YOKOGAWA STARDOM FCN-500, STARDOM FCN-RTU Engineering Manual

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TI 34P02K35-02E

Information

STARDOM

Engineering Guide (FCN-500/FCN-RTU)

1st Edition Apr.28.2016 (YK)

3rd Edition Jun. 6.2018 (YK)

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IMPORTANT

Introduction

About this manual

This engineering guide is intended as a guide for system engineering of a STARDOM system (FCN-500, FCN-RTU) based on given specifications. It supplements the information contained in the following documents, which are required for STARDOM engineering, and explains precautions and pointers, following the engineering workflow sequence.

Copyrights and Trademarks

Copyrights

The copyrights of this document belong to Yokogawa Electric Corporation. No part of this document may be transferred, sold, distributed (including delivery via a commercial PC network or the like), or registered or recorded on videotapes.

Trademarks and Licensed Software

- STARDOM is a trademark.

- Company names and product names included in this document are trademarks or registered trademarks of their respective owners.

- Registered trademarks or trademarks are not denoted with the ‘TM’ or ‘®’ mark in this document.

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TI 34P02K35-02E 3rd Edition

STARDOM Engineering Guide (FCN-500/FCN-RTU)

Introduction ................................................................................................ i

Copyrights and Trademarks .................................................................... ii

CONTENTS ............................................................................................... iii

1. Overview ........................................................................................... 1

2. Basic Design and Function Design ................................................ 3

2.1 Checking Hardware Specification ............................................................ 3

2.1.1 Current Consumption of FCN-500 and FCN-RTU Unit ................... 3

2.1.2 Checking Operation Specifications of I/O Modules ........................ 6

2.1.3 Checking Automatic Loading of I/O Modules .................................. 6

2.1.4 Measures for Duplexing .................................................................. 7

2.2 Pre-Application Creation Checklist .......................................................... 9

2.2.1 Checking Revisions of FCN-500, FCN-RTU and Tools .................. 9

2.2.2 Checking FCN-500, FCN-RTU Control Application Size .............. 12

2.2.3 Checking FCN-500, FCN-RTU Performance ................................ 13

2.2.4 Determining FCN-500, FCN-RTU Scan Cycle .............................. 15

2.2.5 Retentive Variable (Retain Data) Considerations ......................... 18

2.2.6 Time Synchronization .................................................................... 23

3. Hardware Setup .............................................................................. 25

3.1 Resource Configurator Setting ............................................................... 25

3.2 Setup in Web Browser ............................................................................. 27

4. Control Application Creation ......................................................... 29

4.1 Using Logic Designer Setup ................................................................... 29

4.1.1 Selecting a Template for a New Project ........................................ 29

4.1.2 Control Task Setup ........................................................................ 31

4.1.3 Multi-tasking .................................................................................. 34

4.1.4 Specifying Target FCN/FCJ........................................................... 35

4.1.5 Multi-resource Project ................................................................... 37

4.1.6 Application Size ............................................................................. 38

4.2 Application Programming Languages ................................................... 40

4.2.1 Programming Languages Supported by Logic Designer .............. 40

4.2.2 Selecting a Programming Language ............................................. 41

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4.3 Principles of Application Creation .......................................................... 42

4.3.1 Principles of Application Creation ................................................. 42

4.3.2 Example of a Simple Application ................................................... 42

4.3.3 Bottom-up Application Creation .................................................... 45

4.4 Application Creation Know-how ............................................................. 46

4.5 Network Templates ................................................................................... 47

4.6 Application Encapsulation ...................................................................... 48

4.6.1 Features of Application Encapsulation .......................................... 48

4.6.2 Procedure for Creating a POU ...................................................... 50

4.6.3 Modifying Logic of a POU ............................................................. 54

4.7 Handling Compile Errors and Warnings ................................................ 58

4.8 Precautions About Downloading ............................................................ 60

4.8.1 Offline Download and Online Download ....................................... 60

4.8.2 Downloading Boot Project and Source ......................................... 62

4.8.3 Detailed Description of Download Dialog ..................................... 62

4.8.4 Importance of Boot Project ........................................................... 64

4.8.5 Importance of Source .................................................................... 65

4.9 Control Application Backup .................................................................... 66

5. Function Test (Debugging) ............................................................ 69

5.1 Equipment Used for Testing .................................................................... 69

5.1.1 Precautions of Testing When Using In-house Equipment ............. 70

5.1.2 Precautions of Testing When Using FCN/FCJ Simulator .............. 73

5.1.3 Precautions of Testing When Using Target Equipment ................. 75

5.1.4 Precautions of Migrating Testing from In-house Equipment to

Target Equipment .......................................................................... 77

5.2 Unit Test and Combination Test .............................................................. 79

5.3 Unit Test Precautions ............................................................................... 80

5.3.1 Pre-unit Test Checklist .................................................................. 80

5.3.2 Unit Test Methodology ................................................................... 81

5.3.3 Unit Test Know-how ...................................................................... 83

5.4 Combination Test Precautions ................................................................ 86

5.4.1 Combination Test Prerequisites .................................................... 86

5.4.2 Equipment Used for Combination Test ......................................... 86

5.4.3 Checking Log Files of FCN-500, FCN-RTU .................................. 87

5.4.4 System Failure Test ....................................................................... 87

5.5 Checking CPU Load and Application Size ............................................. 92

5.5.1 Checking CPU Load...................................................................... 92

5.5.2 Checking Application Size ............................................................. 93

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5.6 Logic Designer’s Debug Mode ................................................................ 95

5.6.1 Switching to Debug Mode ............................................................. 96

5.6.2 Basic Operation in Debug Mode ................................................... 99

5.6.3 Disconnecting I/O .......................................................................... 99

5.6.4 Entering and Checking Values of Device Label Variables .......... 101

5.7 Software Wiring ...................................................................................... 106

5.7.1 Overview of Software Wiring ....................................................... 106

5.7.2 Software Wiring Creation and Precautions ................................. 107

5.7.3 Precautions When Creating Software Wiring ............................. 109

5.8 Using Loop Check Tool ........................................................................... 110

5.8.1 Values Displayed in Loop Check Tool .......................................... 111

5.8.2 Locating Problems Using Loop Check Tool ................................. 112

6. User Acceptance Test (UAT) ........................................................ 114

6.1 Pre-UAT Checklist ................................................................................... 114

6.1.1 UAT Prerequisites ........................................................................ 114

6.1.2 UAT Implementation Guidelines................................................... 115

6.2 Items Requiring Prior Explanation to Users ......................................... 11 6

6.2.1 Differences in Equipment Used from Actual System ................... 116

6.2.2 Differences between Process I/O and Software Wiring ............... 117

6.2.3 Equipment Communicating with FCN-500, FCN-RTU ................. 11 7

7. System Delivery Precautions ...................................................... 118

7.1 System Delivery Checklist ...................................................................... 119

7.1.1 System Delivery Prerequisites ..................................................... 119

7.1.2 Forms of Delivery ......................................................................... 119

7.2 Delivery for New System ....................................................................... 121

7.2.1 Pre-Delivery Preparation ............................................................. 121

7.2.2 Control Application Backup ......................................................... 122

7.2.3 System Delivery .......................................................................... 123

7.3 Delivery for System Expansion ............................................................. 124

7.4 Delivery for System Modification .......................................................... 125

7.4.1 Pre-Delivery Preparation and Application Backup ...................... 125

7.4.2 System Delivery .......................................................................... 125

7.4.3 Preparation for On-site Installation ............................................. 125

7.4.4 On-site Installation ...................................................................... 126

7.5 Procedure Instruction Sheet and Rehearsal ....................................... 127

8. Detailed Description ..................................................................... 128

8.1 Checking Operation Specifications of I/O Modules ............................ 128

8.1.1 Checking Operation Specification of Analog/Digital Input .......... 128

8.1.2 Checking Operation Specification of Analog/Digital Output ........ 130

8.1.3 Checking Specification of Pulse Input......................................... 132

8.1.4 Checking Specification of Pulse Width Output ........................... 133

8.2 Checking Specification of Serial Communication .............................. 135

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8.3 Precautions about Multi-tasking .......................................................... 137

8.4 Criteria for Selecting Programming Languages in Logic Designer .. 141

8.4.1 Selection Criteria for FBD, LD and ST ........................................ 141

8.4.2 Selecting between FBD and LD .................................................. 149

8.4.3 Combining FBD, LD and ST ....................................................... 150

8.4.4 Selecting between SFC and Stepped FBD or LD ....................... 152

9. Advanced Engineering ................................................................ 156

9.1 General Application Development Know-how ..................................... 156

9.1.1 Variable Definitions ..................................................................... 156

9.1.2 Local Variables versus Global Variables ..................................... 157

9.1.3 _RB and _BOOL Suffix Variables of Device Label Variables ...... 160

9.1.4 Execution Order of Control Application ....................................... 162

9.1.5 Inter-FCN/FCJ Communication Concept .................................... 169

9.1.6 How to Create User Data Types ................................................. 175

9.1.7 Jump, Connector and Return Functions ..................................... 178

9.1.8 Cross References ....................................................................... 182

9.1.9 Specifying Retain Data and OPC Property ................................. 185

9.1.10 Getting FCN-500, FCN-RTU Time .............................................. 186

9.1.11 Precautions When Using Terminal EN of Functions ................... 187

9.1.12 Logic for Saving Retain Data ...................................................... 190

9.1.13 Comparing Logic Designer Projects ........................................... 192

9.1.14 Avoidance of the Error during Execution .................................... 193

9.2 Know-how in Use of NPAS_POU .......................................................... 194

9.2.1 Scan Cycle and Control Cycle .................................................... 194

9.2.2 How to Detect Mode, Status and Alarm ...................................... 197

9.2.3 NPAS_POU Status Propagation ................................................. 202

9.2.4 Blocked NPAS_POU Status Propagation ................................... 207

9.2.5 Selection of Timers and Counters ............................................... 210

9.2.6 Engineering Parameters .............................................................. 211

Appendix 1 STARDOM Engineering Flow Chart ............................... 214

Revision Information ................................................................................. i

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<1. Overview>

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Check require-

ment spec.

User acceptance

test (UAT)

System delivery

Unit test

Integration test

System test

Detailed function

design of

application

software

Check requirement

spec.

Check system

configuration

- Verify that the requirement specification can be implemented using the STARDOM system.

- Verify that the system configuration allows implementation of the requirement specification.

- Based on the requirement specification, prepare basic specifications for FCN/FCJ control applications, operation/monitoring applications and communication functions.

- Based on basic functions, perform detailed design of each application and prepare functional specification.

- Based on function specification, create applications.

- In unit test, check individual applications.

- In integration test, combine applications already tested in unit tests and test the integrated STARDOM system as a whole.

- In system test, combine external equipment and control panels with the STARDOM system, and perform function test, including communication tests.

- Verify along with customer that the designed/created application satisfies the function specification.

- After completion of UAT, deliver STARDOM system.

FCN/FCJ control

applications

Operation and

monitoring

applications

Communication

applications

Basic design and

function design

Application creationFunction test

1. Overview

STARDOM engineering can be divided into phases as shown in the diagram below.

This engineering guide is intended as a guide for system engineering of a STARDOM system based on given specifications. For this purpose, it describes the precautions and checklist for each of the engineering phases after specifications are confirmed, including basic design and function design, application creation, function test, user acceptance test (UAT) and system delivery. This engineering guide focuses on FCN/FCJ control applications.

Details on the functions and use of the FCN-500 and FCN-RTU controller and individual application programming tools can be found in their respective instruction manuals (IM) and Technical Information (TI). Wherever necessary, this manual will refer the reader to these documents for details on functions and usage.

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2. Basic Design and Function Design

The first thing to do in STARDOM engineering is to check whether a given customer specification can be implemented using the hardware, application programming tools, APPFs (application portfolios), and licenses provided with the system.

2.1 Checking Hardware Specification

Review specifications for the hardware given in GS and IM documents to confirm whether specification requirements are achievable.

2.1.1 Current Consumption of FCN-500 and FCN-RTU Unit

Calculate the current consumption of each FCN unit, and check that it does not exceed the rated output current of the power supply module.

● Rated Output of Power Supply Module

The rated output current of the FCN-500 power supply module is given by:

System power supply: 0 A to 7.8 A

Analog field power supply: 4 A (max)

SEE ALSO

Chapter A1.3, “Power Supply Module” of IM “STARDOM FCN/FCJ Guide”

The rated output current of the FCN-RTU power supply module is given by:

NFPW426: System power supply: 0 A to 2.4 A

Analog field power supply: 0.54 A (max)

NFPW441: System power supply: 0 A to 7.8 A

Analog field power supply: 4 A (max)

SEE ALSO

Chapter A2.3, “Power Supply Module (NFPW426, NFPW444)” of IM “STARDOM FCN/FCJ Guide”

The power supply module mounted on a unit supplies power only to that unit so the current consumption of each unit must be kept below the rated output described above.

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● Calculating Current Consumption of an FCN Unit

The current consumption of the system power supply of an FCN unit can be obtained by summing the current consumption values of the base module, as well as the CPU modules, I/O modules, and E2 bus/SB bus modules installed on the base module. If I/O modules requiring analog field supply are mounted in the unit, the current consumption of the analog field supply of the FCN unit should be calculated additionally. The system power supply current consumption and analog field supply current consumption values of individual modules given in the “STARDOM FCN/FCJ Guide” can be used for these calculations.

An example of current consumption calculation

This example calculates the current consumption of the control unit, as well as, that of the extended unit, shown in the figure below.

- Calculating current consumption of control unit System power supply Current consumption of NFCP501 modules : 1200 mA×2 =2400 mA Current consumption of NFAI141 modules : 310 mA×2 = 620 mA Current consumption of NFAV141 modules : 350 mA×2 = 700 mA Current consumption of SB bus repeat modules : 500 mA×2 =1000 mA Total: 4720 mA < rated output current of 7.8A

Analog field power supply Current consumption of NFAI141 : 450mA×2 = 900mA Total: 900mA < rated output current of 4A NFAV141 and SB bus repeat modules do not require analog field power and

are thus excluded from the calculation. (E2 bus interface module does not require analog field power too)

- Calculating current consumption of extension unit System power supply Current consumption of NFDV551 modules : 700mA×2 = 1400mA Current consumption of NFDV557 modules : 550mA×2 = 1100mA Current consumption of SB bus repeat modules : 500mA×2 = 1000mA Total: 3500mA < rated output current of 7.8A

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Analog field power supply Current consumption of NFDV551 modules : 60mA×2 = 120mA Current consumption of NFDV557 modules : 60mA×2 = 120mA Total: 240mA

(For digital output cards, 24Vmust be supplied to each module)

SB bus repeat module does not require analog field power and are thus

excluded from the calculation. (E2 bus interface module does not require analog field power too)

In this example, the current consumption of the system power supply, as well as the current consumption of the analog field power supply, of both the control unit and the extension unit, are below the rated output of the power supply modules so there is no problem.

● I/O Modules Requiring Analog Field Power Supply

In the power consumption calculation example given above, some of the I/O modules of the FCN-500 and FCN-RTU units require analog field power supply.

SEE ALSO

Section A1.13.3 "Field Power Supply" of IM “STARDOM FCN/FCJ Guide."

Any of such I/O modules, when used, require 24 V DC to be supplied to the power supply module, in addition to the power supply used for control. Check the hardware specification for 24 V DC power supply.

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2.1.2 Checking Operation Specifications of I/O Modules

Compare the operation specification of each I/O module against the requirement specification to ensure that requirements can be met. For more details, see Section 8.1, "Checking Operation Specifications of I/O Modules;" Section 8.2, "Checking Serial Communication Specification" of Chapter 8, "Detailed Description," as well as the "STARDOM FCN/FCJ Guide."

2.1.3 Checking Automatic Loading of I/O Modules

Operation settings, device label names and all other configuration information of I/O modules and communication modules are saved in the on-board flash memory of the FCN-500 and FCN-RTU. Using Resource Configurator, whether to automatically load configuration information into a new I/O module when an I/O module is replaced can be specified.

If automatic loading is enabled, configuration information stored on the flash

memory is loaded and a replacement I/O module begins operations automatically provided if the same model name I/O module being replaced. Otherwise, confirmation information is not loaded automatically.

If automatic loading is disabled, configuration information stored on the flash

memory is not loaded automatically regardless of the model of the replacement module. In such case, redefine and download settings using the Resource Configurator and rebooting the FCN-500 or FCN-RTU is required.

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2.1.4 Measures for Duplexing

Within a STARDOM system, the following components can be duplexed: CPU of FCN-500 Power supply module of FCN-500 or FCN-RTU (used long base module only) SB bus of FCN-500 Control network (control LAN) of FCN-500 Communication application Check precautions described below for duplexed system components.

● FCN-500 Operation When Configured with Duplexed CPU

The operation specification and precautions applicable when the CPU of an FCN500 is duplexed are given in the following IM and TI documents: Section B1.3.3, “Precautions on the Creation of Control Applications” of IM

“STARDOM FCN/FCJ Guide”

Chapter C2, “Duplex CPU Module (FCN-500)” of IM “STARDOM FCN/FCJ

Guide”

Section 7.2, “Operation using Duplex FCN CPU Modules" of TI “FCN-500

Technical Guide”

● FCN-500 and FCN-RTU Operation When Configured with Duplexed Power Supply Module

Duplexing of the power supply module can be achieved by simply installing two power supply modules on a long base module.

SEE ALSO

For details on the operation specification of an FCN-500 configured with duplexed power supply module, see Section 3.1.2, “Power Supply Module” of TI “FCN-500 Technical Guide,” Section 3.1.2, “Power Supply Module” of TI “FCN-RTU Technical Guide.”

● FCN-500 Operation When Configured with Duplexed E2 Bus/SB Bus

Duplexing of the E2 bus/SB bus can be achieved simply by configuration using Resource Configurator.

SEE ALSO

For details on the operation specification of an FCN-500 configured with duplexed SB bus, see Section 3.4, “SB Bus Repeat Module for FCN” of TI “FCN-500 Technical Guide.”

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● FCN-500 Operation and Precautions Regarding Duplexed Control Network

For details on the operation specification and precautions applicable to a STARDOM system configured with duplexed control network, see: Section D2.2.2, “Control Network Duplexed Configuration” of IM “STARDOM

FCN/FCJ Guide”

Section 2.6 "Duplexing Control Network" of TI “STARDOM Network

Configuration Guide”

• Diagnostic communication interval

In a duplexed control network, diagnostic frames are transmitted periodically

through multicast communication.

If two successive diagnostic frame transmissions are unsuccessful, system

network failure is assumed, and control network switchover is performed.

One diagnostic frame is transmitted and one receive processing is performed

for each duplexed device within each cycle. When there are many duplexed devices, the CPU load increases proportionally due to increased receive processing of diagnostic frames. The diagnostic communication interval is defined as 500 ms by default and can be lengthened as appropriate if many duplexed devices are present on the network.

SEE ALSO

For details, see Section 2.6.1, “The Duplexed Network Function Provided on STARDOM” of TI “Network Configuration Guide.”

● Operation and Precautions Regarding Duplexed Communication Application

To implement duplexed communication with non-STARDOM equipment such

as FA-M3, third-party PLCs, and remote I/O, a communication application must include logic for executing a transmission path switchover when a communication error is detected.

SEE ALSO

For more details, see Section 2.6.2, “Duplexing Communications Using an Application” of TI “Network Configuration Guide.”

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2.2 Pre-Application Creation Checklist

This section covers checking items on application programming tools, application size, etc, before creating applications.

2.2.1 Checking Revisions of FCN-500, FCN-RTU and Tools

Before programming applications, check the revisions of the FCN/FCJ Basic Software and each tool to be used in subsequent engineering. These include:

- FCN/FCJ Basic Software (stored on the system card)

- Resource Configurator

- Logic Designer

- Various application portfolios The revision of the FCN/FCJ Basic Software should match the revision of the CPU module (on-board flash memory).

SEE ALSO

For details on how to check the revision of the system card, see "● Revision of System Card Used” of Section 5.1.1, “Precautions of Testing when Using In-house Equipment.”

● For New System Implementation

When implementing a new system, using the latest versions of the FCN/FCJ Basic Software and tools listed above is recommended.

If application development is to be carried out using in-house development equipment instead of the target equipment, upgrade the FCN-500, FCN-RTU, Logic Designer and all software tools to the latest versions before starting application creation.

● For System Modification

When modifying an existing application using in-house development equipment, whether revisions of the FCN/FCJ Basic Software and the various tools listed above of the in-house equipment match those of the existing system is needed to be checked.

When carrying out engineering for system modification using in-house equipment having revisions later than the existing system, beware of using new system functions not supported in the existing system. Otherwise, the application may, despite thorough testing on in-house equipment, fail to be downloaded to the existing system or, even if successfully downloaded to the existing system, fail to run or fail to run correctly.

Moreover, even if a function used in the modified application is present on the existing system, its operation specification may be different because of functional enhancements included in the revision upgrade so that the modified application may behave differently when tested on in-house equipment and when executed on the existing system after delivery.

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● For System Expansion

STARDOM allows intermixing of FCN-500 and FCN-RTU of different revisions within a system. When implementing system expansion through addition of a new FCN-500 and FCN-RTU to an existing system, consider whether to use the latest revision for the new FCN-500 and FCN-RTU or to match the existing system revision. Consider the pros and cons described below, and decide whether to use the latest revision for the new FCN-500, FCN-RTU and intermix different FCN-500, FCNRTU revisions within the system, to standardize revisions throughout the system by downgrading the new FCN-500, FCN-RTU to match the existing system revision, or to standardize to the latest revision throughout the system by upgrading the existing system.

• Using the latest revision

In this case, all supported functions can be used. However, beware that the operation specifications of some functions may

have changed due to functional enhancements included in the revision upgrade so that the expanded system may behave differently from the existing system. Furthermore, system revision control may be more tedious with intermixing of FCN-500 and FCN-RTU s of different revisions.

• Matching the existing revision

In this case, the new FCN-500 and FCN-RTU will behave the same as the

existing system but new functionality included in the latest revision will not be available. However, system revision control will be easier with a standardized FCN-500 and FCN-RTU revision throughout the system. The FCN-500 is used R4.02 or later.

● Procedure for System Downgrade

The procedures are essentially the same for downgrading and upgrading the revision of in-house equipment to match the revision of an existing system for the purpose of system modification or system expansion engineering. When upgrading, use the DVD-ROM for the latest system revision; when downgrading, use the DVD-ROM for the required system revision instead. Observe the following precautions for downgrading the FCN/FCJ Basic Software.

• Precautions when downgrading FCN/FCJ Basic Software

FCN-500 can not be downgrading before than R4.02.

FCN-RTU can not be downgrading before than R2.10.

To downgrade a system, follow essentially the same procedure for system

upgrade by decompressing the Basic Software stored on the DVD-ROM for the required revision to the PC, and then issuing an “FcxRevup” command at the command prompt but include a “-s” option.

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If you execute the plain “FcxRevup” command without the “-s" option, as is

usually done when performing a revision upgrade, configuration information stored on the flash memory will be retained after command execution. This may cause an error if the existing configuration information cannot be interpreted by the older revision after system downgrade. Therefore, when downgrading a system, execute the "FcxRevup” command with the “-s" option to perform a clean upgrade along with initialization of configuration information.

● Checking Service Packs and Service Releases

Service releases or service packs may have been published for some system revisions.

For new system implementation, after installing the latest system revision, check for the presence of published service releases and service packs, and apply them as required. Similarly, after having upgraded or downgraded the revision of inhouse equipment to match the existing system, check whether any service releases and service packs have been previously applied to the existing system, and apply them accordingly to the in-house equipment.

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2.2.2 Checking FCN-500, FCN-RTU Control Application Size

Estimate the size of an FCN500 or FCN-RTU control application from the requirement specification and ensure that there is no problem.

SEE ALSO

For details on how to estimate the size of an application, see Section 4.5.2, “Calculation of Control Application Capacity" of TI "FCN-500 Technical Guide," Section 4.5.2, “Calculation of Control Application Capacity" of TI "FCN-RTU Technical Guide."

Estimate the control application size by estimating the ADLST size and retain data size as described in TI “STARDOM Technical Guide.” To investigate the utilization of application resources, calculate the respective utilization rates of ADLST capacity of retain data capacity, and take the larger of the two values as the system-wide utilization rate.

The checking items described in this section is based on calculated values, which should be verified by checking the actual control application size during function test.

SEE ALSO

For details, see Section 5.5.2, “Checking Application Size.”

• For projects using NPAS POUs

Projects using NPAS POUs usually exceed the ADLST size limit (if ever it is

exceeded) before exceeding the retain data size limit. Therefore, first estimate the ADLST size, and if it is within the 4MB upper limit, you can assume that there is no application size problem. You can also use the ADLST utilization as an indicator of the utilization of the control application.

• For projects not using NPAS POUs

For projects not using NPAS POUs, the ADLST size and retain data size

depend on how many variables are specified with OPC property and RETAIN property during engineering.

In this case, estimate both ADLST size and retain data size and if both values

are within their respective upper limits, it can be assumed that there will be no application size problem.

Furthermore, use the larger of the ADLST and retain data utilization rates as

an indicator of the utilization rate of the control application.

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NPAS_POU's execution time

Control task interval

CPU load (%) =

x 100%

2.2.3 Checking FCN-500, FCN-RTU Performance

Estimate the execution time of an FCN-500 or FCN-RTU control application from the requirement specification and determine the CPU load.

SEE ALSO

For details on how to estimate performance, see Section 4.5.3, “Confirmation of Performance" of TI "FCN-500 Technical Guide", Section 4.5.3, “Confirmation of Performance" of TI "FCN-RTU Technical Guide".

The checking items described in this section is based on calculated values, which should be verified by checking the actual CPU load during function test.

SEE ALSO

For details, see Section 5.5.1, “Checking CPU Load."

● Calculating Execution Time and CPU load of Control Application

The method for estimating the execution time of a control application depends on whether the project uses NPAS POUs.

• For projects using NPAS POUs

For a project using NPAS POUs, determine the execution time as described in

the above-mentioned TI document, and calculate the CPU load using the following formula:

• For projects not using NPAS POUs

The above-mentioned TI document does not describe how to calculate the

execution time of a project not using NPAS POUs. This is because the execution time of non-NPAS_POU blocks are very short and hence need not be considered during the estimation phase.

TIP

In the CPU function specification description of the GS document “FCN Autonomous Controller Functions (FCN-500)” or “FCN-RTU Low Power Autonomous Controller Functions”, the execution speed is given as: FCN-500s Execution speed: Approx. 10 µs per kilosteps in an IL program FCN-RTUs Execution speed: Approx. 50 µs per kilosteps in an IL program This means that about 10 µs (FCN-500) or 50 µs (FCN-RTU) is required to process 1 kilosteps of an IL program block. Each function such as AND or OR coded in IL is equivalent to 3 steps. Therefore, the execution time of 1000 functions is about 30 µs (FCN-500) or about 150 µs (50 µs x 3, FCN-RTU). Based on this calculation, about 195,000 functions (FCN-500) or about 65,000 functions (FCN-RTU) can be processed within 10 milliseconds.

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IMPORTANT

Execution time

Scan cycle

Idle time

Execution time

Scan cycle

CPU load ≤ 60%

Executes communication

● Recommended CPU Load

The following FCN-500 and FCN-RTU functions are executed during CPU idle time:

- Ethernet communications of FCN-500 and FCN-RTU

- Communication with VDS/ASTMAC data server

- Inter- FCN-500 and FCN-RTU communication

- Various inter-device communications such as Modbus communications using Ethernet or serial communications

- Operation or setup from Logic Designer or Resource Configurator

- Duolet function

- Downloading of boot project and source

To allow such processing, it is recommended that the CPU load be kept at 60% or lower.

and Duolet functions

CPU load (%) ＝

ｘ 100 %

The CPU load calculation described in this section considers only the execution time of the control application. In an actual system, execution time also includes CPU module and I/O module access time. Therefore, consider a CPU load slightly higher than the value estimated here. The I/O module access time varies with the number of I/O modules and normally ranges between several milliseconds to 20 milliseconds.

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2.2.4 Determining FCN-500, FCN-RTU Scan Cycle

As described in the previous section 2.2.3, “Checking FCN-500 and FCN-RTU Performance,” it is recommended that CPU load be kept at 60% or lower. Check that the estimated CPU load is 60% or lower, and there is no problem with the scan cycle stated in the requirement specification if applicable. If the CPU load exceeds 60%, investigate rectification measures.

● Setting Range for Scan Cycle

The scan cycle of the FCN-500 can be set to a value between 5 ms and 32760 ms in 5 ms increments. The scan cycle of the FCN-RTU can be set to a value between 10 ms and 32760 ms in 10 ms increments. When setting the scan cycle to 4 seconds or longer, note the precautions described later.

● When a Required Scan Cycle is Stated in Requirement Specification

If a scan cycle is stated in the requirement specification, use the stated value to estimate the CPU load and check that it is 60% or lower. If the CPU load exceeds 60%, consider whether it can be reduced using the methods described later.

● When no required scan cycle is stated in requirement specification

If no scan cycle is stated in the requirement specification the engineer is given the responsbility, determine the scan cycle from the execution time of the control application estimated as described in Section 2.2.3, “Checking FCN-500 and FCN-RTU Performance.”

● Example for Determining Scan Cycle

If engineer is asked to decide on the scan cycle, use Logic Designer’s default scan cycle of 100 ms as a baseline consideration.

Example 1: When estimated control execution time is 20 ms

Estimated CPU load = 20 ms/100 ms = 20% Based on the estimated CPU load of 20%, even considering the time for

accessing I/O modules, the CPU load is expected to be below the recommended limit of 60%. Therefore, the scan cycle of 100 ms should be fine.

Example 2: When estimated control execution time is 50 ms

Estimated CPU load = 50 ms/100 ms = 50% The estimated CPU load of 50% is below the recommended limit of 60%. However, if the time for accessing I/O modules is taken into consideration, the

CPU load is expected to approach 60%, or even exceed 60% if many I/O modules are installed.

In this example, we should look into reducing the CPU load using the methods

described hereafter.

If the scan cycle is set to 100 ms, download the application early on in application

creation to check that there is indeed no CPU load problem.

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Execution time

Scan cycle

CPU load

70 ms

100 ms

70%

70 ms

200 ms

35%

IMPORTANT

● Ways for Reducing CPU Load

Consider the ways described below for reducing CPU load.

• Lengthen the scan cycle

By lengthening the scan cycle, CPU load can be reduced even if the execution

time remains unchanged.

After changing the scan cycle, which is the most fundamental setting affecting FCN-500 and FCN-RTU operation, always check that control is not adversely affected.

• Define a task with long control cycle and move the application

For an application that can tolerate a long control cycle, define a task with a

longer cycle and move. By doing so, it reduces the overall CPU load.

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Control Cycle

Windup Time

100 ms

3 seconds

500 ms

15 seconds

1000 ms (= 1 minute)

30 seconds

2000 ms (= 2 minutes)

60 seconds (= 1 minute)

● Precautions When Using a Long Scan Cycle

• When scan cycle is 4 seconds or longer

Analog/digital output modules are defined with line access loss time of 4

seconds.

If the scan cycle is 4 seconds or longer, the interval between FCN-500 or

FCN-RTU CPU accesses of the output modules will be 4 seconds or longer. Depending on individual setting, an output module may assume that a CPU error has occurred and perform output fallback.

SEE ALSO

For details, see Section 8.1.2, "Checking Operation Specification of Analog/Digital Output” of Chapter 8, “Detailed Description.”

• About windup of NPAS POUs

For NPAS POU, after an FCN-500 or FCN-RTU reboot, windup processing is

executed for 30 scan cycles before control computation begins.

As the windup time is proportional to the scan cycle, lengthening the scan

cycle delays the starting of control computation after an FCN-500 or FCN-RTU boot.

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2.2.5 Retentive Variable (Retain Data) Considerations

Retain data of the FCN-500 and FCN-RTU may reside in the following locations:

- Non-volatile memory (factory setting)

- Volatile memory

- Flash memory Based on the requirement specification, decide whether retain data is to reside in volatile memory or non-volatile memory, as well as the procedure for saving retain data to the flash memory.

SEE ALSO

For details on considerations of retain data in FCN-500 and FCN-RTU, see Section 4.3.5, “Retentive Variables” of TI “FCN-500 Technical Guide,” Section 4.3.5, “Retentive Variables” of TI “FCN-RTU Technical Guide.”

● Retain Data Residing in Memory

Retain data can be stored in either volatile memory or non-volatile memory using Resource Configurator and is always resident in one of these locations. By default factory setting, retain data is resident in non-volatile memory.

- Non-volatile memory Retain data, when resident in non-volatile memory, is retained by a backup battery even if the FCN-500 or FCN-RTU is powered off.

- Volatile memory Data, including retain data, resident in the volatile memory is cleared when the FCN-500 or FCN-RTU is powered off.

The management of retain data is rather different depending on whether it resides in volatile or non-volatile memory.

● Saving Retain Data to Flash memory

Retain data residing in memory can also be backed up to the flash memory either manually by an operator or by executing a save instruction from an application. An operator can manually execute the backup using “Save Retain Data” from the FCN/FCJ “Maintenance Menu” or, equivalently, set global variable "GS_RETAIN_SV_SW” to TRUE in Logic Designer’s DEBUG mode. Depending on the conditions present after an FCN-500 or FCN-RTU reboot, retain data may be restored from the flash memory so saving retain data to the flash memory is an important aspect of retain data management.

SEE ALSO

For details on executing a save instruction from an application, see Section 9.1.12, “Logic for Saving Retain Data” of Chapter 9, "Advanced Engineering ". In the FCN-500, the retain data is stored in the flash memory, and can be saved on the SD card. For details, refer to D3.4 "Backup of all data to SD card (FCN-500)" of IM “STARDOM FCN/FCJ Guide”

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TIP

In subsequent description, the term "retain data on the flash memory" refers to retain data which was current as at the time when it was saved to the system card but not necessarily the most up-todate. For instance, if retain data was saved a week ago, “retain data on the flash memory" would be one week old.

● Behavior of Retain Data when FCN-500 or FCN-RTU Power is Off/On

1. If retain data is resident in non-volatile memory

As described earlier, retain data residing in non-volatile memory is retained even after the FCN-500 or FCN-RTU is powered off. When the FCN-500 or FCN-RTU is powered on, the system reboots using retain data in the non-volatile memory so retain data persistency is guaranteed.

However, under certain circumstances, retain data in the non-volatile memory may not be restored. Instead, all retentive variables are first initialized to their initial values after power on. If retain data has been previously saved to the flash memory, that data is restored. Otherwise, the FCN-500 or FCN-RTU reboots with all initial variable values. Some circumstances under which retain data in the nonvolatile memory will not be restored are listed below.

• If the structure of retain data of the application at startup does not match the structure of retain data in the non-volatile memory

If the control application running before power off is inconsistent with the boot

project on the flash memory on the number, data type or some other aspect of retain data, retain data in the non-volatile memory will not be restored after power on.

• If the backup battery was removed

If the backup battery is removed when power is off, retain data, like all other

data residing in the non-volatile memory, will be lost and hence cannot be restored at power up.

• If the CPU module or FCJ has been replaced

If the CPU module or FCJ is replaced, retain data residing in the non-volatile

memory of the hardware naturally cannot be restored.

2. If retain data is resident in volatile memory

Retain data stored in volatile memory is lost when the FCN-500 or FCN-RTU is powered off. After power on, all retentive variables are first initialized to their initial values. If retain data has been previously saved to the flash memory, that data is restored. Otherwise, the FCN-500 or FCN-RTU reboots with all initial variable values.

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● Behavior of Retain Data in FCN/FCJ Start Mode

Performing offline download to FCN-500 or FCN-RTU from Logic Designer stops control on the FCN-500 or FCN-RTU. However, as power supply is not interrupted, retain data, even if resident in volatile memory, retain their data. As such, the behavior of retain data after data download in the FCN/FCJ start mode is the same regardless of whether retain data is resident in volatile or non-volatile memory.

1. If FCN/FCJ is warm started

1.1 If there is no change in retain data area

If there is no change in the retain data area, control is started using retain data

values current before offline download, even if the control application has been changed.

1.2 If retain data structure has been changed

If the number or data type of retain data has been changed so that the retain

data structure is modified, retain data in the memory can no longer be used.

SEE ALSO Point 1 of TIP below In this case, all retentive variables are first initialized to their initial values. If

retain data has been previously saved to the flash memory, control is restarted using that data.

SEE ALSO Point 2 of TIP below If no retain data is saved on the system card, the FCN-500 or FCN-RTU is

rebooted with initial values for retentive variables.

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TIP

1. In the case of 1.2 described above, the following dialog is displayed before offline download:

This message indicates that warm start using retain data residing in the memory will not be

possible after downloading. It does not mean that warm start, in itself, is not allowed.

2. In this case, performing a warm start after completion of offline download generates the following

PLC error:

The first line of the message means that cold start was performed as warm start using retain

data in memory was not possible. The second line of the message means that the FCN-500 or FCN-RTU was restarted using retain data saved on the flash memory. From these two error messages, retain data saved on the flash memory was restored by a warm start after an offline download is understood.

2. If FCN/FCJ is cold started

After a cold start, the FCN-500 or FCN-RTU initializes all variables and start controlling. In other words, all retentive variables are initialized by a cold start.

TIP

The retain data structure will be changed by the following events:

- Adding or deleting an NPAS POU having one or more access parameters or engineering

parameters specified as retain data

- Specifying a non-retentive variable as a retentive variable or vice versa

- Changing the data type of a variable specified as retain data

The behavior of retain data on the FCN-500 or FCN-RTU start mode described above applies similarly when the FCN-500 or FCN-RTU is stopped from Logic Designer’s Application Control dialog,and then restarted without performing downloading.

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● Behavior of Retain Data on Online Download

Even if a modification involves a change in the retain data area, persistency of retain data is guaranteed so long as the modification is online downloaded. Newly added retentive variables, however, will be set to initial values.

● Relationship between Initial Value and Retained Value

After an FCN-500 or FCN-RTU warm start, even if initial values are specified for retain dat, their retained values take precedence.

● Summary

By default setting, FCN-500 or FCN-RTU is configured so that retain data is resident in non-volatile memory. As such, you can first review the specification on this basis.

Data resident in non-volatile memory retain their values even after the FCN-500 or FCN-RTU is powered off because of a backup battery. These retained values are restored at the next FCN-500 or FCN-RTU power on. In this way, the most upto-date data values are always maintained so keeping retain data resident in nonvolatile memory is the usual practice.

However, even if retain data is made resident in non-volatile memory, we recommend saving retain data to the flash memory regularly as a safeguard against unexpected situations where data retained in memory cannot be used. In addition to saving retain data manually, saving data regularly using a control application is also recommended.

SEE ALSO

For details, see Section 9.1.12, “Logic for Saving Retain Data” of Chapter 9, “Advanced Engineering.”

If a backup of retain data is saved on the flash memory, in case of event that data retained in non-volatile memory cannot be used for whatever reason, retained data values as at the time of saving will be restored from the system card. by doing so, it avoids the worst-case scenario where all retain data variables are initialized.

Compared to keeping retain data resident in non-volatile memory, keeping retain data reside in volatile memory enables a shorter execution time, and hence a shorter scan cycle for FCN-500 or FCN-RTU operation. However, if the FCN-500 or FCN-RTU is powered off and on again, retain data values before power off is lost and retain data values are always restored from the flash memory. To prepare for unexpected contigency, save retain data to the flash memory regularly, and also by manually whenever retain data is modified.

SEE ALSO

For details on scan cycle, see Section 2.2.4, “Determining FCN-500 and FCN-RTU Scan Cycle.”

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2.2.6 Time Synchronization

The FCN-500 or FCN-RTU allows time synchronization among external devices supporting SNTP (Simple Network Time Protocol).

SEE ALSO

For details on time synchronization of FCN-500 or FCN-RTU, see:

- Section B1.9.4, “Time Synchronization Function” of IM “STA R DOM FCN/FCJ Guide”

- Section 2.3.3, “Time Synchronization Function” of TI “FCN-500 Technical Guide”

- Section 2.3.3, “Time Synchronization Function” of TI “FCN-RTU Technical Guide”

● For FCN-500 Running as SNTP Server

After setting through FCN-500 maintenance page, the FCN-500 time

synchronization server automatically runs and starts time reporting. Setting for SNTP server is done through FCN-500 maintenance page. The following file is modified to start SNTP sever.

However, the FCN-500 cannot provide highly accurate time reporting as its

reported time includes internal timer error of -17.5 to +12 seconds/day.

1. JEROS Basic Setting File (DOUNUS.PRP)

It specifies whether to start the SNTP server function. This setting is for only

FCN-500 only. Specify YES to start SNTP Server.

Setting item: Start the SNTP server function (SntpServer)

SntpServer = YES use the SNTP server function SntpServer = NO not use the SNTP server function,

default value

SEE ALSO

For details of JEROS basic setting file, see online-help.

● For FCN-500 or FCN-RTU Running as SNTP Client

If the FCN-500 or FCN-RTU runs as an SNTP client. To setup from the

FCN/FCJ maintenance homepage to enable the FCN-500 or FCN-RTU to receive reported time values from an SNTP server (as an SNTP client) and perform time synchronization accordingly.

From the FCN/FCJ maintenance homepage, time synchronization settings are

implemented at the following two locations.

1. JEROS Basic Setting File (DOUNUS.PRP)

Configure for the use of SNTP client function.

2. SNTP Setting File (S NT P.PRP)

SEE ALSO

For details of JEROS basic setting file, see online-help.

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IMPORTANT

3. Hardware Setup

After reviewing and deciding on a desired FCN-500 and FCN-RTU hardware configuration as described in Chapter 2, perform the actual FCN-500 and FCNRTU hardware setup by running Resource Configurator and by accessing the FCN/FCJ maintenance homepage using a generic web browser.

3.1 Resource Configurator Setting

Among the hardware configuration items reviewed and described in Chapter 2, the following items are configured using Resource Configurator:

- I/O module operation

- Enabling/disabling of automatic loading of I/O modules

- Duplexed operation

- Enabling/disabling of hardware backup of retain data

SEE ALSO

- Section 2.1.2,”Checking Operation Specifications of I/O Modules”

- Section 2.1.3,”Checking Automatic Loading of I/O Modules”

- Section 2.1.4,”Measures for Duplexing”

- Section 2.2.5,”Retentive Variable (Retain Data) Considerations”

Do not turn off the power to the FCN-500 and FCN-RTU controller while downloading Resource Configuration. It will take up to three minutes to complete the download operation.

For details on the Resource Configurator and how to use the Resource Configurator Editor, read “STARDOM FCN-500/FCN-RTU Primer – Fundamental”（TI 34P02K1302） and the Resource Configurator online help documentation.

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● Precautions When Using FCN-500 or FCN-RTU with No Actual I/O Modules

Resource configurator R4.20 or later can maintain unimplemented I/O module definition. If FCN-500 or FCN-RTU is not installed with the required I/O modules and new hardware configuration us downloaded using Resource Configurator R4.10 or earlier, existing I/O module configuration already defined will be overwritten and lost.

As an example, consider the following scenario. An engineer defines the required device labels and I/O settings for target equipment installed with the required I/O modules, and downloads the project to the FCN-500 or FCN-RTU. However, as application creation and debugging is to be carried out using an inhouse FCN-500 or FCN-RTU, he relocates the CPU module on the target FCN-500 or FCN-RTU to the in-house FCN-500 or FCN-RTU and reboots the FCN-500 or FCN-RTU. When the engineer connects to the in-house FCN-500 or FCN-RTU using Resource Configurator at this stage, the system reads a state of no I/O module. The engineer then downloads this information using Resource Configurator, resulting in I/O module information being overwritten, and information defined previously is lost permanently.

To prevent this, it is advisable not to modify hardware settings using Resource Configurator when working with no I/O module installed or from using a different set of I/O modules than what is currently defined in the configuration.

● Using Resource Configurator Editor

Resource Configurator works by first reading configuration information from a running FCN-500 or FCN-RTU, and then downloading new configuration information after it has been modified on a PC. As such, it cannot be used to perform hardware setup without a running FCN-500 or FCN-RTU.

To perform hardware setup when an FCN-500 or FCN-RTU is not available, such as in the early phase of engineering or in a job involving modification of an existing system, use Resource Configurator Editor instead.

Settings defined using Resource Configurator Editor can be saved to a file, and downloaded later using Resource Configurator when the FCN-500 or FCN-RTU is available for connection.

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3.2 Setup in Web Browser

Detailed setup and various FCN-500 or FCN-RTU operations can be achieved using FCN/FCJ maintenance homepage through a generic web browser. Among the hardware configuration items reviewed and decided as described in Chapter 2, the following items can be configured by accessing the FCN/FCJ maintenance homepage:

- Serial communication port

- Time synchronization

SEE ALSO

- Section 8.2, “Checking Serial Communication Specification (Serial Communication Port Settings)”

- Section 2.2.6, “Time Synchronization”

In addition to the above configuration items, setting system date and time, saving retain data, read log files of the FCN-500 or FCN-RTU, reading various properties of the FCN-500 or FCN-RTU , display CPU status and display resource configuration can be achieved from the FCN/FCJ maintenance homepage.

SEE ALSO

For details on the operation and configuration items accessible on the maintenance homepage, see:

- Chapter B2, “Advanced Settings Using Web Browser“ of IM “STARDOM FCN/FCJ Guide”

- Section 4.1.6, “Settings of FCN/FCJ by Web Browser“ of TI “FCN-500 Technical Guide”

- Section 4.1.6, “Settings of FCN/FCJ by Web Browser“ of TI “FCN-RTU Tec h nical Guide”

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4. Control Application Creation

Control applications executed by FCN-500 and FCN-RTU autonomous controllers are created using Logic Designer and then downloaded to the FCN-500 and FCN-RTU. This chapter describes precautions on Logic Designer setup, as well as basic principle, know-how and prohibitions on creating control applications.

For details on basic user operations of Logic Designer, see TI “STARDOM FCN500/FCN-RTU Primer – Fundamental" and the Logic Designer online help documentation.

4.1 Using Logic Designer Setup

This section describes the required setup and selection using Logic Designer before creating a control application, along with related precautions and know-how information.

4.1.1 Selecting a Template for a New Project

When creating a new project using Logic Designer, select a project type from a list of template projects. For details on how to create a new project and select a template, see Section 4.1.2, “Creating a New Project” of TI “STARDOM FCN-500FCN-RTU Primer – Fundamental.”

● Template Types and Selection Criteria

When creating a new project, the project type can be selected from the following three template projects.

• STARDOM FCX

This is the minimal template, which provides only system-defined functions and

function blocks. It does not include NPAS_POU, PAS_POU, serial communication function blocks and function blocks for Foundation Fieldbus.

As such, select this template only when creating an application that uses neither

NPAS_POU nor PAS_POU.

• STARDOM FCN-500

It is the standard template for creating control application for the FCN-500.

Necessary functions for creating the control application has been prepared in advance. (NPAS_POU, serial communication function block, function block for Foundation Fieldbus, Turbomashinary, etc.) If necessary, it is possible to add other library after creating a project.

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• STARDOM FCX_A

It is the standard template for creating control application for the FCN-RTU.

● Adding Libraries

Logic Designer allows libraries to be added to a project to expand the available functions. Similarly, an application using an APPF can be created by installing the required APPF from DVD-ROM to a PC running Logic Designer, and adding the relevant libraries to the project.

Examples:

- To create an application using NPAS POUs, select the STARDOM FCX template

when creating the project, and then add the related NPAS_POU library.

Which library to add depends on the function to be aded. For details on the type of library to be added and the procedure, see the online help documentation of each function.

● Logic Designer Libraries and FCN-500, FCN-RTU Licenses

No license is required for adding a library to Logic Designer. In other words, application development using a system function is allowed even if no license for that function is registered in the FCN-500 or FCN-RTU. However, a PLC error will be generated and the FCN-500 or FCN-RTU cannot run if a project is downloaded to an FCN-500 or FCN-RTU without registering with the required licenses for all functions used in the project. When adding a library for functionality expansion, check that the required license is registered in the FCN-500 or FCN-RTU .

SEE ALSO

Section 2.1.5, "Required Licenses”

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4.1.2 Control Task Setup

Control applications created in Logic Designer are created by assigning to tasks and turn into instances. This section describes task types and task settings.

● General Limitations of Control Tasks

All control tasks are subject to the following limitations.

• Limit on number of tasks

Up to 16 control tasks can be created for one FCN-500 or FCN-RTU. Running

only one control task on one FCN-500 or FCN-RTU is known as single-tasking, while creating and running multiple control tasks concurrently on one FCN-500 or FCN-RTU is called multi-tasking.

• Task name

A task name consists of up to 7 alphanumeric and underscore (‘_’) characters

with the following restrictions:

- A task name cannot begin with a number.

- A task name cannot contain two contiguous underscore (‘_’) characters.

- A task name cannot end with an underscore (‘_’) character.

● Types of Control Tasks

There are three types of control tasks with different behaviors.

• Cyclic

A cyclic task is run at a specified interval, known as scan cycle. This task type is

used for most control applications.

• Default

A default task has the lowest execution priority among all control tasks. It is not

executed at fixed intervals. Instead, it is executed automatically when all other control tasks are idle (not executing).

A default task is executed at variable execution intervals as its execution is

dependant on the operation of other control tasks. Hence, this task type is, in general, not used in control applications.

• System

A system task is run when there is a change in the operating status of the FCN-

500 or FCN-RTU, or when an error is detected in the FCN-500 or FCN-RTU.

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IMPORTANT

Execution triggers (status change or error) for a system tasks can be selected

from a list of predefined triggers.

System tasks are run only under specific FCN-500 or FCN-RTU conditions.

Hence, this task type is, in general, not used in control applications except for some special-purpose applications.

As default and system task types are, in general, not used in control applications, the description hereafter is limited to the cyclic task type. Moreover, the term "control task" hereafter shall refers to a cyclic control task.

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● Control Task Settings

The Task Settings dialog is used for specifying the execution interval, execution priority, watchdog time and other settings of a control task.

For details on the relationship between the execution interval, priority and watchdog time of a control task, and how these settings affect task execution, see Section

4.3.3, “Task Schedule” of TI “FCN-500 Technical Guide,” Section B4.3.3, “Task Schedule” of TI “FCN-RTU Technical Guide.”

1. Execution interval of control task

Specify the execution interval of a control task in the [Interval] field on the Task Settings dialog. The default execution interval for a new project is 100 ms. Modify it according to the value decided as described in Section 2.2.4, ”Determining FCN/FCJ Scan Cycle.”

2. Priority

When running multiple tasks concurrently on an FCN-500 or FCN-RTU, specify a value (ranging from 0 to 31 in decreasing priority) for [Priority] on the task settings dialog as the priority level of a task relative to other tasks during execution. Assigning different priority values to individual tasks running in multi-tasking mode is recommended.

3. Watchdog time

When the actual execution time of a control task exceeds the specified [Watchdog Time], a watchdog error is generated and handled according to the setup described in Section 4.1.4, “Specifying Target FCN/FCJ.” Setting the watchdog time to 0 disables the watchdog timer. Set the watchdog time to the same value as the control task execution interval as described in Section 4.1.4, “Specifying Target FCN-500, FCN-RTU” is recommended

4. Other Settings

The other settings on the Task Settings dialog including [Stack] and [Options] can be left unchanged at default values.

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4.1.3 Multi-tasking

This section describes the considerations and precautions for running multiple tasks concurrently on an FCN-500 or FCN-RTU.

SEE ALSO

For details on the behavior of the FCN-500 or FCN-RTU when multiple tasks are created, see Section

4.3.3, “Task Schedule” of TI “FCN-500 Technical Guide,” Section 4.3.3, “Task Schedule” of TI “FCNRTU Technical Guide.”

● Considerations Multi-tasking

Two possible reasons for considering implementing multi-tasking are given below:

1. To c reate control tasks having different execution intervals in an attempt to

reduce CPU load of the FCN-500 or FCN-RTU. For details, see Section

2.2.4, “Determining FCN-500, FCN-RTU Scan Cycle.”

2. To c reate control tasks having the same execution interval and priority

level for sorting control tasks to be instantiated by function.

The FCN/FCJ runs without problems even with multi-tasking. However, in multitasking mode, tasks are processed alternately at intervals of 30 ms in a time-sharing manner as described in TI “STARDOM Technical Guide” and this complicates desk investigation of control applications.

Therefore, running one task per FCN-500 or FCN-RTU is generally recommended. When deciding on control application execution, start with single-tasking and consider multi-tasking only if it is necessary.

Even when considering creating multiple tasks so as to reduce the CPU load of the FCN-500 or FCN-RTU, listed as the first reason above, first consider the option of lengthening the execution interval of a single control task, and consider multi-tasking only if the first option is disallowed by the requirement specification.

Creating multiple tasks having the same execution interval and priority for sorting purpose, listed as the second reason above, is unnecessary. Multi-tasking not only complicates system operation, it may also increase CPU load due to processing for sharing such as shared access to I/O modules. For these reasons, it is best to avoid splitting a single task into multiple tasks having the same execution interval and priority.

● Precautions When Multi-tasking

Pay attention to some precautions when using multi-tasking.

SEE ALSO

For details on precautions when multi-tasking, see Section 8.3, “Precautions about Multi-tasking" of Chapter 8, “Detailed Description."

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4.1.4 Specifying Target FCN/FCJ

The following Target dialog is used for specifying the IP address of the FCN-500 or FCN-RTU.

Besides the IP address, this dialog also displays a checkbox with the message “The task aborts when the execution time of a task exceeds a watch dog time.” The checkbox setting is explained below.

SEE ALSO

For details on how the above setting affects system behavior in the event of a watchdog error, see Section 4.3.3, “Task Schedule” of TI “FCN-500 Technical Guide,” Section 4.3.3, “Task Schedule” of TI “FCN-RTU Technical Guide." For details on how to specify the IP address of an FCN-500 or FCN-RTU, see Section 4.1.3, “Specifying Target FCN-500, FCN-RTU (by Specifying IP Address)" of “FCN-500/FCN-RTU Primer – Fundamental.”

● Defining Task Behavior upon a Watchdog Error Event

How a control task behaves when its execution time exceeds the specified watchdog time described in Section 4.1.2, “Control Task Setup” differs whether the “The task aborts when the execution time...” checkbox described above is ticked or not.

• Common behavior regardless of whether checkbox is ticked or not

If the watchdog time described in Section 4.1.2, "Control Task Setup” is set to a

value other than 0 ms, a watchdog error will be generated when the execution time of a control task exceeds the preset value.

At the same time, a watchdog error will be logged in the log file on the FCN-500

or FCN-RTU.

• Behavior when checkbox is ticked

If the checkbox is ticked, execution of the associated task will be aborted at the

same time a watchdog error is generated. The control application associated with the task also stops execution. Moreover, once aborted, execution of the task will not be restarted until the FCN-500 or FCN-RTU is rebooted.

• Behavior when checkbox is not ticked

If the checkbox is not ticked, nothing happens when a watchdog error is

generated, and the control task continues execution.

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IMPORTANT

The above description shows that if the “The task aborts when the execution time...” checkbox is ticked, control computation of the FCN-500 or FCN-RTU will stop even if only one watchdog error is generated. To prevent this, untick the “The task aborts when the execution time...” checkbox.

● Watchdog Time Setting

On the other hand, monitoring task execution time using watchdog time provides important diagnostic information about the current state of the system. Therefore, set the watchdog time described in Section 4.1.2, “Control Task Setup” to the same value as the scan cycle to enable monitoring of the execution time of a control task. In this way, a watchdog error will be generated and recorded in the system log file whenever a control task fails to complete execution within the specified duration.

Moreover, as described in Section 2.2.3, “Checking FCN-500, FCN-RTU Performance,” control execution time increases as CPU load increases. In cases where an increased CPU load for whatever reason is expected to affect the entire system, set the watchdog time to a value between 80% and 90% of the scan cycle. With this setting, a watchdog error will be generated whenever the CPU load (%) exceeds 80% to 90%, thus providing an effective means for monitoring the CPU load.

Do not tick the “The task aborts when the execution time...” checkbox when using a redundant CPU. Watchdog time modifications cannot be applied through an online download. To apply a watchdog time modification, stop the FCN-500 or FCN-RTU and perform an offline download.

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FCN01 FCN02 FCN03

Project

Project01

Project02 Project03

4.1.5 Multi-resource Project

In Logic Designer applications, FCN-500s or FCN-RTUs are called resources and one FCN-500 or FCN-RTU controller maps to one resource.

In the example shown in the figure below, a system comprises three FCN-500s so three resources are created. When creating projects for this system, you can choose either to create three resources within one project, as indicated by the solid line, or create three projects, one for each resource, as indicated by the dotted lines.

In cases like this where there is more than one resource within a system, consider and decide whether to create one project containing multiple resources, or one project per resource.

When creating a multi-resource project, the number of resources that can be defined within one project of Logic Designer is limited to 100 as described in Section 4.1.6, “Application Size.” This system limit, though present, is actually large enough for most practical systems.

On the other hand, creating one project per resource requires creating as many projects as the number of resources, which makes project management on the development PC more tedious.

Hence, in principle, create only one project even if there are multiple resources within a system is recommended.

However, having many resources within one project makes engineering work more tedious and may cause confusion. Therefore, we recommend limiting the maximum number of resources per project to between 5 and 10.

TIP

This recommendation for limiting the maximum number of resources within one project to between 5 and 10 is based on considerations of efficient project management and engineering. The system itself can accommodate up to 100 resources per project so even defining more than 10 resources per project is not a problem.

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4.1.6 Application Size

The upper limit for the size of an application is described in Section 2.2.2, “Checking FCN-500, FCN-RTU Control Application Size." In addition to application size, the system imposes limits on the number of resources, the number of logical POUs, etc. While these limits are described in Logic Designer’s online help documentation, we elaborate on some of the more important limits here.

1. Maximum number of resources in the project tree: 100

2. Maximum number of program instances in the resources: 1000

This is the maximum number of logical POUs that can be created as an instance in one resource (FCN-500 or FCN-RTU).

3. Maximum number of tasks in the resources: 16

This is the maximum number of tasks that can be defined for one resource (FCN-500 or FCN-RTU).

4. Maximum number of program instances in the tasks: 500

5. Maximum number of global variables: 15000

6. Maximum number of local variables in the logical POUs: 15000

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7. Maximum value of code size in the logical POUs: 200KB

This is the upper limit on the size of one logical POU. If the size of a logical POU exceeds 200 KB, a compiler error is generated. If the size exceeds 80% of 200 KB, a compiler warning is displayed.

8. Maximum number of input/output parameters of the functions/function blocks:

300

9. Maximum number of logical POUs in the projects: 2000

10 Maximum number of POU instances that can be defined in project: 64000

11. Maximum number of code worksheets in the logical POUs: 255

12.Maximum number of types of available functions/function blocks in the logical

POUs: 620

13. Maximum number of available functions/function blocks in the logical POUs:

1024

14. Maximum number of jumps and labels in the logical POUs: 750

15. Maximum number of contacts/coils in the logical POUs: 3600

TIP

As the above list of system limits is not exhaustive, browse the above-mentioned online help documentation before creating your application.

SEE ALSO

For details on the Jump function, see Section 9.1.7, “Jump, Connector and Return Functions” of Chapter 9, “Advanced Engineering.” For details on user-defined function blocks, see Section 4.7, “Application Encapsulation.”

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4.2 Application Programming Languages

Logic Designer supports 5 types of programming languages for creating control applications. This section describes the characteristics of each of these languages, and the types of applications for which they are best suited.

4.2.1 Programming Languages Supported by Logic Designer

Logic Designer supports 5 types of programming languages conforming to the IEC 61131-3 standard for creating applications.

• FBD (Function Block Diagram)

In FBD, functions, application blocks and NPAS_POUs are provided as blocks

and connected using signal lines, along which data is propagated. FBD offers a visual representation of data flow, and is thus ideal for programming regulatory control of analog signals.

• LD (Ladder Diagram)

LD is the most widely used language for programming PLC applications, where

logical computations are coded using symbols of contacts and coils as basic components.

Besides offering a visual representation of data flow like FBD, LD allows not only

analog signals but also digital signals to be represented visually using BOOLtype contacts and coils.

• SFC (Sequential Function Chart)

An SFC consists of steps, transitions and actions. While a step is active, actions

coded within the step are executed. When the transition of the step becomes true, the following step then becomes the active step, and its actions are executed until its transition becomes true, and so on.

SFC’s step-by-step processing makes it ideal for building process progress type

applications and sequence control applications.

• IL (Instruction List)

In IL, each line consists of one operator and its operands, so coded expressions

are unambiguous but it is cumbersome for coding complex logical relations.

• ST (Structured Text)

In ST, control applications are coded using text. ST allows conditionals, such as

IF, CASE and FOR statements, as well as complex calculations to be coded easily. As such, it is well suited for conditional decision and calculation processing.

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FBD

(Function Block Diagram) LD (Ladder Diagram) ST (Structured Text) IL (Instruction List)

SFC

(Sequential Function Chart)

Step execution languages

Continuous

execution

languages

Graphical

languages

Text-based

languages

These five languages can be broadly classified into continuous execution languages and step execution languages. FBD, LD, IL and ST belong to the former group, whereby application content is executed continuously, while ST belong to the latter group, whereby application content is segmented into and executed as steps. FBD, LD, IL and ST can be further classified into graphical languages and textbased languages, with FBD, LD belonging to the former group, and ST, IL belonging to the latter group.

TIP

As IL is seldom used in practice, descriptions about continuous execution language type hereinafter will be limited to three programming languages, namely, FBD, LD and ST.

4.2.2 Selecting a Programming Language

Logic Designer allows programming language to be selected on logical POU (program, function, function block) basis. When using SFC, programming language can also be selected on transition or action basis. While a programmer may select any language according to preference, it is important to select a language suited for a specific purpose to fully exploit its unique features. For details on selection of programming language, see Section 8.4, “Criteria for Selecting Programming Languages in Logic Designer.”

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4.3 Principles of Application Creation

In previous sections, we discussed task settings and selection of programming language in Logic Designer. This section discusses some principles for good application creation.

4.3.1 Principles of Application Creation

When creating a function in Logic Designer, consider different techniques but select an appropriate language and creating a simple application are the two principles that should be adhered to.

● Select a Suitable Language

Select a programming language suited for creating application according to the selection criteria for programming language described in Section 8.4, “Criteria for Selecting Programming Languages in Logic Designer” of Chapter 8, “Detailed Description.” Using a programming language not suited for an application leads to complicated logic, with greater likelihood of bugs.

● Simple Application

Creating an application that is easy-to-understand simplifies logic checking at the time of application creation. It increases the accuracy of desk debugging, and reduces the number of bugs during application creation.

Moreover, a simple application is not only easily understood by the developer himself but also by other engineers. For ease of future job handover to other engineers as the development team grows, it is important to create simple applications that are easy-to-understand.

4.3.2 Example of a Simple Application

We discuss the concept of simple application with a concrete example below.

● Segmentation of Code Worksheet

Logic Designer allows more than one code worksheet to be created within one logical POU. Exploit this feature by segmenting logic to be created by function and creating one code worksheet for each function. Doing so yields simple worksheets and clear worksheet segmentation by function.

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Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern A

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern B

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern C

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Unsegmented worksheet

Consider the example logic to be created below, which consists of multiple analog inputs, NPAS_PIDs and analog outputs, as well as logic for setting MV to MAN, 0%, PV value calculation processing and logic for writing SV value for the NPAS_PID.

This application can be segmented by function into four pieces: analog I/O and NPAS_PID; logic for setting MV to MAN, 0%; PV value calculation processing and logic for writing SV value. The first option is to create one worksheet for each segment, as shown in segmentation pattern A below.

As the logic for setting MV=0% and logic for writing SV value are relatively simple, including their codes into the same worksheet for analog I/O and NPAS_PID may increase ease of understanding. This option for worksheet creation is shown in segmentation pattern B above.

Over segmentation may sometimes lead to a more complicated application. In segmentation pattern C, the analog I/O and NPAS_PID function is segmented into three pieces, namely, analog input, NPAS_PID, analog output. The figure below shows the actual view displayed in Logic Designer after creation.

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Analog input

NPAS_PID

Analog output

Program POU A

MV=0% sequence logic

Program POU B

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

ＰＶ value calculation processing

Logic for writing ＳＶ value

Unsegmeted program POU

Logic for writing ＳＶ value

Program POU C

PV value calculation processing

Program POU D

IMPORTANT

In this segmentation, while the worksheet is organized by individual functions of analog input, NPAS_PID and analog output, the connections between the NPAS_POUs are not implemented by direct links, but implemented through data passing by variables. As a result, the data flow and inter-block relationships are not visually captured, which destroys one of the features of FBD. This counter example shows how over segmentation can produce a more complicated application.

In short, code worksheet segmentation by function is necessary for creating simple applications but over segmentation may actually increase complexity.

● Segmentation of Program POU

Besides code worksheet segmentation, program POU creation by function is also allowed.

However, doing this increases complexity as connections between program POUs are implemented through global variables instead of local variables. Therefore, unless there are special reasons such as the size of one program POU exceeding the system limit, segmenting a program POU is not recommended.

If the data in the FCN-500 orFCN-RTU is referenced from the outside (e.g. via FCN/FCJ OPC server), you need to pay attention to the length of a variable name and a POU instance name..

- Variable name, instance name: up to 30 characters The hierarchy of POU can be up to 6. If it is referred to as "POU instance name .POU instance name .------. Variable name", it will be up to 216 characters.

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Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Example in Section 4.3.2

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

Logic for writing SV value

PV value calculation processing

Result of investigation

Component 1

Component 2

4.3.3 Bottom-up Application Creation

In Section 4.3.2, “Example of a Simple Application," we have investigated code worksheet segmentation and logical POU segmentation. After deciding on the organization of the code worksheets and logical POUs, create the control application in a bottom-up manner starting from the smaller parts by investigating which parts, if any, should be combined or componentized.

In the example given in Section 4.3.2, the application is divided by function into 4 parts: analog I/O and NPAS_PID; logic for setting MV to MAN, 0%; PV value calculation processing and logic for writing SV value.

- Analog I/O and NPAS_PID

Create this part without encapsulating as there is no special need to do so.

- Logic for setting MV to MAN, 0%

Consider encapsulating this part to enable reuse in multiple locations.

- Logic for writing SV value

Consider encapsulating this part to enable reuse in multiple locations.

- PV value calculation processing

Consider encapsulating of this part to enable reuse in multiple locations.

Comparing the logic for setting MV to MAN, 0% and the logic for writing SV value, both logics write to access parameters, and are executed when a condition is true so they can also be created collectively as one component without any problem. On the other hand, the logic for calculation processing of PV value is always executed regardless of condition, and thus must be created separately from the above two parts.

From the above discussion, the example given in Section 4.3.2 can be created into three parts, namely, Analog I/O and NPAS_PID; component for setting MV to MAN, 0% and writing SV value and component for PV value calculation processing, as shown in the figure below.

After deciding on the organization of the code worksheets and logical POUs, create the application through bottom-up investigation and combination, starting from the smaller logics.

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4.4 Application Creation Know-how

Control application is created using Logic Designer. For details on know-how relating to control application creation, see Chapter 9, “Advanced Engineering.”

Section 9.1, “General Application Development Know-how ” of Chapter 9, “Advanced Engineering” Section 9.2, “Know-how in Use of NPAS_POU” of Chapter 9, “Advanced Engineering”

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automatically.

(2) Specify variable names (tag names).

(1) Select a suitable network

the list.

4.5 Network Templates

In the term “network template”, network refers to control logic connections, and network template refers to a control logic (circuit diagram) model. Model codes are made into templates to enable code reuse. Use of network templates simplifies control logic construction.

Basic control loop templates, published on the Members Only Page of the “Yokogawa Partner Portal STARDOM” website (https://partner.yokogawa.com/global/member/rtu/nettemp/index.htm), can be downloaded and copied into a prescribed folder for reuse. For more details, read the documentation accompanying the templates.

(3) Circuit diagram is generated

template (model code) from

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4.6 Application Encapsulation

User-defined POUs and function blocks can be registered in Logic Designer. This section describes the features of user-defined POUs, how to create these POUs and the relevant precautions.

4.6.1 Features of Application Encapsulation

● What is an Application Encapsulation?

Application encapsulation in this document refers to user-created logic defined as a user defined POUs. It may also include system-defined functions, system-defined function blocks or NPA S POUs. User defined POUs can be created using any programming language.

● Deciding on Encapsulating Applications

Before encapsulating certain logic, first investigate whether it is indeed necessary to encapsulate logic. As described later, the merits of encapsulating lie in more efficient application creation and debugging arising from using a registered component in multiple places.

As such, encapsulating logic that is used in only one place in Logic Designer has little merit. On the contrary, you should consider encapsulating application when the same logic is used in multiple places in Logic Designer.

● Merits of Encapsulating Application

Followings are the benefits.

1. Reduced application creation effort

To create logic by copying logic from another location in Logic Designer, first

specify the range for copying, execute a copy and paste, and then modify the function block names and variable names in the copied logic.

Moreover, such work has to be repeated for all copies of the logic in different

locations.

On the other hand, encapsulating logic, like system-defined function blocks and

NPAS POUs, are created not by copying but by definition using the Edit Wizard.

Compared to copying, definition using Edit Wizard is simpler and

componentization is expected to save application creation effort.

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2. Reduced debugging effort

As described earlier, besides copying and pasting, creating logic by copying also

requires modification of variables names. Such hand work must be checked using desk debugging, as well as actual operation.

Encapsulated logic, on the other hand, runs exactly the same way wherever it is

used in Logic Designer.

In other words, using a debugged and proven encapsulated logic in another

place does not require rechecking of its internal logic.

In practice, variable assignment validation and simple execution validation is still

required but compared to the checking required for copied logic, application encapsulation is expected to save debugging effort.

3. Better support of specification changes

Sometimes, created logic needs to be modified to support a specification change

or fix a bug.

For logic created through copying, any modification has to be repeated in all

copies of the logic. Moreover, there is a risk of missing some modifications.

Encapsulated logic, on the other hand, requires only the registered component to

be modified for the modification to be reflected in all places where the encapsulated logic is used.

In other words, even if a encapsulated logic used in many places, only one place

needs to be modified, which translates into better support of specification changes.

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4.6.2 Procedure for Creating a POU

This section describes the procedure for creating a POU using as example the logic for detecting a mode, status or alarm condition of an NPAS POU given in Section

9.2.2, “How to Detect Mode, Status and Alarm” of Chapter 9, “Advanced

Engineering.”

● Selecting Usage for Variables of a POU

When creating a POU, the property of a variable its usage can be selected. The five available usage options are VAR, VAR_EXTERNAL, VAR_INPUT, VAR_OUTPUT and VAR_IN_OUT. Among these, VAR and VAR_EXTERNAL are similar with general programming languages.

VAR_INPUT : External data to be read into a POU

Besides global variables, data of VAR_INPUT type are read and used for calculation within a POU.

VAR_OUTPUT : Output data from a POU

Select VAR_OUTPUT type for outputting internal calculation results of a POU.

VAR_IN_OUT :Select VAR_IN_OUT type for external data to be read into

a POU, overwritten and then re-output from the POU.

When creating a POU, in addition to VAR and VAR_EXTERNAL, VAR_INPUT, VAR_OUTPUT and VAR_IN_OUT can be used.

● Procedure for Creating a POU

Create the control logic shown in the figure below as a POU.

1. Register a POU

1.1 Right-click on [Logical POUs] in Logic Designer, and then select [Insert]-

[Function Block] from the pop-up menus.

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1.2 On the displayed dialog, specify a POU name and language. Click [OK]. For this

example, specify “SAMPLE” for the name and select “FBD” for the language.

1.3 A user function block named "SAMPLE" is created under [Logical POUs]. Next,

create logic within this block.

2. Create logics

2.1 Open the SAMPLE code worksheet, place one AND function block and one EQ

function block, and then connect the output terminal of the AND function block to the input terminal of the EQ function block.

2.2 Double-click the input terminal of the AND function, and specify a variable name,

usage and data type on the displayed dialog.

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For this example, specify "IN" for [Name]. This becomes the terminal name of the

POU. As this terminal is to be used for reading external data into the POU, select "VAR_INPUT” for [Usage]. Select “DWORD” for [Data Type] (the same data type for an NPA S POU mode, status or alarm condition).

2.3 Similarly, create terminals to be connected to the mode, status or alarm condition

global variable. For this example, specify "GM” for name, "VAR_INPUT” for [Usage] and “DWORD” for [Data Type] (the same data type as the system global variable). Connect GM to the terminals of AND and EQ.

2.4 Create a terminal for outputting the calculation result of the POU.

For this example, specify “OUT” for [Name], “VAR_OUTPUT” for [Usage] and “BOOL” for [Data Type] (the same data type as the output terminal of EQ), and then connect the variable to the output terminal of EQ. This variable is the terminal for outputting result to the external.

2.5 This completes the creation of the logic. Compile the project.

3. Paste to Logical POU

3.1 In Edit Wizard, the created POU is displayed in green. Created POUs can be

treated like any other functions, functions blocks and NPAS POUs.

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3.2 In the figure below, the first row shows the basic logic of the POU while the

second row shows two logics, which make use of the created POU for detecting HH and LL alarms of NPAS_PVI_1 respectively.

(*Detects HH alarm of PVI_1*)” (*Detects LL alarm of PVI_1*)

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4.6.3 Modifying Logic of a POU

This section describes the procedure for modifying a created POU along with precautions.

● Precautions on POU Modification

1. Selective Modification of POU is not Allowed

As described in the merits of componentization in Section 4.7.1, “Features of Application Encapsulation,” once a registered POU is modified, the modification will be reflected in all logic using that POU. This also means that it is not possible to apply a logic modification to some applications. A new POU should be created if previous logics have to be kept in some applications.

2. When increasing or decreasing the number of I/O terminals

Some logic modifications may involve increasing or decreasing the number of I/O terminals. For FBD or LD code worksheets, increasing or decreasing the number of I/O terminals involves a graphical change. To apply a graphic change requires redefinition of the POU as described later.

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● Procedure for Modifying a POU

This section describes here the procedure for modifying a POU, using an example involving adding an input terminal to the “SAMPLE” POU created in Section 4.7.2, “Procedure for Creating a POU.”

Change in requirement specification

The OUT terminal is to be turned on if the mode, status or alarm condition

becomes true and remains true for a certain duration, which can be specified individually for each logic.

1. Add an input terminal

Open the variable worksheet of user function block “SAMPLE,” and define a new

terminal.

For this example, specify “TM” as the name of the input terminal for setting the

duration, “VAR_INPUT” as its usage and “TIME” as its data type.

Precautions when adding terminals

- Sequence of variables The sequence of terminals follows the sequence of the variables on the

variable worksheet. In the above figure, three VAR_INPUT type variables are defined with the following sequence: IN, GM and TM. The terminals of the user function block follow the same sequence: IN, GM and TM.

- Initial value of variable The initial value of input terminal “TM” is defined as “TIME#1s”. With this setup, if terminal “TM” is connected to nothing, its default value is 1

second.

In this example, if terminal “IN” or terminal “GM” is connected to nothing, this

comparison logic would be meaningless so this case is not considered in the logic.

However, terminal “TM” is used for setting the duration so even if it is

connected to nothing, the comparison logic is still meaningful.

Therefore, a default value is defined in case that terminal “TM” is connected

to nothing.

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2. Modify the control logic

Modify the logic within the user function. The figure below shows the logic after modification using jump and return

functions described in Section 9.1.7, “Jump, Connector and Return Functions” of Chapter 9, “Advanced Engineering.”

Firstly, if the mode, status or alarm condition becomes true, variable “V001”

becomes true. Next, the preset duration TM is compared against 0 second using EQ. If the preset duration is 0 second, logic execution jumps to label “TM_SET_0s”,

skipping TON_1. As a result, terminal “OUT” becomes true when the condition is

true without executing the duration logic.

On the other hand, if TM is set to a non-zero value, the jump is ignored and

TON_1 is executed. Moreover, as a RETURN function is coded below TON_1, subsequent logic is

not executed if a duration is specified using TM.

After modifying the control logic, compile the project.

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(*Detects HH Alarm of PVI_1*)

3. Redefine the control logic

The modification of the control logic is completed. However, adding terminal “TM” involves a graphical change, which is not

reflected graphically in Logic Designer unless the POU is redefined in Logic

Designer.

3.1 Click “PVI_1_HH,” whose logic has been modified. The display is shown in the

figure on the right below.

3.2 In this state, double-click user function block [SAMPLE] in the Edit Wizard.

3.3 A dialog is displayed. Click [OK] without modifying anything.

3.4 This completes redefinition of the POU with the added terminal. Connect a

variable to terminal TM and specify the required duration. If no variable is connected to terminal TM, the duration defaults to the initial

value of 1 second as described in point 1 above.

(*Detects HH alarm of PVI_1*)” (*Detects LL alarm of PVI_1*)

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4.7 Handling Compile Errors and Warnings

When compiling a project in Logic Designer, compile errors and warnings may sometimes be displayed as a compile result.

A compile error indicate the presence of a system error or a syntax error in the application program that prevents successful completion of compile. Performing downloading without first removing all compile errors will cause invalid code to be downloaded, thus affecting normal control. To avoid this, always fix and remove all compile errors before downloading.

On the other hand, compile warnings are not errors but may also affect normal control if ignored. Fix all reported compile warnings.

TIP

Performing downloading without first removing all compile errors will cause the following dialog to be displayed.

Figure Compilation Error Message Dialog

● Compile Warning Example

Shown below is a list of warnings generated during compile of a project. The list of warnings includes a warning which, if left unresolved, affects normal control.

Message displayed at the end of compile

0 Error(s), 34 Warning(s)

Detailed description of warnings

Worksheet empty. Worksheet empty. : : Variable 'NewVar4' is never used. Variable 'NewVar3' is never used. Variable 'NewVar2' is never used. Variable 'NewVar1' is never used. Variable 'ALARM_HI' is never used. Instance 'SAMPLE_1' is never used. Instance 'R_TRIG_1' is used more than once. Variable 'V07' is never used. Variable 'GM_ALRM_HI' is never used. Variable 'V006' is never used. Variable 'V007' is never used.

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Variable 'V008' is never used. Variable 'V009' is never used. Variable 'V011' is never used. : Among these warnings, the warning “Instance 'R_TRIG_1' is used more than once.” indicates a real problem. From the warning, we know that function block “R_TRIG” for detecting a rising edge is used in multiple places with the same name “R_TRIG_1”.

Problem

Consider the following scenario. Variable “a,” which is connected to input parameter CLK of R_TRIG_1 in one location becomes ON and remains ON after R_TRIG_1 detects the rising edge and performs output. Variable “b,” which is connected to input parameter CLK of R_TRIG_1 in another location now becomes ON. As variable “a” connected to input parameter CLK of R_TRIG_1 in the first location remains ON after the first rising edge is detected, R_TRIG_1 fails to detect the rising edge in variable “b” and thus performs no output. In other words, the rising edge in variable “b” goes undetected.

This is an example where leaving an unresolved warning affects normal control.

● Recommendation: Fix All Compile Warnings

In the above example, one out of 34 warnings indicates a real problem. When there are not so many warnings (say 30 or less), it may be easier to spot a problematic warning among all displayed warnings. However, when there are many warnings, it is possible that a problematic warning in the midst may be ignored.

As such, fixing all compile warnings is recommended, even if they are nonproblematic, to avoid missing out a problematic warning.

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4.8 Precautions About Downloading

A control application can be downloaded to the FCN-500 or FCN-RTU after successful compile. This section describes some precautions about downloading.

For details on this topic, read the online help documentation shown below.

TIP

In this document, unless otherwise stated, download refers to downloading a project to the main memory.

4.8.1 Offline Download and Online Download

A control application can be downloaded in offline mode or online mode.

- Offline download

There are no restrictions associated with offline downloading except that control

operation on the FCN-500 or FCN-RTU stops at the time of download.

SEE ALSO

For details on the relationship between start mode and retain data after offline downloading, see Section 2.2.5, “Retentive Variables (Retain Data) Considerations.”

- Online download

Online download allows changes to be made to a control application without

stopping control operation on the FCN/FCJ.

However, online download limits some of application modification.

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IMPORTANT

Error

Action

Division by zero occurs (integer variables)

The task will stop.

Data exceeds the range of the array or

The operation of a task differs in the target setting

The memory contents next to the array may be broken.

An error occurs in a string operation

STRING type data(*1)

The task will continue. If string processing continues,

The execution of the task is not completed

The task will stop when the check box "The task aborts

A stack is overflowed

The task will stop when the check box "Stack check" on

checked.

Error items to be checked during the execution of the control application are shown in the table below. If an error occurs, the task may stop and multiple error messages may be displayed. In this case, online downloads are no longer enabled. Once again, please download project offline. Please test the project to avoid the error before performing an online download. For details, see 9.1.14, “Avoidance of the Error during Execution.” Errors are confirmed on FCN/FCJ system alarm message during operation and message window on Logic Designer during programming and debugging.

Table Operation of the Control Application Error

structure

EX1: Input more than 32 bytes a characters as

STRING(32) type data

EX2: Input more than 80 bytes a characters as

within the watchdog time

*1：STRING type is usually up to 80 bytes.

dialog. When the check box “Array boundary check” on the extended setting is checked, the task will stop. (recommended) Please check the array boundary. If you do not check, the task will not stop.

multiple error messages are displayed.

when the execution time of task exceeds a watch dog time." in the target setting dialog is checked.

the extended setting in the target setting dialog is

SEE ALSO

For details on online downloading, see Chapter B3, “Online Download" of IM “STARDOM FCN/FCJ Guide.”

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(1)

(2)

(3)

(4)

4.8.2 Downloading Boot Project and Source

This section describes downloading boot project and source .

SEE ALSO

For details on boot project and source, see Section 4.8.4, “Importance of Boot Project” and Section

4.8.5, “Importance of Source.”

● Boot Project

A boot project is stored on the on-board flash memory and loaded automatically into main memory when the FCN-500 or FCN-RTU is powered on and control begins.

● Source

A source is a Logic Designer project stored on the flash memory. A source is downloaded to the flash memory by Logic Designer. The project is compressed into zwt format before download. A project in Logic Designer can be restored by uploading its source from the flash memory.

4.8.3 Detailed Description of Download Dialog

The following picture shows Logic Designer’s Download dialog.

1. Include Bootproject; Include Sources

Ticking the checkboxes enclosed by blue box (1) causes the boot project and sources to be downloaded at the same time when the project is downloaded.

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2. Download Source

Clicking the [Download Source] button enclosed by blue box (2) causes only the source to be downloaded to the flash memory. As source download is performed during the CPU’s idle time, it will not affect control operation if the CPU load is below the recommended limit of 60% as described in Section 2.2.3, “Checking FCN-500, FCN-RTU Performance.”

Use of the User-Libraries, Pagelayouts and Backend-Code checkboxes are described in detail in Section 4.10, “Control Application Backup” but these three checkboxes should in general be left unticked.

Clicking the [Delete Source on Target] button causes existing source loaded in the flash memory to be deleted.

3. Download Boot Project

Clicking the [Download] button enclosed by blue box (3) causes only the boot project to be downloaded to the flash memory. Like source download, boot project download is performed during the CPU’s idle time so it will not affect control operation if the CPU load is below the recommended limit of 60%.

4. Download File

Clicking the [Download File] button enclosed by blue box (4) allows any file to be downloaded to the flash memory for storage.

SEE ALSO

For details on how to download a project, see Section 4.6, “Hands-on: Downloading a Project” of TI “STARDOM FCN-500/FCN-RTU Primer – Fundamental.”

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4.8.4 Importance of Boot Project

It is extremely important to download the latest project to the boot project in real systems.

As described in Section 4.8.2, “Downloading Boot Project and Source,” when the FCN-500 or FCN-RTU is powered on, it begins control using the boot project. If the boot project is out-dated, powering off and then on the FCN-500 or FCN-RTU will cause control to be started with an out-dated control application.

A Case Story

In daily operation, an application was modified using online download and its operation tested but the changes were not downloaded to the boot project. At the next routine inspection, the FCN-500 or FCN-RTU was powered off and then powered on. The FCN-500 or FCN-RTU started control using the boot project, which was outdated, so control was unfortunately started with an old control application instead of the latest control application used before the routine inspection.

To avoid this unfortunate scenario, we recommend downloading the boot project at the same time whenever the project is downloaded to the FCN-500 or FCN-RTU. Specifically, this means ticking the [Include Bootproject] checkbox as shown within blue box (1) in the picture given in Section 4.8.3, “Detailed Description of Download Dialog.” If it is not feasible to download the boot project at the same time as the project for some reason, download the latest control application to the boot project subsequently using the button enclosed by box (3) of the picture shown in Section

4.8.3.

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4.8.5 Importance of Source

As described in Section 4.9.2, “Downloading Boot Project and Source,” a source is actually a Logic Designer project compressed into zwt format and stored on the flash memory. Moreover, by a simple operation, a project can be restored on a PC by uploading the source.

Whether a source is present on the flash memory does not directly affect control operation on the FCN-500 or FCN-RTU but a source can be used as a backup copy of the application.

A Case Story

A Logic Designer project created on a PC is normally backed up to a server or other media for safekeeping. However, when the PC was damaged or replaced, it was discovered that the backup copy was missing or may not be the most up-to-date, making project recovery difficult.

In such unfortunate situations, if the source of the latest project had been downloaded to the flash memory previously, restoring the Logic Designer application would be easy.

While keeping a backup copy of a Logic Designer application on a server or other media is basic, we also recommend saving the source on the flash memory just in case.

Specifically, ticking the [Include Sources] checkbox as shown within blue box (1) in the picture given in Section 4.9.3, “Detailed Description of Download Dialog” causes the source to be downloaded at the same time as the project. If it is not feasible to download the source at the same time as the project for some reason, download the source of the latest control application subsequently using the button enclosed by box (2) of the picture shown in Section 4.9.3.

Logic Designer R4.02.01 and later versions allow a project on a PC and a project on a FCN-500 or FCN-RTU to be compared. For details, see 9.1.13, “Comparing Logic Designer Projects.”

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4.9 Control Application Backup

Daily backup of control applications is important to guard against damage or replacement of he PC used for creating the control applications. This section describes the procedure for application backup.

● Folder for Storing Logic Designer Applications

Applications created using Logic Designer are stored in the following folder on the PC: <Logic Designer’s installed path>\FCN-FCJ\LogicDesigner\Projects If Logic Designer is installed in its default location, this folder corresponds to: C:\YOKOGAWA\FCN-FCJ\LogicDesigner\Projects

Within this folder, application data is stored in a folder having the same name as the Logic Designer project and a file named “<project name>.mwt”. Depending on the size of an application, the folder named after the project may be several tens of megabytes, making direct backup a little difficult. In this case, compress the application into a zwt format file first and backup the compressed zwt file. Typically, a folder several tens of megabytes can be compressed into a zwt file below 1 megabyte.

● Procedure for Compressing a Project into zwt Format

1. Select [File]-[Zip and Save As] from Logic Designer’s menu bar.

2. On the displayed dialog, select “Zipped Project Files (*.zwt).”

3. When “Zipped Project Files (*.zwt)” is selected, the Zip Options checkboxes are

enabled for selection. Unless required for some reason, these options should

generally be left unticked. Click [Save].

4. A compressed “zwt” file will be created in the folder displayed in the dialog.

5. Save a backup copy of the compressed zwt file.

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TIP

The Zip Options checkboxes should generally be left unticked unless page layout has been edited. Even if you are creating a user library, user library, please do not compress. It will also be compressed libraries such as NPAS POU and APPF POU at the same time. When you unzip the compression project in a different environment, it will be different versions of the POU are mixed. It is recommended to separately manage the user library.

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5. Function Test (Debugging)

Function test is synonymous to debugging, and involves checking whether a created control application runs in compliance to a requirement specification and checking for application bugs. Function test may also help discover contradictions in the requirement specification. This chapter describes know-how and precautions relating to debugging of FCN-500 and FCN-RTU applications.

5.1 Equipment Used for Testing

Function test of a control application may be carried out using the target equipment, in-house test equipment or FCN/FCJ simulator. This section describes precautions to these test environments.

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5.1.1 Precautions of Testing When Using In-house Equipment

When using in-house test equipment for debugging, the test environment may be different from the target equipment.

● Style of CPU module

When debugging a new system, the FCN-500 or FCN-RTU of the in-house test equipment used for debugging may be of an older version and its style number of the CPU may be different from that of the target equipment. On the other hand, when testing a modification of an existing system, the production FCN-500 or FCN-RTU may be old and the style code of its CPU may differ from that of the in-house test equipment.

A control application can be debugging using in-house test equipment whose CPU style code differs from that of the target equipment or production equipment, provided some restrictions and precautions to be described later are observed.

• How to check style code of CPU

Connect to the FCN/FCJ Maintenance homepage using a Web browser to

display the Top Page as shown in the figure below. On the Top Page, check the displayed Type, which is enclosed by a blue box

below.

In the above figure, "S1U" is displayed after the model name (“NFCP502-W05”)

of the CPU module, indicating the latest S1 style CPU.

SEE ALSO

For details on checking CPU load, see Section 5.5.1, “Checking CPU Load.”

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● Revision of CPU module

Before starting debugging using in-house test equipment, check the revision of the FCN/FCJ Basic Software (OS) stored on the CPU module. When testing using in-house equipment, the FCN/FCJ OS stored on the CPU module may not be of the latest revision and thus should be checked.

• How to check revision of system card

Connect to the FCN/FCJ Maintenance homepage using a Web browser to

display the Top Page as shown in the figure below. On the Top Page, check the displayed OS Revision and BootROM Revision,

which are enclosed within a blue box below.

After determining the revision of the CPU module of the in-house test equipment, check whether it matches the revisions of the tools verified in Section 2.2.1, “Checking Revisions of FCN-500, FCN-RTU and Tools.” If the revisions differ, upgrade or downgrade accordingly to match the revisions.

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● Suffix code on CPU module

Consider whether the suffix code on CPU module of the in-house test equipment differ from the suffix code for target equipment. Compare the suffix code on CPU module of the in-house test equipment against the suffix code for target equipment, and check for any debugging problem.

Debugging Problem Example 1

To create a using NPAS POU application, an FCN-500 extended type (with

NPAS license) was purchased for the target equipment, but the NPAS POU

license was not included in the FCN-500 standard type for the in-house test

equipment.

Debugging Problem Example 2

As there is no need to use NPAS_POU, NFCP501 standard type (without NPAS

license) was purchased for the target equipment. However, the in-house

development equipment has FCN-500 extended type (with NPAS_POU license),

and an engineer created an application using NPAS_POU without realizing that

FCN-500 standard type (without NPAS_POU license) was purchased for the

target equipment.

In this example, the FCN-500 of the in-house equipment ran normally during

function test as an NPAS_POU license was present. However, when the application was moved to the target equipment, the FCN-500

no longer runs and it was necessary to either fix the application or purchase an

FCN-500 extended type for the target equipment.

● Installed I/O Modules

As described in Section 5.5.1, “Checking CPU Load,” CPU load includes I/O module access. If the I/O modules installed on in-house test equipment differ from those to be installed on the target equipment, an accurate CPU load cannot be reflected so CPU load checking cannot be done on the in-house test equipment.

● Duplexed Parts

In a STARDOM system, the CPU of the FCN-500, the power supply module, the E2 bus/SB bus, the control network (Ethernet) and the communication application can be duplexed. However, parts required to be duplexed in the system may not be duplexed in the inhouse test equipment. In such cases, investigate whether there is any problem with performing function tests without duplexing, and how to perform switchover test for the duplexed parts.

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5.1.2 Precautions of Testing When Using FCN/FCJ Simulator

The FCN/FCJ Simulator tool is used to simulate the execution of a control application on a PC. Using a FCN/FCJ Simulator allows the function test of a control application to be carried out on a PC without an FCN-500 or FCN-RTU. For details on the FCN/FCJ Simulator, see the online help documentation of the FCN/FCJ Simulator.

Functions Not Supported by FCN/FCJ Simulator

The FCN/FCJ Simulator does not support the following functions.

• I/O function

Input to I/O cannot be done as no I/O module can be installed.

• CPU duplex function

Switchover test for a duplexed CPU cannot be done as the FCN/FCJ Simulator

can only simulate a single CPU.

• Network duplex function

Switchover test for a duplexed network cannot be simulated as the FCN/FCJ

Simulator can only run with a single network.

• FCN/FCJ Maintenance page (Web)

• Upload/download to Resource Configurator

• Duolet runtime environment

The Duolet Application Development Kit is used for development and execution

(debugging) of Duolet applications. The FCN/FCJ Simulator only provides an

environment for accessing variables defined in a running control application.

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• Communication function of POU performing communication processing

Inter-FCN/FCJ communication, Modbus communication, serial communication,

Ethernet communication, communication using communication POUs, etc.

cannot be done.

● Items that can be debugged using FCN/FCJ Simulator

As described earlier, the I/O function is not supported by the FCN/FCJ Simulator. Therefore, debugging using FCN/FCJ Simulator is in fact debugging with I/O in disconnected state. Moreover, as various communication modules using communication POUs are not supported, connection test and combination test using these modules cannot be done, as well.

For these reasons, use the FCN/FCJ Simulator for unit test of a control application but use a real FCN-500 or FCN-RTU for connection test and combination test.

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5.1.3 Precautions of Testing When Using Target Equipment

Target equipment is delivered after completion of user acceptance test for use in the factory. Therefore, it is important to ensure that all settings are properly done and avoid failures due to oversight.

● FCN-500 Equipment Setup

Install power supply module, CPU module, various I/O modules, communication module, E2 bus interface module and SB bus repeat module in the base module based on hardware specifications. Perform equipment setup as described in Section

2.1, "Checking Hardware Specification."

Some equipment setup is done using Resource Configurator, while others are done on the hardware itself. The first kind of setup is done after installing target equipment and starting the FCN-500; while the second kind of hardware setup described below is done at installation before starting the FCN-500.

• Unit number setting of base module

FCN-500 uses the same base module hardware for control units (unit 1) and

expansion units (unit 2 to 9).

When using the E2 bus, set the unit number with the rotary switch of the E2 bus

interface module. It is unnecessary to change the setting of hardware switch on

the base module as Unit 1.

When using the SB bus, whether a base module is to be used as a control unit

or expansion unit is defined using a hardware switch on the base module.

Before shipment, all base modules are set to unit 1 (for control unit) so during

installation, you need to set the switch of each base module to be used as an

expansion unit.

If a system has only one base module with no expansion unit, unit number setup

is not required.

SEE ALSO

For details on how to set the switch of a base module, see Section A1.2, “Base Module” of IM “STARDOM FCN/FCJ Guide.”

• Single/Duplexed CPU module setting of base module

Whether an FCN-500 uses a single CPU module or duplexed CPU modules is

also defined using the resource configurator and a hardware switch of the base

module.

The factory default setting is for a single CPU and must be changed accordingly

when using duplexed CPU modules.

SEE ALSO

For details on how to set the switch of a base module, see Section A1.2, “Base Module” of IM “STARDOM FCN/FCJ Guide.”

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• 2-wire/4-wire setting of current input module

The following current input modules must be configured for 2-wire or 4-wire

system during installation. NFAI141 NFAI143 NFAI841

SEE ALSO

For details on the 2-wire/4-wire setting, see Section 8.1.1, “Checking Operation Specification of Analog/Digital Input.”

● FCN-RTU Equipment Setup

Install power supply module, CPU module, various I/O modules and communication module in the base module based on hardware specifications. Perform equipment setup as described in Section 2.1, "Checking Hardware Specification."

Some equipment setup is done using Resource Configurator, while others are done on the hardware itself. The first kind of setup are done after installing target equipment and starting the FCN-RTU; while the second kind of hardware setup described below are done at installation before starting the FCN-RTU.

• Unit number setting of base module

FCN-RTU uses the base module hardware for control units only.

Before shipment, all base modules are set to unit 1 (for control unit) so during

installation.

● Prevention of Equipment Failure

Handle equipment with care to prevent target equipment failure due to physical shock.

Beware that improper power supply connection will cause power supply module failure. Examples of improper power supply connection:

- Connecting a 24V DC power supply module to 100 V AC

- Connecting a 100V AC power supply module to 240 V AC

- Connecting the 24V DC analog field supply to 100 V AC

- Connecting to the 24V DC power supply of an FCJ with reverse polarity

- Connecting the 24 DC power supply of an FCJ to 100 V AC To avoid power supply module failure, perform power supply connections carefully.

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5.1.4 Precautions of Migrating Testing from In-house Equipment to Target Equipment

Debugging is sometimes started on in-house test equipment and then migrated to the target equipment halfway through function test. We describe two migration scenarios below.

● If CPU Module of In-house Equipment Are Used before Migration

In this migration scenario, debugging started using the CPU module of in-house equipment is to be migrated to the target equipment upon delivery of its CPU module.

Firstly, migrate the information stored on the CPU module of the in-house equipment to the target CPU module using the following steps:

1. Save retain data specified on in-house equipment to its CPU module.

2. Execute the FcxBackup command to save data stored on the CPU module of the in-house equipment to a PC.

4. Define the IP address on the target CPU module.

5. Execute the FcxRestore command to migrate the data of the CPU module of the in-house equipment saved on the PC earlier to the target system card.

• Resource Configurator settings

Configuration data defined using Resource Configurator is saved in the CPU

module on-board flash memory. However, if the I/O module configuration is different between the in-house equipment and target equipment, I/O modules need to be reconfigured and device labels redefined for the target equipment.

• Items saved by FcxBackup command

The list of items to be saved by FcxBackup command is defined in a file named

“backuplist.txt” stored in the same folder as the “FcxBackup.exe” executable file. The default backuplist.txt file list covers IEC 61131-3 language control applications but does not include files added by Duolet applications. Read “README.TXT” and edit the “backuplist.txt” file accordingly to add to or modify the list of items to be saved by FcxBackup command as required.

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● If FCN/FCJ Simulator Is Used before Migration

In this migration scenario, debugging started using FCN/FCJ Simulator is to be migrated to the target equipment upon its delivery.

As no hardware setup is done using FCN/FCJ Simulator, test migration from FCN/FCJ Simulator to target equipment requires only migration of retain data. The procedure for migration to target equipment depends on the state of retain data.

If the number of variables with retain data option is less, re-enter data on the target FCN-500 or FCN-RTU without migrating retained data from FCN/FCJ Simulator. Otherwise, migrate the retain data using the following procedure.

1. Save retain data specified using FCN/FCJ simulator to the CPU module using the same procedure for a real FCN-500 or FCN-RTU. Retain data of FCN/FCJ Simulator is saved as a csv format file named "RETAIN.CSV" on the PC in the following folder:

<FCN/FCJ Simulator's installed path>\WorkSpace\Current \USERS\STARDOM\RETAIN

If FCN/FCJ Simulator is installed in its default location, this folder corresponds

to:

C:\YOKOGAWA\FCN-FCJ\FCXSim\WorkSpace\Current \USERS\STARDOM\RETAIN

2. Download Logic Designer projects not used by FCN/FCJ Simulator to the target FCN-500 or FCN-RTU.

3. Execute FcxBackup command for the target FCN-500 or FCN-RTU. This backs up data on the CPU module of the target FCN-500 or FCN-RTU to a folder named “Backup” on the PC.

4. Copy the “RETAIN.CSV” file saved in step 1 to overwrite backup data saved in step 3. The folder is: \BACKUP\JEROS\USERS\STARDOM\RETAIN

5. Switch the target FCN-500 or FCN-RTU to Maintenance mode, and restore the data saved in item 3 using an FcxRestore command. At the same time, retain data copied in step 4, in other words, retain data used by FCN/FCX Simulator, is also restored.

6. Reboot the FCN-500 or FCN-RTU. Download the project used by FCN/FCJ Simulator and perform a warm start.

This procedure restores retain data stored on the CPU module under the same conditions described under TIP of ”● Behavior of Retain Data on FCN-500, FCNRTU Start Mode” of Section 2.2.5, “Retentive Variables (Retain Data) Considerations”

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5.2 Unit Test and Combination Test

Function test can be divided by scope into unit test and combination test.

• Unit test

The control applications such as its control logic and control loops are tested.

• Combination test

Including FCN-500 or FCN-RTU application graphics, displays and third-party

equipment/sub-systems, and communication functions.

Applications using programming languages such as Duolet function and VB (on

VDS) are also tested in combination test.

Function test normally begins with unit test and moves on to combination test after control applications are checked.

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5.3 Unit Test Precautions

Unit test focuses on confirming the operation of control applications running on the FCN-500 or FCN-RTU. This section describes know-how and precautions related to unit test.

5.3.1 Pre-unit Test Checklist

Check the following items before starting unit test.

• Verify the source code.

Print out the source code, and check. Besides checking control logic, check that

application meets requirement specification.

• Verify that no Logic Designer compile errors and warnings are reported.

Check no errors or warnings are displayed in Logic Designer's compile result.

SEE ALSO

For details on compile errors and warnings, see Section 4.8, “Handling Compile Errors and Warnings.”

TIP

If multiple compile warnings on unused local variables and unused FB instances are reported, they can be removed from all POU variable worksheets by selecting [Build]-[Remove unused variables and FB instances] from the menu bar. This function, however, is only supported by Logic Designer R2.01.01 and later versions.

• Check for unused global variables.

Check for the presence of unused global variables following the procedure

described in Section 9.1.8, “Cross References” of Chapter 9, “Advanced Engineering.” Specifically, if unused device label variables are found, determine whether it is intentional or whether application programming is incomplete.

• Verify that no PLC error is reported at download.

Verify that no PLC error is reported when the project is downloaded to the FCN-

500 or FCN-RTU through Logic Designer.

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Temperature control PID�

TIC001

Heating application

Control loops

Heating

program setup

TIC001PG

Logic for

starting heating

START

Logic for

ending heating

END

Logic for

stopping heating

STOP

Conditional logics

5.3.2 Unit Test Methodology

Like creation of control application, unit test should be carried out in a bottom-up manner, starting from the smaller logic parts and combining them into larger parts. This section describes this method using the control application example described below.

Application Example: Reaction Tank Heating Application

This sample heating application consists of several parts as described below, with multiple reaction tanks using the same heating application.

- Control loops

NPAS_PID (tag name TIC001) for temperature control NPAS_PG_L30 (tag name TIC001PG) for heating program setup

- Conditional logics

Conditional logic for starting heating Conditional logic for ending heating and logic for transiting to constant state Logic for stopping and restarting heating

- User function blocks

As the above conditional logics are used in multiple places, they are registered

as user function blocks. START : Conditional logic for starting heating END : Conditional logic for ending heating and logic for transiting to constant

state

STOP : Logic for stopping heating

The figure below shows the schematic of the application example.

In this example, the basic control involves two main control loops, named TIC001 and TIC001PG, which are activated and deactivated by conditional logic. The conditional logic cannot be tested unless the control loops operate correctly. So, first debug the control loops.

Next, debug the user function blocks. At this stage, debug the logic of each user function block by itself, without considering the operation of the control loops.

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After debugging each control loops and conditional logics, combine and debug them together. In combined debug, start by debugging the two normal paths: from starting to ending heating and from stopping to restarting heating.

After debugging the normal paths, debug the exception paths. Exception paths involve failure of equipment during heating. Assume failure of the temperature detector or control valve, generate IOP or OOP in the analog I/O, and check whether the control application operates correctly.

Besides checking for correct operation, also check whether the operation is correct within the plant environment. For instance, when a failure occurs, consider whether the valve controlling the temperature should be fully-open, fully-closed or maintained at its current state, and whether the operation of the control application is correct within the plant environment. Moreover, if the requirement specification is inconsistent with correct operation within the plant environment, check with the user.

After the first heating application has been successfully debugged, copy it to the other locations where the same application is used. As each destination uses the same logic, provided the copying is done correctly, it should operate the same way as the first debugged location. Hence, when debugging each destination, it is sufficient to check for correct operation of the normal paths.

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5.3.3 Unit Test Know-how

This section provides some useful know-how for testing a control application.

● Testing Control Loops

When testing a control loop that makes use of NPA S POUs, besides checking loop connections such as processing of regulatory data and cascade connection, also check for correct assignment of engineering parameters.

● Testing Control Logics

When testing control logic, besides checking for true condition, false condition, also check for concurrent true/false conditions, prevention of chattering and pulse/status type conditions.

• Concurrent true/false conditions

Consider an example where the open/close state of a valve having both open

and close signals is used as a condition within a control application. At the time of valve opening or closing, it is possible that open and close signals are both OF F.

Consider another example where the TRUE/FALSE calculation results of two

control logics are used as conditions of other logics so that processing is performed when the condition is true. Depending on how the application is programmed or the requirement specification, it is possible that both calculation results may be true at the same time.

With these considerations, investigate and debug possible scenarios of

concurrent true results or conditions in control logic and the expected operation under these scenarios.

• Prevention of chattering

When the PV value or alarm status of an N PAS POU or the state of a digital

input is used within control logic, chattering may occur under actual plant conditions due to rapid cyclical state changes. However, such chattering may not be observed in the test environment, which differs from the plant environment.

During debugging, investigate the possibility, suppression and handling of

chattering.

• Pulse-type data versus status-type data

Data used within control logic may be designed as pulse-type or status-type.

For instance, logic for initiating control may make use of a status-type start condition or a pulse-type start trigger.

If a Start PB is also a status-type, control may be started at the time the start

condition is true.

With these considerations, consider whether data used within control logic is

status type or pulse type and debug accordingly.

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● Testing User Function Blocks

A function block created as a POU behaves the same way in every location where it is used. Therefore, when debugging a user function block, thorough testing is only required in any one location. Once debugged, it can be expected to operate correctly in every other location, and thus requires only simple verification of correct operation.

● Testing Exception Paths of Control Logic

When debugging control logic, in addition to checking normal execution paths, it is important to also check exception paths. For exception paths, consider the following events:

- IOP or OOP event due to equipment failure, etc.

- Indefinite state of digital input due to equipment failure, etc.

- No response to output signal in input signal

- Time lag in response to output signal

- Disconnection or no response during communication with other equipment

In addition to the above, consider other kinds of exception conditions.

Besides exception handling described in the function specification, investigate and debug other possible errors and exceptions due to equipment failure, etc.

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● Testing Communication Applications

Connections between an FCN-500 or FCN-RTU, which uses communication application, and communication equipment can be tested in four steps as described below.

1. Check physical hardware connection with communication equipment and its setup

Check the cable connecting the FCN-500 or FCN-RTU and communication

equipment, as well as its wiring system.

The cable to be used varies with the equipment but the following general

checklist can be used.

Straight cable or cross cable 2-wire, 3-wire or 4-wire system Pin assignment This check is important as failure to establish communication with other

equipment is often due to improper cable and other physical connections, or invalid connection-related settings.

2. Test communication application

After completing the checks described in step (1), check the operation of the

communication application. Connect variables to the ERROR terminal and STATUS terminal of POUs used in the creation of each communication application, and verify that no communication error has been reported. If any communication error is reported, check the error code stored in the variable connected to the STATUS terminal, and fix the application.

3. Check mapping of received data

After ensuring the absence of communication error in step (2), check the

mapping of received data. Verify that data of the remote equipment is correctly read and written.

4. Check application which uses received data

Steps (1) to (3) check the communication itself. After ensuring the absence of

communication problems, check the operation of the control application, which makes use of the communication data.

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5.4 Combination Test Precautions

Combination test goes beyond the control applications of FCN-500 or FCN-RTU. With the FCN-500 or FCN-RTU connected to graphics, higher-level computers and other equipment through various means of communication, combination test verifies whether the system as a whole operates correctly, whether it operates correctly even in the event of failures, and whether there are any inconsistencies in the requirement specification.

5.4.1 Combination Test Prerequisites

Before starting combination test, ensure that the following preconditions are met.

• Unit test of FCN-500, FCN-RTU is completed.

The purpose of combination test is to test the operation of the system as a

whole.

When a problem is detected in combination test, it takes time to pinpoint whether

the cause lies in the control application itself or other system components. The test is interrupted if control application has bugs.

To avoid this, always complete unit tests of FCN-500 or FCN-RTU control

applications before starting combination test.

• Unit tests of graphics and displays are completed.

For the same reason explained earlier for FCN-500 or FCN-RTU control

applications, always complete unit tests for any graphics and displays to be connected before starting combination test.

• Communication is successfully established for communication applications.

For equipment to be connected through various means of communication,

ensure that communication is successfully established and data sending and receiving is allowed before starting combination test.

5.4.2 Equipment Used for Combination Test

Combination test is intended for testing not just the control application, but the system as a whole. As such, we recommend using target equipment for combination test is recommended.

Using In-house equipment during combination test may result in following:

1. Any problems faults in hardware will go undetected

2. Any missing licnese on target system will go undetected

To avoid these problems, use target equipment during combination test if possible.

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5.4.3 Checking Log Files of FCN-500, FCN-RTU

System errors such as watchdog errors caused by a sudden increase in CPU load, inter-FCN/FCJ communication interruptions, as well as array boundary errors and division by zero errors caused by control applications, whenever detected, are recorded by the FCN-500 or FCN-RTU in system log files. During the combination test phase, display the FCN-500 or FCN-RTU log files once a day to investigate and rectify reported system errors, if any.

SEE ALSO

For details on how to display log files of FCN/FCJ, see Section B2.4.8, “Displaying Log Files” of IM “STARDOM FCN/FCJ Guide.”

5.4.4 System Failure Test

Perform system failure test during combination test. System failure test includes testing for recovery from FCN-500 or FCN-RTU power off, recovery from system-wide power off, operation and recovery after communication disconnection, as well as operation and recovery after failure of one of two duplexed FCN-500 components.

This section describes how to simulate failure and recovery of some typical system failures for testing purposes. However, how the system behaves in the event of a system failure depends on the factory condition and requirement specification. Verify that the control operation both after a system failure and after system recovery comply with the requirement specification. In addition to the system failure tests described below, perform other system failure tests as required.

● Recovery from FCN-500, FCN-RTU System Power Off

Turn off the system power of the FCN-500 or FCN-RTU. Verify that operation of all equipment other than the FCN-500 or FCN-RTU complies with the requirement specification. Next, turn on the system power of the FCN-500 or FCN-RTU and verify the operation after recovery. Besides checking the operation of the control application, verify that each communication function is restored and retain data is preserved.

• Procedure for checking preservation of retain data

1. Select any one retain data item.

2. Before powering off the FCN-500 or FCN-RTU, save the current data to the

on-board flash memory.

3. Modify the value of the retain data item. As this point, the data on the FCN-500 or FCN-RTU is different from the data

saved on the flash memory.

4. Power off the FCN-500 or FCN-RTU.

5. Power on the FCN-500 or FCN-RTU.

6. After FCN-500 or FCN-RTU startup, check the value of the selected retain

data item.

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If retain data is resident in non-volatile memory, the value specified in step 3 should be restored. If retain data is resident in volatile memory, the value saved to the flash memory in step 2 should be restored.

● Operation and Recovery after Power Off of External Field Power Supply of FCN-500, FCN-RTU

When the external field power supply of FCN-500 or FCN-RTU is turned off, IOP (input open alarm) or OOP (output open alarm) is reported in device label variables of I/O modules requiring I/O field power. If IOP is reported in an input device variable, this status is sent to applications. If OOP is reported in an output device variable, this status is sent to applications. By turning off and then turning on the external field power supply, compare the actual operation of the control application against the IOP and OOP operation and recovery stated in the requirement specification and ensure that requirements are met.

Details on IOP and OOP, as well as the behavior of NPAS POUs under these alarm conditions are described in the online help as shown below.

● Operation and Recovery after Communication Disconnection

With the FCN-500 or FCN-RTU running, disconnect the communication using any of the following means and check the operation of the control application.

1. Switch off the connected equipment;

2. Pull out the communication cable;

3. Switch off hubs or other relay equipment, if any, on the communication path;

4. If an FCN communication module is used, unmount the communication

module; or

5. Any other means as required to disconnect communication. After communication is temporarily disconnected, restore the original state by reversing the above operation and check that communication is properly restored.

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IMPORTANT

● Recovery from System–wide Power Off

Power off and then power on, not just the FCN-500 or FCN-RTU but the entire system. Check the operation after power is restored.

● Operation and Recovery after Failure of One of Two Duplex CPUs (FCN500 only)

To s im ul ate failure of one of two duplexed CPUs, press the RESET button of the corresponding CPU. When the control CPU is made to fail, control right is transferred to the standby CPU and control continues. However, control switchover causes momentary interruption of the communication over the control network, which is restored shortly after. When the standby CPU is made to fail, control continues with the control CPU running like a single CPU. Verify that control switchover and momentary interruption of the control network do not cause control problems.

To recover from single CPU state to duplexed CPU state requires execution of APC (All Program Copy). If automatic APC is enabled, APC is automatically executed after control switchover. If automatic APC is disabled, execute APC manually using Resource Configurator. Moreover, control continues during APC execution, but the control cycle is lengthened by 1 to 2 seconds for one cycle. Verify that there is no problem in control operation during APC execution and after duplexed configuration is restored by APC execution.

SEE ALSO

For details on the operation specification and precautions of Duplex FCN-500 CPU modules, see: Section B1.3.3, “Precautions on the Creation of Control Applications” of IM “STARDOM FCN/FCJ Guide.” Chapter C2 , “Duplex CPU Module (FCN)” of IM “STARDOM FCN/FCJ Guide.” Section 7.2, “Operation Using Duplex FCN CPU Modules” of TI “FCN-500 Technical Guide”

The control and standby CPUs synchronize their timing while accessing process I/O. When I/O is put in disconnected state for debug purposes, process I/O is inaccessible, consequently the control CPU and standby CPU cannot be synchronized. Therefore, when disconnecting I/O, switch the CPU to single mode. Testing control switchover with the control CPU and standby CPU in nonsynchronized state is not only meaningless but may even cause abrupt changes in control output. To avoid this, cancel I/O disconnection before testing control switch over.

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● Operation and Recovery after Failure of One of Two Duplex Power Supply Modules

To simulate failure of one of two duplex power supply modules, unmount one power supply module from the base module or interrupt the power supply to one power supply module. When one power supply module fails, verify that a system alarm is generated but control itself is not affected and continues normally. Ver ify also that operation is not affected when the failed power supply module is restored.

● Operation and Recovery after Failure of One of Two Duplex Control Networks (FCN-500 only)

To simulate failure of one of two duplex control networks, disconnect the cable from one of two duplex control network ports, or power off the Hub on one of two duplex transmission paths. As described in Section 2.1.4, “Measures for Duplexing,” when communication unsuccessful communication diagnostic frames are sent two times, communication on that path is diagnosed as error. Therefore, wait several seconds before checking the operation. After that, restore the control network and again check the operation.

● Operation and Recovery after Failure of One of Two Duplex E2 Bus Interface Modules (FCN-500 only)

To simulate failure of one of two duplex SB bus repeat modules, unmount one of the E2 bus interface modules from the base module or disconnect one of the two E2 bus cables. When one SB bus repeat module fails, verify that a system alarm is generated but control itself is not affected and continues normally. Verify also that operation is not affected when the failed E2 bus interface modules is restored.

● Operation and Recovery after Failure of One of Two Duplex SB Bus Repeat Modules (FCN-500 only)

To simulate failure of one of two duplex SB bus repeat modules, unmount one of the SB bus repeat modules from the base module or disconnect one of the two SB bus cables. When one SB bus repeat module fails, verify that a system alarm is generated but control itself is not affected and continues normally. Verify also that operation is not affected when the failed SB bus repeat module is restored.

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● Fall-back Operation of Analog/Digital Output Modules

As described in Section 8.1.2, “Checking Operation Specification of Analog/Digital Output” of Chapter 8, “Detailed Description,” an analog/digital output module performs fallback if it detects a loss of line access with the CPU module beyond 4 seconds. Cause output fallback using the following procedure and check the control operation after output fallback is activated.

1. Stop control operation on the FCN-500 or FCN-RTU using Logic Designer’s

Project Control dialog.

2. Press the shutdown button of the FCN-500 or FCN-RTU or execute Shutdown

from the Maintenance homepage of the FCN-500 or FCN-RTU to put the FCN500 or FCN-RTU in “Power Off OK” state.

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5.5 Checking CPU Load and Application Size

Section 2.2.2, “Checking FCN-500, FCN-RTU Control Application Size" and Section “2.2.3, “Checking FCN-500, FCN-RTU Performance" describe checking of FCN-500 or FCN-RTU control application size and performance before application creation. These checks performed before application creation give desk-calculated values, which must be verified by actual size and performance during function test.

5.5.1 Checking CPU Load

In Logic Designer, display the CPU load and verify that the displayed value is 60% or less.

Procedure for checking CPU load

1. Display Logic Designer’s Control Dialog.

2. Click [Info] on the displayed dialog.

3. The CPU load is displayed on the [Resource] tab screen of the displayed Info

dialog.

Other than the CPU load, the free space for retain data is also displayed. This

data is used in Section 5.5.2, “Checking Application Size.”

YOKOGAWA STARDOM FCN-500, STARDOM FCN-RTU Engineering Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Copyrights and Trademarks

CONTENTS

1. Overview

2. Basic Design and Function Design

2.1 Checking Hardware Specification

2.1.1 Current Consumption of FCN-500 and FCN-RTU Unit

2.1.2 Checking Operation Specifications of I/O Modules

2.1.3 Checking Automatic Loading of I/O Modules

2.1.4 Measures for Duplexing

2.2 Pre-Application Creation Checklist

2.2.1 Checking Revisions of FCN-500, FCN-RTU and Tools

2.2.2 Checking FCN-500, FCN-RTU Control Application Size

2.2.3 Checking FCN-500, FCN-RTU Performance

2.2.4 Determining FCN-500, FCN-RTU Scan Cycle

2.2.5 Retentive Variable (Retain Data) Considerations

2.2.6 Time Synchronization

3. Hardware Setup

3.1 Resource Configurator Setting

3.2 Setup in Web Browser

4. Control Application Creation

4.1 Using Logic Designer Setup

4.1.1 Selecting a Template for a New Project

4.1.2 Control Task Setup

4.1.3 Multi-tasking

4.1.4 Specifying Target FCN/FCJ

4.1.5 Multi-resource Project

4.1.6 Application Size

4.2 Application Programming Languages

4.2.1 Programming Languages Supported by Logic Designer

4.2.2 Selecting a Programming Language

4.3 Principles of Application Creation

4.3.1 Principles of Application Creation

4.3.2 Example of a Simple Application

4.3.3 Bottom-up Application Creation

4.4 Application Creation Know-how

4.5 Network Templates

4.6 Application Encapsulation

4.6.1 Features of Application Encapsulation

4.6.2 Procedure for Creating a POU

4.6.3 Modifying Logic of a POU

4.7 Handling Compile Errors and Warnings

4.8 Precautions About Downloading

4.8.1 Offline Download and Online Download

4.8.2 Downloading Boot Project and Source

4.8.3 Detailed Description of Download Dialog

4.8.4 Importance of Boot Project

4.8.5 Importance of Source

4.9 Control Application Backup

5. Function Test (Debugging)

5.1 Equipment Used for Testing

5.1.1 Precautions of Testing When Using In-house Equipment

5.1.2 Precautions of Testing When Using FCN/FCJ Simulator

5.1.3 Precautions of Testing When Using Target Equipment

5.1.4 Precautions of Migrating Testing from In-house Equipment to Target Equipment

5.2 Unit Test and Combination Test

5.3 Unit Test Precautions

5.3.1 Pre-unit Test Checklist

5.3.2 Unit Test Methodology

5.3.3 Unit Test Know-how

5.4 Combination Test Precautions

5.4.1 Combination Test Prerequisites

5.4.2 Equipment Used for Combination Test

5.4.3 Checking Log Files of FCN-500, FCN-RTU

5.4.4 System Failure Test

5.5 Checking CPU Load and Application Size

5.5.1 Checking CPU Load