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

Technical

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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iii

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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.”

+ 196 hidden pages

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