumper Placement for T6200-C Channels 17-22, 31, and 32 14 Wiring and Jumper Placement for T6200-C Channels 23-26 16 Wiring for T6200-C Channels 27-30 17 Wiring and Jumper Placement for T6200-D Channels 1-26, 31, and 32 17 Wiring for T6200-D Channels 27-30 19 Ethernet Communication Network 19 Network Security 19

Ethernet Network Connectors 19

Network Cabling 20 Non-Redundant Network 20

Redundant Network 21 T6200R Subrack Ethernet 23

Operator Interface Installation 24 Firmware Changes 27 Serial Communication Connection 28

Hardware Installation/Maintenance

3-1

Hardware Installation/Maintenance

3-2

Hardware Installation/Maintenance

Hardware

Installation/Maintenance

Site Selection Considerations

The T6200 Controller requires following conditions during normal operation:

 32 to 122º F (0 to 50º C)  5 to 96% Relative humidity  Protection from direct contact with water, chemicals, and conductive dust.  Protection from exposure to sulfur compounds, acid, other corrosive or reactive vapors or

fumes, dust, and lint.

For estimating heat load requirements, the T6200 Controller dissipates a maximum of 10 BTU/hr. (or 24 KGM-CAL/Hr) to the inside of the control panel.

Access Considerations

There are very few restrictions on the mounting position of the T6200 Controller. The following should be taken into consideration:

 All electrical power and input/outputs are connected on the rear termination panel.

Because as many as 70 conductors and four cables can be terminated to each T6200 Controller adequate wireway space should be provided.

 The T6200 Controller is operated from the front of the unit with switches on the

bottom. The Operator Interface slides up 0.5 in. (12 mm) to remove.

3-3

 The control boards slide out the front of the unit.  To ensure a proper viewing angle, the Controller should be installed approximately

64 inches (1.6 m) above the floor.

 Outdoor installation is not recommended. However, for outdoor installations, the

face of the Controller should be shielded from direct sunlight, since bright light produces a poor display contrast.

T6200 Controller Mounting

Figure 3-1 provides mounting dimensions for the T6200 Controller. Dimensions are shown in inches (mm).

 Remove Operator Interface by pushing up and pulling out at the bottom. Disconnect cable

from Operator Interface

 Use the two Phillips head screws and clamps to mount the T6200 Controller in the user’s

panel.

 When the T6200 Controller is positioned properly, hand-tighten both clamps in place. Note:

Do not exceed 15 in-lbs (17 cm-kgs) of torque on panel clamp screws.

The panel cut-out dimensions, as well as the Operator Interface front outline dimensions are shown in Figure 3-2. The T6200 Controller would normally be mounted in a vertical posit ion.

Figure 3-3 provides mounting dimensions for the optional Remote I/O Termination Panel. The I/O cable that connects the T6200 Controller to the Remote I/O Termination Panel is 6 ft. (2m) long. Dimensions are shown in inches (mm). The Remote I/O Termination Panel can be snapped onto a user supplied standard 35 mm DIN rail.

T6200R Subrack Mounting

Each T6200R Subrack Housing accommodates up to six redundant T6200 Controllers. The subrack may also include two power supplies, Operator Interface, and two Ethernet hubs. Refer to Figure 3-4 for T6200R Subrack mounting dimensions. The subrack should be mounted in a EIA standard 19 inch rack. Refer to Section Nine Specifications for more detailed physical dimensions.

Hardware Installation/Maintenance

3-4

FIGURE 3-1.

T6200 Mounting

Hardware Installation/Maintenance

FIGURE 3-2.

T6200 Controller Panel Cutout Dimensions

OPERATOR INTERFACE

PANE L CU TO U T

5.95 [151]

5.44 [138]

5.50 [139]

1.375 [35]

4.30 [109]

2.74 [69]

2.68 [68]

1.72 [44] MIN

3-5

FIGURE 3-3

Remote I/O Terminal Panel Mounting Dimensions

Hardware Installation/Maintenance

T6200 Controller Electrical Power Wiring

The guidelines below should be followed when wiring the power to the T6200 Controlle r:

 The maximum wire size is 16 AWG stranded.  All wiring should be multi-stranded annealed copper with insulation that meets the

requirements of all applicable electrical codes.

 AC power wiring should be run in a separate conduit from the T6200 Controller power and the

I/O.

 The stripped portion of the wire should be 3/16” (5 mm) long.  Wires should be inserted in the clamp type terminals until they touch the internal stops. The

terminal screw should be tightened while holding the wire in place. Check for proper clamp pressure with a gentle tug on the wire.

 Electrical power should be provided from a redundant, highly reliable, dedicat ed 26 Vdc power

source.

 Power consumption is 15 watts for the T6200 Controller and 15 watts for the Operator

Interface, not including field devices.

The T6200 Controller has redundant 26 Vdc power supply connections.

3-6

FIGURE 3-4

T6200R Subrack Mounting Dimensions

Hardware Installation/Maintenance

Figure 3-5 shows the internal power distribution for the T6200 Unit Automation System. Connect 26 Vdc (18-32 Vdc) power to the 26V PRI (Primary) terminals and to the 26V SEC (Secondary) terminals.

There is a jumper (W1) on the T6200 Termination Panel that connects the minus side of the 26 volt supply to earth ground. This jumper may be cut if the power source is referenced to earth ground somewhere else in the system.

3-7

FIGURE 3-5

Internal Power Distribution

Hardware Installation/Maintenance

T6200R Subrack Electrical Power Connection

Once the T6200R Subrack is mounted, plug the included external power supply’s DC power cord into the matching power jack on each of the Ethernet Hub’s rear panel. The Ethernet Hub shelf may be removed to connect the power. Plug each of the power supply’s transformers into an AC receptacle that is six feet (two meters) or less away. The green “Pwr” LED should light up.

Refer to the guidelines in T6200 Controller Electrical Power Wiring above and Figure 3-6 and connect AC power wiring to each of the 26 Vdc Power Supplies.

The 26 Vdc power to the T6200 Controllers and Operator Interface is usually prewired as shown in Figure 3-6.

Figure 3-6

T6200R Subrack Power Wiring

3-8

Input/Output Hardware Configuration

There are several different ways the hardware can be configured for each input/output. Refer to Section Two Input/Output Circuit Description for details on each configuration. The different configurations are achieved by the placement of jumpers (shorting bars) on a multi-pin headers located on the printed circuit board. Each channel has a separate header and can be configured independently. To access the jumpers:

CAUTION

 Unplug the optional front panel Operator Interface  Carefully slide the printed circuit board out the front of the chassis.

The Controller contains parts susceptible to damage by electrostatic discharge. Normal precautions should be taken to avoid high static

voltages.

When facing the component side of the printed circuit board with the LEDs on the left, the headers/jumpers will be at the right Pin one on the headers will be as shown in the illustrations. Pin one also has a square pad on the circuit side of the printed circuit board. Refer to Figure 3-7 for T6200C. Refer to Figure 3-11 for T6200D.

Hardware Installation/Maintenance

FIGURE 3-7.

T6200C Control Board

The headers may vary from input/output group to group. All the headers are oriented the same way within one group. A group is where a`ll consecutive inputs/outputs have the same configuration options. For example, channels one through eight are in the same group.

3-9

Signal Wiring

FIGURE 3-8

Hardware Installation/Maintenance

Individually shielded wires are not required (except for frequency inputs). Twisted pairs and overall cable shields are recommended. Each multipair cable should contain a few pairs of spare wires. Shiel ds and unused conductors should be terminated to ground at Controller end only. Refer to appropriate Wiring and Jumper Placement.

The following general guidelines apply to all signal wiring discussed in the following paragraphs.

 Wire size range for the terminal panel is 26-16 AWG stranded; recommended wire size range

is 18-14 AWG.

 Wire size range for the remote I/O terminal is 26-14 AWG stranded; recommended wire size

range is 18-14 AWG.

 All wiring should be multi-stranded annealed copper with insulation that meets the

requirements of all applicable electrical codes.

 Keep all wire runs as short and direct as possible. Long wire runs are vulnerable to picking up

stray electrical noise. Use care when running signal wiring near to or crossing conduit or wiring that supplies power to motors, solenoids, lighting, horns, bells, et c.

 Avoid bringing signal wiring into junction boxes which contain ot her wiri ng.  AC power wiring should be run in a separate conduit from the signal wiring.  The stripped portion of the wires should be 5/16” (8 mm) long.  Wires should be inserted in the clamp type terminals until they touch the internal stops. The

terminal screw should be tightened while holding the wire in place. Check for proper clamp pressure with a gentle tug on the wire.

Integral Termination Panels

3-10

FIGURE 3-9

Redundant Remote I/O Termination Panel

Hardware Installation/Maintenance

FIGURE 3-10

Dual Non-Redundant Remote I/O Termination Panel

3-11

Wiring and Jumper Placement for T6200C Channels 1-8

Two-Wire Transmitter

This wiring and jumper placement is normally used with isolated two-wire transmitters where the transmitter power is supplied by the Controller. Refer to Figure 2-3.

Analog Current Inputs

This wiring and jumper placement is normally used with four-wire current transmitters when the power is not

supplied by the

Power

Source

Controller. Refer to Figure 2-2.

Analog Voltage Inputs

This wiring and jumper placement is for voltage inputs. Refer to Figure 2-1.

Power

Source

4-20 mA

Two-Wire

Transmitter

(Isolated)

4-20 mA

Transmitter

Transmitter output may be referenced

to common

DC Voltage Transmitter

Transmitter output may be referenced

to common

Hardware Installation/Maintenance

T6200C Controller

24 Vdc

Supply

mA Input

(reference to

common

through resistor)

SHLD

T6200C Controller

mA Input

(Isolated from

common)

SHLD

T6200C Controller

DC Voltage Input

(Isolated from

common)

SHLD

Factory Default

3-12

Wiring and Jumper Placement for T6200C Channels 9-16

Two-Wire Transmitter

Hardware Installation/Maintenance

This wiring and jumper placement is normally used with isolated two-wire transmitters where the transmitter power is supplied by the Controller. Refer to Figure 2-3.

Analog Current Input

This wiring and jumper placement is normally used with four-wire current transmitters when the power is not

supplied by the Controller. Refer to Figure 2-2.

Analog Voltage Input

This wiring and jumper placement is for voltage inputs. Refer to Figure 2-1.

Power

Source

Power

Source

4-20 mA

Two-Wire

Transmitter

(Isolated)

4-20 mA

Transmitter

Transmitter output may be referenced

to common

DC Voltage Transmitter

Transmitter output may be referenced

to common

T6200C Controller

24 Vdc

Supply

mA Input

(reference to

common

through resistor)

SHLD

T6200C Controller

mA Input

(Isolated from

common)

SHLD

T6200C Controller

DC Voltage Input

(Isolated from

common)

SHLD

Factory Default

3-13

Hardware Installation/Maintenance

Discrete Inputs with Excitation from Controller

This wiring and jumper placement is for discrete (On/Off) inputs. The Controller supplies 24 VDC power for the input. Refer to Figure 2-6.

Alternate

Open Collector

Transistor

Contact

T6200C Controller

Discrete Input

(24 Vdc/5 mA

excitation)

Circuit

Common

Isolated Discrete Inputs

This wiring and jumper placement is for discrete (On/Off) inputs. The discrete inputs are isolated from other circuits and the external power for the input

Power Source

18 V to 32 V

ac/dc

Contact

Polarity

Arbitrary

is either 18-32 Volt AC or DC. Refer to Figure 2-5.

T6200C Controller

Discrete Input

(Optically coupled)

Wiring and Jumper Placement for T6200C Channels 17-22, 31, and 32

Discrete Inputs with Excitation from Controller

This wiring and jumper placement is for discrete (On/Off) inputs. The Controller supplies 24 VDC power for the input. Refer to Figure 2-6.

Isolated Discrete Inputs

This wiring and jumper placement is for discrete (On/Off) inputs. The discrete inputs are isolated from other circuits and the external power for the input is either 18-32 Volt AC or DC. Refer to Figure 2-5.

Power Source

18 V to 32 V

Open Collector

ac/dc

Alternate

Transistor

Contact

Polarity

Arbitrary

Contact

T6200C Controller

Discrete Input

(24 Vdc/5 mA

excitation)

Circuit

Common

T6200C Controller

Discrete Input

(Optically

coupled)

Factory

Default

3-14

Hardware Installation/Maintenance

Frequency Inputs

This wiring and jumper placement is for a

PWR

frequency/pulse preamplifier input with the Controller supplying the power (Channel 22,31 and 32).

Frequency/Pulse

Preamplifier or other

Discrete Device

0-25KHz only for

Channels 22, 31 &

OUT

COM

Discrete Outputs with Internal Power

This wiring and jumper placement is for discrete (On/Off) outputs. The Controller supplies 24 VDC power for the 20 mA max load. Load Example: Entrelec RB

Discrete

Load

<20 mA

131 (010055.23) relay. Refer to Figure 2-7.

Discrete Outputs with External Power

T6200C Controller

24 Vdc

Supply

Input

(Circuit Common)

SHLD

Discrete

T6200C Controller

24 Vdc

Supply

Discrete Output (Open Collector

Transistor)

This wiring and jumper placement is for discrete (On/Off) outputs. The power source (less than 38 VDC) is external. The discrete load is 0.25 Amp max. Refer to Figure 2-8.

Power Source

<38 Vdc

Discrete

Load

<0.25 A

T6200C Controller

Discrete Output

+-+

(Open Collector

Transistor)

Circuit

Common

3-15

Wiring and Jumper Placement for T6200C Channels 23-26

Two-Wire Transmitter

Hardware Installation/Maintenance

This wiring and jumper placement is normally used with isolated two-wire transmitters where the transmitter power is supplied by the Controller. Refer to Figure 2-3.

4-20 mA

Two-Wire

Transmitter

(Isolated)

T6200C Controller

24 Vdc

Supply

mA Input

(reference to

common

through resistor)

SHLD

Factory Default

Current Inputs

This wiring and jumper placement is normally used with four-wire current transmitters when the power is not

supplied by the Controller. Refer to Figure 2-2.

Power

Source

4-20 mA

Transmitter

Transmitter output

may be referenced

to common

T6200C Controller

mA Input

(Isolated from

common)

SHLD

Analog Voltage Inputs

This wiring and jumper placement is used for voltage input. Refer to Figure 2-1.

Power

Source

DC Voltage Transmitter

Transmitter output

may be referenced

to common

T6200C Controller

DC Voltage Input

(Isolated from

common)

SHLD

Analog Current Outputs

0-20mA (4-20mA) Analog current outputs. Refer to Figure 2-4.

4-20 mA or

0-20 mA Receiver (Isolated)

T6200C Controller

+-mA Output

Circuit

Common

SHLD

3-16

Wiring for T6200C Channels 27-30

Analog Current Outputs

Hardware Installation/Maintenance

FIGURE 3-11

T6200D Control Board

0-20mA (4-20mA) Analog current outputs. Refer to Figure 2-4. Channels 27-30 do not have jumper placements.

4-20 mA or

0-20 mA Receiver (Isolated)

T6200C Controller

+-mA Output

Circuit

Common

SHLD

Wiring and Jumper Placement for T6200D Channels 1-26, 31, and 32

Discrete Input with Excitation from Controller

This wiring and jumper placement is for discrete (On/Off) inputs. The Controller supplies 24 VDC power for the input. Refer to Figure 2-6.

Alternate

Open Collector

Transistor

Contact

T6200D Controller

Discrete Input

(24 Vdc/5 mA

excitation)

Circuit

Common

Factory Default

3-17

Hardware Installation/Maintenance

Isolated Discrete Input

Power Source

18 V to 32 V

ac/dc

Contact

Polarity

Arbitrary

T6200D Controller

Discrete Input

(Optically

coupled)

Frequency Input

This wiring and jumper placement is for a

PWR

frequency/pulse preamplifier input with the Controller supplying the power (Channel 22,31 and 32).

Frequency/Pulse

Preamplifier or other

Discrete Device

0-25KHz only for

Channels 22, 31 &

OUT

COM

Discrete Output with Internal Power

This wiring and jumper placement is for discrete (On/Off) outputs. The Controller supplies 24 VDC power for the 20 mA max load. Load example: Entrelec RB 131

Discrete

Load

<20 mA

(010055.23) relay Refer to Figure 2-7.

Discrete Outputs with External Power

This wiring and jumper placement is for discrete (On/Off) outputs. The power source (less than 38 Vdc) is external. The discrete load is 0.25 Amp max. Refer to Figure 2-8.

Power Source

<38 Vdc

Discrete

Load

<0.25 A

T6200D Controller

24 Vdc

Supply

Discrete

Input

(Circuit Common)

SHLD

T6200D Controller

24 Vdc

Supply

Discrete Output (Open Collector

Transistor)

T6200D Controller

Discrete Output

+-+

(Open Collector

Transistor)

Circuit

Common

3-18

Wiring for T6200D Channels 27-30

Discrete Inputs with Excitation from

Controller

Hardware Installation/Maintenance

These channels are for placement is for discrete (On/Off) Inputs only. The Controller supplies 24 VDC power for the input. Refer to Figure 2-6 Channels 27-30 do not have jumper placements.

Ethernet Communication Network

The T6200 Controller uses IEEE 802.3 10Base-T Ethernet communication network. Ethernet uses the Carrier Sense, Multiple Access, Collision Detect (CSMA/CD) datalink protocol, which employs a broadcast method for communicating with nodes. When a station senses that the network is idle and it is ready to send, it transmits its data packets to the network. Since all nodes hear the data, each node checks to see if the packet is intended for it. The station that matches the d estination address in the packet is the one that responds. The collision detection part of CSMA/CD tells nodes to halt transmission if a collision is detected and to try again later at a randomly determined delay period.

Network Security

The T6200 Controller incorporates automatic control redundancy to insure process equipment operation in the event of failure. Redundant network components can further enhance overall system security by maintaining communications in case of certain device malfunction and by allowing online repair of faulty components. With proper redundancy implementation an Ethernet network can detect when a particular path cannot pass data and then automatically switch to a backup path. Refer to T6200 Equipment Selection and Planning G ui de for more information on network security.

Alternate

Open Collector

Transistor

Contact

T6200D Controller

Discrete Input

(24 Vdc/5 mA

excitation)

Circuit

Common

Ethernet Network Connectors

The T6200 Controller includes two individual IEEE 802.3 10Base-T Ethernet connections (ENET1 and ENET2) with standard RJ-45 connectors to facilitate control network communication. Refer to Figure 3-8 (Integral Termination Panel), Figure 3-9 (Redundant Remote I/O Backplane) or Figure 3-10 (NonRedundant Dual Remote I/O Backplane) for connector location and Figure 3-12 for Ethernet ENET1 and ENET2 connector pin assignments. Note on Figure 3-10 (Non-Redundant Dual Remote I/O Backplane) ENET1 on the Primary Control Board is referenced as ENET1P and ENET2 is referenced as ENET2P. ENET1 on the Second Control Board is referenced as ENET1S and ENET2 is referenced as ENET2S.

3-19

FIGURE 3-12

Ethernet ENET1 and ENET2 Connector Pin Assignments

Network Cabling

Pin Signal

1 TXD+ 2 TXD3 RXD+ 4 NC 5 NC 6 RXD7 NC 8 NC

Ethernet is used as the high-speed wire media to provide the control network communication capabilities for the T6200 Controller systems. Typically, the control network is an isolated Ethernet network that provides communication between the T6200 Controller and workstations. It uses

Ethernet hubs and/or switches for communication connections.

Use Ethernet category five (Cat 5) cables for the Ethernet network cables. The maximum cable length from the T6200 Controller to the hub/switch is 10 ft. (3 m). The maximum cable length from the hub/switch to any other node is 330 ft. (100 m) for longer distances, fiber optic cables are required.

Pin 1

Hardware Installation/Maintenance

Pin 8

Non-Redundant Network

The basic simplex network consists of a hub and Cat 5 cables that connect to each node. The T6200 Controllers have redundant Ethernet ports as a standard feature (whether they contain simplex or redundant control boards). When installing a simplex network, using Ethernet 2 port is optional. Refer to Figure 3-13 for a single T6200 Controller and Figure 3-14 for multiple T6200 Controllers.

FIGURE 3-13

Non-Redundant Network with Single T6200 Controller and Single Workstation

3-20

FIGURE 3-14

Non-Redundant Network with Multiple T6200 Controllers and Dual Workstations

Hardware Installation/Maintenance

Redundant Network

Network redundancy for communication security is provided by a secondary hub and cables that establish a secondary network identical to the primary netw ork. The secondary n etwork is connected to the redundant communications port of each workstation and Controller, and is connected to a separate hub/switch. Refer to Figure 3-15.

FIGURE 3-15

Redundant Network with Single T6200 Controller and Redundant Workstations

3-21

FIGURE 3-16

Redundant Network with Multiple T6200 Controllers and Redundant Workstations

Hardware Installation/Maintenance

FIGURE 3-17

Redundant Network with Multiple T6200 Controllers Mounted in a T6200R Subrack and Redundant Workstations

3-22

FIGURE 3-18

Non-Redundant Network with Single Dual T6200 Controller and Single Workstation

Hardware Installation/Maintenance

FIGURE 3-19

Redundant Network with Multiple Dual T6200 Controller and Redundant Workstations

T6200R Subrack Ethernet

The Ethernet Hubs on the T6200R Subrack are usually connected as shown in Figure 3-17.

If the workstation is not part of an existing network, connect the workstation to port eight on the hubs. Set the Up-Link switch to “Normal”.

To connect the hubs to an existing network; set the Up-Link switch to “Up-Link” and connect existing network to port eight.

The Operator Interface is usually connected to port seven on Ethernet 1 Hub.

3-23

FIGURE 3-20

Internal Ethernet/Power J6 Connector for O

erator Interface

Hardware Installation/Maintenance

Operator Interface Installation

Ethernet/Power Cable Installation

The Operator Interface Ethernet/Power cable is routed thru the center of the T6200 Controller housing and plugged into connector J6 inside the Controller on the Termination Panel or I/O Backplane. Refer to Figures 3-20 and 3-21. The Ethernet cable carries the 10Base-T Ethernet communications and the 26Vdc power from the T6200 Controller. Refer to Figure 3-22 for connector J6 pin assignments.

3-24

FIGURE 3-21

Operator Interface Internal Ethernet/Power Cable Installation

Hardware Installation/Maintenance

FIGURE 3-22

Operator Interface J6 Connector Pin Assignments

Pin Signal

1 TXD+ 2 TXD3 RXD+ 4 +26V PRI 5 +26V SEC 6 RXD7 COM 8 COM

Pin 1

Pin 8

Operator Interface Attachment to T6200 Chassis

The Operator Interface is attached to the T6200 Chassis by four screw collars.

The Operator Interface is installed by placing the two top screw collar slots at the rear of the case over the two top screw collars. The case should be angled slightly out at the bottom. Once the top screw collars align thru the top screw collar slots, the case can be straightened vertically and then slide down until it stops on the case slots edge. Refer to Figure 3-23.

The Operator Interface may be removed by pulling the Latch Release Pull located at the bottom right of the case at the same time sliding the case up then away from the T6200 Chassis.

FIGURE 3-23

Operator Interface Attachment to T6200 Chassis

3-25

FIGURE 3-24

Standalone T6200 Controller Operator Interface Ethernet Crossover External Cable Connection

Hardware Installation/Maintenance

Standalone T6200 Controller Operator Interface Ethernet External Cable Connection

For Standalone T6200 Controller applications where no communications to other controllers or workstations are required, the T6200 Controller ENET1 connector may be connected directly to the OI (Operator Interface) connector with a short Ethernet crossover cable (ICS Triplex p/n 6009-0 030) eliminating the necessity of an Ethernet hub. Refer to Figure 3-24.

3-26

Firmware Changes

Firmware is the software, operating system, and function library that has been programmed into an EPROM (erasable programmable read-only memory). Should it become necessary to update the firmware or install a custom firmware in the field, the EPROM will have to be replace. To change the EPROM:

CAUTION

FIGURE 3-25

 Carefully slide the control board out the front of the chassis.  Use an Amp 44 pin PLCC extraction tool number 82159-1 to remove the EPROM from the

socket. The EPROM is the 44 pin IC with a label. Refer to Figure 3-25.

 Install the new EPROM. The EPROM is keyed with a notch on one corner. This notch must

be in the same orientation as the notch on the EPROM socket while plugging the EPROM into the socket.

 Replace the control board.  Load configuration.

Hardware Installation/Maintenance

The Controller contains parts susceptible to damage by electrostatic discharge. Normal precautions should be taken to avoid high static voltages.

T6200 EPROM Placement

3-27

Serial Communication Connection

The T6200 includes two individual RS-232/RS-485 serial port connections (COMM 1 and COMM 2) with RJ-45 connectors to facilitate serial communication. COMM 1 and COMM 2 are software configurable for either RS-232 or RS-485. See Appendix C Modbus Interface RS-232 for COMM 1 and COMM 2 RS-232/RS-485 Configuration. Note: RS-485 is not multidrop. Refer to Figure 3-8, Figure 3-9, or Figure 3-10 for appropriate COMM 1 and COMM 2 connector location. Note: NonRedundant Dual Remote I/O Backplane (Figure 3-10) has only COMM 1 for the Primary and Second Control Board. Refer to Figure 3-26 for COMM 1 and COMM 2 connector pi n assignme nts.

FIGURE 3-26

Serial Communication Connector

Pin Signal

1 NC 2 NC 3 TD (RS-232)/COMM-(RS-485) 4 SG (SIGNAL GND)/COM 5 SG (SIGNAL GND)/COM 6 RD (RS-232)/COMM+ (RS-485) 7 NC 8 NC

Hardware Installation/Maintenance

Pin 1

Pin 8

3-28

Section Four

The Micon OPC Server Compact Disc 2 Install The Packet Driver Software 2 Install the MICON OPC Server and Related Components 5 Ethernet Addresses 7

Software Installation

4-1

Software Installation

Instructions for the installation of the MICON OPC Server and a sample OPC Client software on Microsoft Windows XP.

The Micon OPC Server Compact Disc

The MICON OPC compact disc contains the Micon OPC Server, a sample OPC Cliente. The setup program for the MICON OPC Server software and the sample OPC Client software are located in the “MICON” folder. Create a directory "C:\MICON" on the installation computer. Note that the "MICON" folder must be in the root directory of the "C" drive. IMPORTANT NOTE: If you plan to use the IEC-61131 based graphical configurator from MICON called “Straton for MICON”, then you MUST install that package before installing the MICON OPC Server.

Install The Packet Driver Software

Open the Network Connections window:

 Right-click “My Network Places” icon, located on the desktop (Figure 4-1)  Select “Properties”

4-2

Figure 4-.1

Software Installation

Desktop Window

Figure 4-2

Network Connections Window

Open the “Local Area Connection Properties” window:

 Right-click “Local Area Connection” (Figure 4-2)  Select “Properties”

Open the “Select Network Component Type” window:

 Select “In

stall…” (Figure 4-3)

Open the “Select Network Protocol” window:

 Select “Protocol” (Figure 4-4)  Select “A

dd…”

Open the “Install From Disk” window:

 Select “H

ave Disk…” (Figure 4-5)

4-3

Software Installation

Figure 4-3

Local Area Connection Properties Window

Figure 4-4

Select Network Component Type Window

Open the “Locate File” window:

 Select “B

rowse” (Figure 4-6)

 Locate the "\ndisnt” folder on the installation CD  Select “OK”

4-4

Figure 4-5

Select Network Protocol Window

Software Installation

Figure 4-6

Install From Disk Window

Windows will select “OEMSETUP.INF” in the “File name:” field as shown in Figure 4-7. Select “O

pen” to install the NDIS3P2K.INF driver.

The “Virtual Packet Driver” will be highlighted as shown in Figure 4-8. Select “OK” to complete the driver installation.

Install the MICON OPC Server and Related Components

Install the MICON OPC Server and related components. Execute the file "\MICON\Setup.exe” on the CD:

 Double click “MICON” folder located in the root directory of the CDROM drive  Double click “Setup.exe”. The setup program will copy various files to your hard disk drive

and copy the OPC Server and related files to a directory of your choice. Then the setup program will proceed to install the OPC Data Access components. This will open the “InstallShield Self-extracting EXE” window (Figure 4-9).

4-5

Figure 4-7

Locate File Window

Software Installation

 Select “Yes”. This will open the “Readme Information” window (Figure 4-10).  Select “Next”. This will open the “Setup Complete” window (Figure 4-11).  Select “Finish”

Figure 4-8

Select Network Protocol Window

Figure 4-9

InstallShield Selfextracting EXE Window

4-6

Figure 4-10

Readme Information Window

Software Installation

Figure 4-11

Setup Complete Window

Ethernet Addresses

Edit or create a file "C:\MICON\devlist.txt" using Notepad or some other text editor. In this file, add one line for each T6200 Controller's Ethernet addresses as follows:

4-7

Software Installation

Primary Control Board E thernet Address

Backup Control Board Ethernet Address

UC254,00:08:9A:D2:05:02,00:0D:9A:D2:05:02, UC255,00:08:9A:D2:06:02,00:0D:9A:D2:06:02,

BAK ID from I/O Backplane

PRI ID from I/O Backplane

Figure 4-12

devlist.txt – Notepad Window

Figure 4-13

T6200 Controller Name

The strings are separated by a comma. The first string is the name for the T6200 Controller. The second string is the Ethernet address for the primary control board and the third string is the Ethernet address for the backup. Make sure there is a comma at the end of each line. There can be only one Controller per line. Refer to Figure 4-12. The Controller/s listed in this file will be the only one/s that the MICON OPC Server will communicate with at runtime.

The T6200 Controller name must be a unique name and should have from one to 16 alphanumeric, dash (), and/or underscore (_) characters. The name cannot contain spaces (blanks) or other symbols. The first character of a name cannot be a dash or number. Both upper and lower case letters are accepted.

The PRI ID and BAK ID numbers on the T6200 Controller I/O Backplane is used to build the Ethernet addresses. Refer to Figure 4-13. Add “00:” in front of each number, add “:” between every other digit, and add “:02,” to the end.

T6200 PRI ID and BAK ID

4-8

T6200 Controller Operation

Push to Activate Switch 5 System Start-up 6 Replacing Control Boards 6 Loading Controller Configuration 8 Watchdog Timer 8

T6200 Controller Operation

Section Five

5-1

T6200 Controller Operation

5-2

T6200 Controller Operation

The redundant T6200 Controller consists of two identical control boards, primary and backup, and one termination panel. Refer to Figure 5-1. The primary control board is always on the left and the backup is always on the right. Normally, the primary board is the active board and the backup board is the standby board. These roles may be reversed. When the backup board is active, it transmits a “Backup Active” alarm to the host.

The active board controls both the analog and discrete outputs to the field. The analog and discrete outputs are disabled on the standby board. Refer to Figure 5-2. When the outputs are required to feedback as inputs, the outputs of the active board are used in both boards. A primary board without a backup is always active. The active and standby boards have the same inputs and configuration.

Push to Activate Switch

A PUSH TO ACTIVATE switch (SW1) is located at the front of each control board at the bottom. Refer to Figure 5-3. The switch has three functions:

 Used to activate a standby Controller. The NORMAL LED must be illuminated before

this Controller can be activated. If the Controller is activated, the redundant Controller will be deactivated automatically.

 This switch can also be used to clear all the configuration in the Controller memory.

This can be accomplished only during the first three seconds when the Controller is being powered up by depressing the switch for one second or more.

 Each time this switch is depressed, the Controller identification number will be

transmitted to the host over the Ethernet communications. This may be used when adding a Controller to the network.

5-3

FIGURE 5-1

T6200 Primary and Backup Control Boards

T6200 Controller Operation

Figure 5-2

T6200-C Active and Standby Current Outputs

System Start-up

When power is first applied, the T6200 Controller forces the analog outputs to zero and the di screte outputs to open. Next, the T6200 Controller starts the self-test and flashes the COMM LEDs. After the self-test has been successfully completed, the primary board will become active. The OUT LED will illuminate on the backup board during this wait period. There must be a board in the primary positi on when running the Controller Definition program in A/S VIEW. If the T6200 Cont roll er does not have a primary board when power is first applied the backup board outputs will remain in their power-up reset condition.

5-4

TABLE 5-1

Control Board LEDs

LED

ACT

(TOP)

NOR

EN1

EN2

COMM1

COMM2

OUT

T6200 Controller Operation

NAME

COLOR

DESCRIPTION

Active Green This LED shows the Active/Standby status

of the Controller. When illuminated, the Controller is “Active” and controls the outputs. When a backup Controller is used, either primary or backup can be active, but not both of them.

Normal Green The LED shows the status of the watchdog

timer. The LED is illuminated when the microprocessor is properly toggling the watchdog timer.

Ethernet 1 Yellow This LED will flash when data is being

transmitted or received on Ethernet 1

Ethernet 2 Yellow This LED will flash when data is being

transmitted or received on Ethernet 2

Communication 1 Green This LED will flash when data is being

transmitted or received on COMM 1 or backup communication

Communication 2 Green This LED will flash when data is being

transmitted or received on COMM 2

Outputs Red This LED illuminates when the outputs are

inhibited. This condition normally occurs during power up. The backup control board cannot be active if this LED is illuminated.

Figure 5-3

Push to Activate Switch

Backup

Control Board

Primary

Control Board

“Push to Activate”

Switc

If the primary board has a configuration in its memory, it will start the loop processing. If the primary boards do not have configuration, the outputs will remain in their power-up r eset condition.

At startup, the backup board's memory is always cleared, and the primary board transfers the configuration to the backup board through the backup serial link.

During runtime operation, if a new configuration is downloaded, it automatically goes to the active board. If the active board is the primary board, the backup board's memory is cleared, and the primary board

5-5

transfers the configuration to the backup board through the backup serial link. The standby primary board’s memory cannot be cleared during runtime operation without removing the board. To transfer a configuration from a backup board to a primary board, the primary board must be removed (unplugged) and reinstalled, clearing the memory at the same time (see Replacing Control Boards below). The primary board, with cleared memory, will then request a configuration transfer from the active backup board.

Replacing Control Boards

In a system with redundant boards, the backup board can be activated to allow removal of t he primary board without upsetting the system. Depressing the PUSH TO ACTIVATE switch will activate the backup board. The NORmal LED must be illuminated and the OUT LED must not be illuminated before the board can be activated. When the backup board is active, it transmits a "Backup Active" alarm to the host on the Ethernet. This alarm cannot be cleared as long as the backup board is active.

After the backup board has been activated, the primary board may be removed by pulling on the handle on the front of the board to unplug it.

The memory must be cleared in the replacement board. To clear the memory, plug in the replacement board and depress the PUSH TO ACTIVATE switch for one or more seconds within the first three seconds. The OUT LED will illuminate for a few seconds while it gets the configuration from the backup board and then compiles it. After the OUT LED goes off, depress the PUSH TO ACTIVATE switch to activate the primary board.

If you do not clear the memory, the replacement board will retain its old configuration.

CAUTION

it is the same model and the jumper placements are the same.

Each Controller model has a different mechanical key to prevent the incorrect model from being plugged into the termination panel.

Plug in the replacement Controller. The NORmal LED will not illuminate for a few seconds while it gets the configuration from the Backup Controller and then compiles it. After the NORmal LED illuminates, depress the PUSH TO ACTIVATE switch to activate the Primary Controller.

When replacing a Controller that does not have a backup and the application process is shutdown, the Controller can just be unplugged and the matching replacement board plugged in its place. If the replacement board has an undesirable configuration, it can be cleared by depressing the PUSH TO ACTIVATE switch for more than one second within the first three seconds after the Controller has been plugged in. A new configuration can be down loaded from the host.

Before plugging in a replacement Controller, verify

Refer to the jumper placement in Section Three,

T6200 Controller Operation

Hardware Installation/Maintenance.

Loading Controller Configuration

If a Controller is unplugged or power is removed long enough for the capacitor (that is used to keep the RAM alive) to discharge (usually about one week) the above process will have to be repeated.

5-6

Watchdog Timer

The microprocessor toggles the watchdog timer at least once every 100 milliseconds. If the watchdog timer is not toggled within this time period, the watchdog timer will reset the microprocessor. If t he board is on standby, the outputs will be disabled. If the board is active, control will be transferred to the backup board. If there is no backup board or if the OUT LED is illuminated, the outputs will remain at the condition before the watchdog timer reset the microprocessor.

If the microprocessor does not start after being reset, the watchdog timer will continue to reset the microprocessor every 1.6 seconds. If the microprocessor does restart in a redundant system, the board will remain in the standby mode. If there is no backup board, the primary board will resume t he active m ode.

T6200 Controller Operation

5-7

T6200 Controller Operation

5-8

Preface 2 Overview of HMI-6200 Features 3 Event Information Processing 5 Display Layout 11 General Display Description 14 Graphic Displays Configuration 17 HMI Example – Single Stage Compressor 18 Adaptation of Pre-Defined Displays 21 Surge Curve Screens 25 Custom Graphic Screens - 26 Configuring the Security System 27 Communications 30 Downloading the Updated Application 34

Section Six

HMI-6200 Operator Interface

HMI-6200

erator Interface

6-1

HMI-6200 Operator Interface

HMI-6200

OPERATOR INTERFACE

Preface

To be effective in a small (5.7” P/PC size) footprint, the operator interface must be ergonomically pleasing and comfortable to the user. While this may seem to be a fairly easy goal to achieve with today's well accepted Menu Bar interfaces, a number of elements come into play with a process controller-based environment that must be brought into proper relationship with the operator-elements such as instant alarm access, prevention of accidental value entry, value setting accuracy, etc.

The HMI-6200 display architecture is flexible, yet clean and simple in appearance and interacts with every application in the same manner. The windows, menus, etc. are consistent looking and behaving.

The prompting and pre-formatted type display hides the complex window access procedure and simplifies operation to a point where a virtually untrained person can easily navigate between displays. It provides an intuitive means of interacting with the process.

The touch screen provides for simple operator interaction. Direct touch or a pen (stylus) are used for contact with the screen.

For lager size touch panel computers (12.1, 15 ..etc inch screen size) several displays can be grouped on each screen. The screen grouping is accomplished by right-clicking the Group Screen on the Screen menu of the WEB Studio software.

6-2

Overview of HMI-6200 Features

A standard option of the T6200 Unit Automation System is to incorporate an integral 5.7 inch P/PC based full-featured human-machine interf ace – HMI-6200.

This Operator and Engineering Interface Software offers…

- Standard and Customized Screens

- On-Line Operation and Control

- On-Line and Remote Diagnostics

- Alarm and Event Management

- Critical Event Archiving

- Trend and Historian

- OPC Compliant Client-Server Architecture

- Unit Asset Condition Management - UAM HMI-6200 Microcontroller –

- Intel StrongARM SA1110 microprocessor

- 32 MB Flash Memory

- 64 MB SDRAM Memory

- Integrated LCD controller

- Ethernet connectivity

- CompactFlash slot

- Card Speaker

Database Management –

Object oriented database

- Fill-in-the-blank definitions

- Data accessible system wide

Standard Environment –

Based on Microsoft’s DNA architecture

- Industry standard operating system – Windows CE

- Distributed COM

- XML technology

True Multi-User Capabilities –

- Supports multiple P/PC’s and workstations

- Networkable on popular local and wide area nets

- Web enabled to serve HTML pages over the Web with real-time data

- Allows sub-division of process responsibilities to different users

Business Interoperation – Unit control can be integrated into a total plant/business system.

- Integrates TMC Unit Control and Business Asset technology

- Imports and exports real-time data and reports in XML

- Protected data ownership and security

HMI-6200 Operator Interface

6-3

HMI-6200 Operator Interface

OPC Client/Server – The build-in CE OPC Server is compatible with the StrongARM processor Enables communication with control modules

- Open systems OPC link

- Server identifier

- Configurable data update rate

If an operator interface other than the HMI 6200 is selected make sure that the OPC server is compatible with its processor.

Comprehensive GUI –

Based on WEB Studio, the graphical user interface offers object oriented easy to use graphics. User-defined and pre-defined graphic displays. Used to monitor and control a TMC process.

- Pre-defined displays include: Home; Graphics, Face-Plates; AIN/AO; DIN/DO; Alarm Summary, Alert Summary; Trend; Historical Trend;

- Scripting language including math expressions, statistic and logical functions, module activation functions, etc.

- Build hierarchies and networks of displays

- Displays real-time & historical data

- Translation Tool for multi-language operation

Time-Scheduled Tasks – Provides time-based user defined operations

- Event types: Reports, Recipes, Calculations, data logs, match/logic functions or any program

- Scheduling intervals from seconds to years

- Quickly defined and interactive

- Schedules application programs

Alarms and Alerts Processing – Provides comprehensive alarm reporting

- SOE (sequence of events) capabilities

- Individual or multiple alarm acknowledgements

- Remote Ack (acknowledge)

- User definable priorities

- User definable status colors (start, ack, norm)

- Archive storage an d call back

Real-Time and Historical Trending – All data base points may be selected for trending

- Selectable plot scales, time spans, colors, grid sizes

- Up to 8 plots per window

- Selectable curve type (X/t, X-Y)

- Save On Trigger or Save on Tag Change selection

- Archive storage an d call back

Recipes and Reports – Facilitates assessment of unit performance

- Easy creation of reports (without programming tool)

- Load recipes and retrieve values in XML format

6-4

Event Information Processing

The following describes the information structure for alarm and alert handling and for t ren d a nd historical recording

Alarm and Alert Definition –

The T6200 includes comprehensive detection and notification of alarms and alerts. Alarms are defined as conditions which require user acknowledgement; alerts are records of actions/conditions for which operator acknowledgement may or may not be specified (Ack is configuration selectable).

Alarm and Alert Detection –

For reliability and speed-of-response alarm and alert detection and processing takes place in the con trol module of the T6200. All alarms and alerts are time-stamped upon detection.

Deterministic Alarming –

Deterministic alarms/alerts are generated by comparing the performance of combinations of discretes and/or variables against pre-defined limits of alarmable conditions of operations. Practically unlimited logic/math/selection functions are provided in the control module of the T6200 to allow for simple or sophisticated alarm/alert interlocking.

Deterministic alarm configurations serve basically two purposes - 1) they can be used to advise or take action based on the nature of alarm combinations or 2) deterministic alarming can also be used to disregard alarms/events that are merely further effects of a fault that has already been recognized. Two examples of combinational alarms would be:

- Do not generate a low flow alarm if a corresponding pump is turned off.

- Alarm on deviation of a process signal from a trip-point only if the rate of change or another variable exceeds specification at the same time that certain valves are fully open and a feed pump is off.

HMI-6200 Operator Interface

Alarm and Alert Suppression –

Alarm and alert processing can be suppressed at the control module level. The configured suppression may be for specific alarm/alert points or groups and is normally process condition related. Notification of suppression is provided via alarm “cutout” attributes.

Alarm and Alert Notification –

The HMI-6200 (operation interface) provides several features for notification of alerts and alarms. These include: HMI display, audible annunciation and optional control triggering.

6-5

FIGURE 6-2

Alerts - Summary Display

HMI-6200 Operator Interface

FIGURE 6-3

Alarms - History Display

Historical Alarm and Alert Display -

The Alarm/Alert History display provides for means of viewing past Alarm and Alert events. Historical data can be retrieved with convenient date/time selection buttons.

6-6

FIGURE 6-4

Trend History Definition Windows

HMI-6200 Operator Interface

Dynamic Trending Module –

The HMI-6200 trend capability provides for viewing of real-time and historical data. A trend display format, with up to six plots, is included.

Trend Configuration –

The contents of the Trend and the Trend History display are defined by trend window templates as shown below.

FIGURE 6-5

Trend Points Configuration Window

Compressor App

6-7

HMI-6200 Operator Interface

6-8

FIGURE 6-6

On-Line Trend Display

HMI-6200 Operator Interface

Trend Display –

The trend display is presented in the popular strip chart recorder format.

Historical Tend Display -

The Trend History display provides for a comprehensive means of viewing process and calculated data over periods of time. Historical data can be retrieved with convenient date/time selection buttons

6-9

FIGURE 6-7

Trend History Date/Time Selection

HMI-6200 Operator Interface

6-10

Display Layout

Preformatted displays provide the basic operations interface for: compressor /turbine contro l, continuous process control, batch/sequence control, SCADA alarms, trends, etc. Information is presented in an easily understood manner.

The operational displays are organized into a structural hierarchy consisting of overview(s), graphics, face-plates, etc. Displays are called up through a simple menu bar procedure. In addition to the menus, the user is provided with “go-to” display buttons to allow for customized window selection.

Besides the configuration at the time the systems is set up, some configuration is normally done later on, such as building additional graphics.

Analysis of process conditions is fully supported. A standard trend display (real-time and historian trend), alarm and alert indication (real-time and historical) and diagnostic displays allow for quick process analysis and situation correction.

Reports and Recipe screens and the ability to retrieve values in XML format facilitate the assessment and correlation of unit performance.

FIGURE 6-8

Operational Display Hierarchy -

Overview

Graphics

HMI-6200 Operator Interface

T6200

Unit Controller

MICO

HOME

U-200

T6200

Unit Controller

GRAPHIC

MICO

U-200

T6200

Unit Controller

ALARM

MICO

ALERT

U-200

SUMM

T6200

Unit Controller

GRAPHIC

MICO

U-200

T6200

Unit Controller

TREN

MICO

U-200

HIST

T6200

Unit Controller

MICO

GRAPHIC

U-200

T6200

Unit Controller

OPER

MICO

U-200

STATUS

T6200

Unit Controller

DIAGN

MICO

FLOW

U-200

CHARTS

T6200

Unit Controller

PROC

MICO

U-200

STATUS

T6200

Unit Controller

DIAGN

MICO

FLOW

U-200

CHARTS

T6200

Unit Controller

I-LOCK

MICO

U-200

ESD

T6200

Unit Controller

DIAGN

MICO

FLOW

U-200

CHARTS

Face-Plates

T6200

Unit Controller

FACE-PL

MICO

U-200

Operation

T6200

Unit Controller

FACE-PL

MICO

U-200

T6200

Unit Controller

FACE-PL

MICO

U-200

T6200

Unit Controller

LOOP

MICO

U-200

TUNING

/Process Displays Status/

T6200

Unit Controller

REPORT

MICO

U-200

RECIPE

Diagnostic

T6200

Unit Controller

AUX

MICO

GRAPHIC

U-200

#1 -- #N

/Aux displays

The HMI-6200 is designed to facilitate operation at all levels. It allows simplified access to the controls, provides a logical display format, and incorporates methods for easy interaction with the process. Operation and management may call up displays from many different unit areas for a concise picture of unit and plant/pipeline performance.

The HMI-6200 also supports engineering functions in the creation and scheduling of reports and recipes.

Status displays, diagnostic flow charts, tuning indication and other user-defined auxiliary displays enable rapid situation correction.

6-11

FIGURE 6-1

Graphic display of a Column with Top and Bottom Reflux

Pre-defined Header and Footer template described below

HMI-6200 Operator Interface

HMI-6200 Header and Footer Template

The Web Studio screen editor allows you to create a variety of windows and dialogs which feature user inputs by screen selection and touch pad. The following relates to the HMI-6200’s process display access formats that are pre-defined by a standard Header and Footer template.

Header

- Next (f) and Last (e)

- Home display access

- Graphic display(s) access

- Face-Plate display access

- Trend/Historian display access

- *** Miscellaneous display access

Footer

6-12

HMI-6200 Operator Interface

- UAM displays access

- Alarm Summary/History display access

- Alert Summary/History display access

6-13

General Display Description

“Home” Display –

The “Home” display typically provides for an overview presentation of the compressor performance with an “at a glance” identification of off-normal and alarm conditions. The operator can select directly subdisplays (Graphics, Face-Plates, Diagnostics and Operation etc.) from this display to bring details into view.

HMI-6200 Operator Interface

Graphic Display(s) –

While pre-defined custom graphic displays meet the need of most users, many still may wish to create additional displays that are specific to their respective TMC operations.

The displays normally consist of graphical symbols, bar-graphs and alphanumeric information. They represent real-time database information graphically and allow for user-specific actions and control. From the graphic display(s) the operator can also directly select sub-displays (Face-Plates, Operation and Process Status, Diagnostics, etc.).

Face-Plate Displays –

These displays show PID “face-plates” and process control parameters associated with the displayed loops – Anti-Surge, Incipient Surge, Capacity, Load Share, I/O Overview.

Direct go-to buttons to displays of Operation Status, Diagnostics, Interlocks, Tuning are provided.

Alarm Summary Display –

The alarm summary display identifies and summarizes all new alarm points along with other acknowledged alarm points. It lists time of occurrence and description. The display shows 16 alarms per page. A scroll-bar is used to access all alarms.

Alarm priority and filter as well as the message color are defined during configuration (creation of the alarm worksheet).

The Alarm History display allows for dissemination/ diagnostics of historical alarm conditions. This display includes convenient date and time selection.

6-14

Alert Summary Display –

In order to provide segregation between alarms and alerts/events a separate alerts group is included. Operation and function of this display is identical to the alarm summary display.

HMI-6200 Operator Interface

Trend Display –

The trend module displays analog and discrete points on trend of any tagged system variable. The trend display can contain up to six variables (plots) – continuously updated. Plot colors, scale (Min, Max), Cursor Value and time span are selectable. Curve type can either be X/t or XY.

One can store the trend points in a history file for data collection and display. The historian module includes a dead band (for data storage reduction) and incorporates save on Trigger or Tag Change selection. The Trend History display also contains time and date selection.

Miscellaneous Displays Operation and Process Status Displays –

Operation indication is structured to quickly and accurately determine process status and to allow for fast response.

Diagnostic Displays –

The unit maintenance functions can be supported by diagnostic displays which provide the us er with a flow-chart type view of the control loops.

Analog and Discrete I/O Displays –

The I/O displays provide a summary of the analog and discrete point values. Each rectangle includes the abbreviated point name and the value.

Equipment Condition Displays –

Condition display(s) can be provided to illustrate status (Interlock, ESD status, etc.) and pertinent values of the process equipment.

Detail Display(s)

Displays for calculation and fall-back value settings are typically included to provide an overview of key parameters.

Reports and Recipes –

Reports can be created without needing any special programming tool (like VB, etc.). Using the report workstheet and the scheduler, reports can be custom designed and scheduled for display and transmission.

The recipes module (worksheet) is used to create, load and delete recipes. Recipes, in this case, means a group of tags that have their values saved and retrieved like a database. The values can be retrieved from the ASCII file in standard format or the XML format.

6-15

FIGURE 6-9

Workspace Window

HMI-6200 Operator Interface

FIGURE 6-10

Scheduler –

Critical and control related timed-tasks normally reside in the T6200 control module(s). However, timed tasks for reports, supervisory recipes, trend and math are typically handled by the HMI-6200 Scheduler module.

The timed-task module (scheduler) supports reports, logs, recipes and general actions (math and logic functions). It provides for the scheduling, definition and detection of timed tasks. The tasks may be scheduled to execute automatically once, or any number of times at fixed intervals as pre-defined by the user.

The Clock event is used to trigger actions based on regular time intervals such as timers and counters. The base time (minimum of 100 ms) is set in the Time column. In the Tag column, one must configure the tag that will receive the result from the expression configured in the Expression column. The Disable field can be used to prevent an expression in the line from being executed.

The Calendar event is used to trigger actions on a scheduled time. Also, it is possib le to specify a fixed date for an event in the Date column.

The Change event is used to trigger an action upon a change in tag value (such as special trend on incipon). In the Trigger column, one must configure a tag that will be used to trigg er the event when the change in value has occurred.

Scheduler Configuration Example for IncipInitiated Trending

6-16

Graphic Displays Configuration

The HMI-6200 graphics software is a runtime-only version of the workstation PC graphics. All configurations of graphic displays are made using a workstation PC and then downloaded to the HMI6200 P/PC Operator Interface. Once in run-time mode, the user is able to execute all runtime functional dynamics that have been added/defined during configuration.

Powerful HMI Visualization -

A complete set of drawing and animation tools is furnished. One can create graphic objects and build displays using any combination of drawing tools (boxes, lines, circles, text, etc.); save the graphic objects in a library, add expressions and animation.

Dynamic Object Animation –

Considering the small (P/PC size operator interface) footprint, it is important to provide highperformance animation effects based on dynamic real-time links. The dynamic action tool offers rotation, animation, analog color, flash, etc.

Summary of Graphic Features:

- High Performance Object-based Graphics

- Powerful Display Creation Tools

- Dynamic Animation

- Import Popular Display Formats

- Extensive Symbol Library

- Built-in Math, Expressions and Calculations

HMI-6200 Operator Interface

FIGURE 6-11

Graphics Configuration Screen

6-17

HMI Example – Single Stage Compressor

The following shows an example of a T6200 Compressor Unit HMI for single stage centrifugal machines.

The HMI is designed to facilitate operation at all levels. It permits simplified access to the unit, provides a logical display hierarchy, and a choice of navigation for easy interaction with the process.

FIGURE 6-12

Compressor Home Screens display the Performance Map and process values at “a glance”

HMI-6200 Operator Interface

FIGURE 6-13

Compressor Graphic Screens provide for visual overview and for control

Graphic Overview Display/Control

6-18

FIGURE 6-14

Compressor FacePlate Screens and Aux Displays provide for traditional operation convenience

HMI-6200 Operator Interface

A/S Face-Plate Display/Control

LS Face-Plate Display/Control

Capacity Face-Plate Display/Control

LSE Face-Plate Display/Control

Lube Oil Display/Control

Seal Gas Display/Control

6-19

FIGURE 6-15

Compressor Driver Display provides for Turbine Status Indication

HMI-6200 Operator Interface

From operator displays to maintenance screens to engineering displays th e HMI-6200 covers the full interface spectrum. This color LCD display represents an HMI with full DCS/SCADA capabilities. It provides a complete “window” on the process by which one can operate/control, maintain and manage the process unit.

Driver Status Display

FIGURE 6-16

Quench Control Overload Contro l Suction Control – all on one display

Quench & Overload Face Plates

6-20

HMI-6200 Operator Interface

FIGURE 6-17

Maintenance Screens facilitate process and control diagnostics

Operation Status Display

Process Status Display

Load Share Diagnostic Display

Loop Tuning Display/Entry

Adaptation of Pre-Defined Displays

The general HMI-6200 operator interface consists of preformatted displays. These displays are structured into overview(s), graphics, face-plates, trend, etc. The user is provided with an operator

Load Efficiency Diagnostic Display

Interlock Display

6-21

HMI-6200 Operator Interface

interface that allows for easy customization and adaptation to the specific process/plant configuration. Besides adaptation at the time of system set-up, some display configuration is usually done later on.

System Requirements

The HMI-6200 operator interface is based on Web Studio. To develop/adapt an application with Web Studio software, the following hardware and software is recommended for the Host computer...

- IBM-compatible computer with an Intel compatible processor

- Windows NT/XP/2000 operating system

- 128 MB of RAM

- 200 MB of free hard disk space

- MS Internet Explorer 4.0 or higher

- CD-ROM drive (only for initial setup)

- Ethernet connection for downloading applications

Installing Web Studio

The installation CD is used to install InduSoft Web Studio. The development environment runs on Microsoft Windows NT/XP/2000; the CEView runtime environment, which is downloaded to the HMI6200 operator interface, comes pre-installed on the runtime workstation.

The Web Studio provides the tools needed to adapt the pre-formatted HMI-6200 operator interface to the customer’s specific application. Refer to InduSoft Web Studio installation instructions.

Screen Editing and Configuration

The screen editor p ermits to change th e pre-defined ICS TRIPLEX screen s and create new s creens and dialogs. The configuration task allows for changing any element in the configuration, including the database. An emulation of the revised/extended application can be run and tested on the development computer before downloading it to the HMI-6200 operator interface.

Refer to the on-line Technical Reference and User Manual under the Help tab for detailed instructions.

Tag Database

The T6200 is delivered with a pre-configured Application Tag database. These tags are shown/declared under the Tag List and Datasheet View of the Database tab.

The pre-configured Application Tag database consists of generic tags generic tag structure be retained and that custom tag requirements be accommodated by simple labels on faceplates, etc. (not database tag changes).

. It is recommended that this

6-22

FIGURE 6-18

Workspace Window Database Tab selection of Application Tags

HMI-6200 Operator Interface

Class Tags

Loop tags – PV, SP, Out, Mode – are defined in a tag format called “classes”. This permits a high degree of encapsulation. When a class-type tag is created, it does not contain a single value, but a set of values associated with the loop. When a new loop is created, it is recommended to follow the predefined class type definition.

Database Exercise

In the development computer Workspace window, select the Database tab. Click the Application Tags folder to expand it and double-click the Datasheet View line to open the database worksheet.

FIGURE 6-19

Application Datasheet Analog Input configuration

Note that the database was updated during the development (tags appear as they are created and empty spaces are present as a result of deletions).

For this database exercise example, we add/define a discharge temperature tag and associated alarm tags. We need to configure the Application Datasheet as follows (in order to fill in the field, click on the field after the last defined tag and type the data).

On line # 64… Name: type Td_a; Array Size: type 3 (four stage compressor, 0-3); Type: click ▼ and select Real; Description: type Td Absolute (Deg R or K); Web Data: click ▼ and select Local or Server.

On line # 65… Name: type Td_FB; Array Size: type 3; Type: click ▼ and select Boolean; Description: type FALLBACK Disch Temp; Web Data: click ▼ and select Local or Server.

Repeat the data entry on line # 66 as shown below, to define the high temp alarm.

We have created an additional analog input with High and FB alarms; now expand the Tag List folder to verify the database addition you have created. Note that during the screen development, when you type in a nonexistent tag, Web Studio will prompt you to check if you desire to create a new tag (if you accept, it will create a window which permits to create the tag).

6-23

HMI-6200 Operator Interface

Changing/Expanding Screens

Before changing and/or expanding screens, you should consider the pre-defined structure of the application screens. For new screens, you can use existing screens (including the Standard screen), saving it under different names. To update/change an existing screen, insert/change the objects in the window between the he ader and footer. It is not recommended to change the header or footer

arrangement itself.

The standard header and footer was used as template for all application screens. The footer area includes a single line alarm object that displays the latest active alarm. The individual objects that make up graphics, faceplates, etc. on the application screens are taken from the pre-configured objects in the Library.

Database Updates/Additions Recommendation: For most applications there are no update or addition requirements of the pre-defined Tags that are stored in the Application Database. Or in other words, the pre-defined generic Application Database does not have to be changed in most cases; user tags are accommodated by tag labels (not database tags) ‘drawn’ with the screen editors’ A/N characters.

If updating/changing Application Tags is required, keep the following syntax rules in mind:

• Although the maximum Tag length is 32 characters, Tags should be as short as possible

(typically not exceeding 12 characters)

• Tags must begin with a letter. They can be composed of letters, numbers, and the underscore

character (_)

• The tag name must be different from the Web Studios’ reserved internal tag names and math

functions

• While tag names are NOT case sensitive, both uppercase and lowercase characters should be

used to make tag names more clear

Make sure that No

corner DRAG status). Enable DRAG (strike Ctrl > D on keyboard) only if you need to move/reposition objects on the screen.

DRAG is set before working with any screen (see screen, lower right-hand

6-24

Surge Curve Screens

FIGURE 6-20

Surge CurveOp Point Display:

X/Y Map

SLL Configuration below

HMI-6200 Operator Interface

- Surge Curve Configuration: The Surge Limit Line (SLL) is arranged in a lookup table format

with linear vector interpolation. Up to 20 points can be defined. The X points define the domain input – Hp,sim. The Y points define the range (output) – Q2,sim.

- Click on Edit Mode Enable check. Drag the surge points to the desired position or use the

Up/Down buttons to position the surge points.

6-25

Custom Graphic Screens

While the pre-defined operating displays that are provided with the HMI-6200 operator interface meet the needs of some users, many still wish to create displays that are specific to their respective unit operations. Like the pre-defined displays, user-defined graphic displays are constructed via the Web Studio Object Toolbar and by importing symbols from the Library.

FIGURE 6-21

Overview Graphic Stage Graphics Screens:

Custom Graphics generated from predefined examples

HMI-6200 Operator Interface

The Overview screen (on left hand side above) is customized to provide a key variable type graphical representation of the actual multi-stage CO compressor application.

The Stage graphic screen (on right hand side above) is configured to show the individual compressor stages. One graphic screen is provided for each stage.

Control of process equipment should be built into the graphic displays so that an operator can select Loops, etc. and command the equipment associated with it. By providing users with graphical illustrations of the equipment, control is simplified and easier to understand. It is however recommended that several steps requiring confirmation and authorization of control be used to minimize the chance of accidentally actuating equipment. Carefully consider the Object Properties (such as Confirm and Password) and evaluate if Security (see Configuration of the Security System) should be enabled for the screen and/or specific control variables/points.

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Configuring the Security System

The Security folder allows you to define Groups and Users as well as their access privileges to Web Studio tools and to the application. Through the Database tab, you can tailor Groups and Users to your security needs.

FIGURE 6-22

Workspace Window Task Tab

Selection of Security

HMI-6200 Operator Interface

FIGURE 6-23

Security Group Account Window

Development Group

- Password: __________ is pre-defined as the Main Password. You will need to enter the password

each time you access the Security System (so it is mandatory that your remember it). To change the Main Password contact the factory.

- Development Group: Double-click Development, enter the Password, and the Group Account

window will open.

In this window, you enable/disable the Development Group operations and you set the range levels. Verify that the Security Levels and Access are defined in accordance with your application requirements.

6-27

FIGURE 6-24

Security Group Account Window

Maintenance Group

HMI-6200 Operator Interface

- Maintenance Group: Double-click Maintenance, enter the Password, and the Group Account

window will open.

FIGURE 6-25

Security Group Account Window

Operations Group

In this window you enable/disable the Maintenance Group operations an d you set the range levels. Verify that the Security Levels and Access are defined in accordance with your application requirements.

- Operations Group: Double-click Operations, enter the Password, and the Group Account window

will open.

In this window you enable/disable the Operations Group operations and you set the range levels. Verify that the Security Levels and Access are defined in accordance with your application requirements.

6-28

FIGURE 6-26

User Account Windows

- Dev1

- Maint1

- O

FIGURE 6-27

HMI-6200 Operator Interface

- Users: Double-click the User Account labels of the Security System window, enter the Password,

and the individual User Account windows will open.

In these windows, you create and maintain accounts for application users. Verify (and if needed redefine) the application users that will be in each group in the Group Account list. Users can also be accessed by selecting the User option under Insert on the Main Menu Bar.

Password Button – Opens the User Password window, in which you can define a password for the user. The pre-defined User Password is 64266.

- Guest User: After you initialize Web Studio, a default user is logged on the Guest user. If no user is

logged on or the current user has logged off, Guest user is automatically logged on. Thus, the Guest group has default privileges. Since the installation parameters of the Guest group leave all tasks enabled, you should change it and set as few privileges as you want for a star t up procedure.

Log On/Log Off: This utility is used to log on or off. For development purposes, you can log on or off by selecting Logon under Project on the Main Menu Bar. The Log on/off feature on the HMI-6200 operator interface is provided by the Log on/off button (using the Web Studio Scripting Language function) on the Miscellaneous screen (Misc scr). The pre-defined Log On password is 64266.

Log On Window

Security System Review/Setup

Before beginning to verify/change the security system, it is important to have the groups and users you want to configure in mind. You need to define the rights that each group has in your

environment. Each group has a range for the level in Development and Runtime. You should carefully review the Security of all operation/maintenance/engineering screens (Screen Attributes, Security) and the individual point security access on those screens.

Do not forget to review Object Properties for security access (Security level entry) of critical buttons (with commands configured to turn on/off equipment) and of critical pre-set calculation/fallback values.

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Communications

OPC Communication

The Web Studio OPC Client module communicates with the MICON OPC Server module using the OPC Data Access Standard. The Tag Names passed between the OPC Client and Server are defined under OPC in the Comm tab.

FIGURE 6-28

Workspace Window Comm Tab

Selection of OPC Sheets

OPC Worksheets: Double-click on the desire OPC item (GEN, AI/AO, Stage) to open the OPC Client worksheets.

HMI-6200 Operator Interface

FIGURE 6-29

OPC Worksheet:

GENeral Parameters

6-30

FIGURE 6-30

OPC Worksheets:

Stage#1 Parameters

HMI-6200 Operator Interface

Verify that all Name and are associated with the correct OPC Server item. Also, make sure that tags are not

dynamic tags required by the HMI-6200 Operator Interface are listed under Tag

selected as Scan Always unless the specific tags require continuous scanning, such as Alarm/Alert related tags.

Tag Names are obtained from the Database (double-click on Tag Name column). To associate the Tag Name to the OPC Server item, right click on the item column and hit OPC Browser. This enables you to browse all the OPC Server configured items. If the T6200 connection is not already established it will open the OPC Server link.

6-31

FIGURE 6-31

HMI-6200 Operator Interface

WEB Communication:

Web Studio allows you to save your application screens in HTML format and export them to Internet Browsers (Internet Explorer).

You need to set the parameters in the Web tab in the Program Settings dialog window and save the screens which you desire for Web communications as HTML (menu File – Save as HTML). Caution: The Web Pages generated by the Save As HTML function are independent of the screen file they were generated from. As such if you make a change to the Display Screen that change will not appear on the Web page until you again Save As HTML.

Any tags which are used to display data or input commands need to have their web settings changed to server in order to communicate over the web. Select Application Tags in the Database and verify the Web Data column.

Application Datasheet Database Tab Web Data selection

FIGURE 6-32

Project Settings Web Tab

The computer where the HTML files are stored (Page Server) must be a WEB Server (HTTP Server driver) and the computer where the application is running (Data Server) should have a fixed IP address. Note the Page Server and the WEB Server can, but do not have to be, the same computer. For T6200,

the Page and WEB Servers are both contained in the operator interface.

To be able to view your web pages you must first configure the web setting. These can be found in the

Project Settings window under the Web tab (see above). First you need to input the Data Server IP Address, this is the IP address where the application is running. Next you need to enter the URL in the following format: http://<the IP address of the unit where the web server is running>/<path from the server to the web page directory>/. Once these two fields are correct click the ok button. Then

go to Tools on the menu bar and select Verify application (if you have any windows open in the development system Studio will demand you close them before verifying the application).

Caution: If you change any of the web information under the Project Settings you will need to ReVerify the application for the new setting to take affect. Because the Web Pages Display information from the application through the Web Server, the Runtime System, the Web Server and the TCP/IP Server need to be running to view the Web Pages.

6-32

FIGURE 6-33

UAM Report Screen

Real-Time Web Data

HMI-6200 Operator Interface

Once all the settings are correct, turn on the Web Server then run the application. With both of these running you should be able to use Internet Explorer to connect to the application By selecting the URL (http://<the IP address of the unit where the web server is running>/<path from the server to the web page directory>/<application screen name>.html). A prompt for a username and password will appear, enter one of the username and passwords from the security section. Once the screen appears you can interact with the application.

Example: UAM Report screen on-line data exported to Internet Explorer.

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Downloading the Updated Application

After the adaptation of the pre-defined displays is completed, connect the development computer to the controller operator interface via a direct HMI Crossover Ethernet cable or via the controllers’ Primary Ethernet connection (T6200 rear termination panel, Ethernet 1). If the connection is made through the Primary Ethernet at the controller termination panel, make sure that the T6200 control board(s) is unplugged and that the connection from the termination panel is made direct computer using a standard Ethernet cable.

HMI-6200 operator interface Arrangement

Select the Miscellaneous Screen (click on the *** button on the Header of the operator interface display) Log Off and press the CEViewSD (CE View Shutdown, grayed out before Log Off confirmation) button on lower right area of the screen. The operator interface will exit the CE View program and display a Remote Agent window.

FIGURE 6-34

Button Log On/Off and CEViewSD on Misc *** Screen

HMI-6200 Operator Interface

to the development

6-34

- Remote Agent Window

The user needs to move the "Remote Agent" window down only if he cannot see the information that he wants to see. Typically, this will be required in order to expose the “My Computer” and “T6200 Configuration” icons.

- Delete existing COMPR_~1 Folder: Double-click the My Computer icon and then double-click the

IPSM folder icon to access the COMPR_~1 folder. Click the COMPR_~1 folder and click File and Delete. The “Confirm Folder Delete” pop-up window with the text “Are you sure you want to remove the folder ‘COMPR_~1’and all its contents?” will appear. Press Yes and close the pop-up. The COMPR_~1 folder will be deleted. Close the window. The Remote Agent window (as it was previously positioned) will appear.

Rockwell Automation T6200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual