Application Module Specification and Technical Data

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1 Application Module Specification and Technical Data 8/97 detergant coffee chocolate

2 Page 2 TotalPlant Solution (TPS) Application Module Specification and Technical Data Introduction This publication defines the significant functions of the TotalPlant Solution (TPS) Application Module. The Application Module is one of the modules on the Local Control Network (LCN). As Figure 1 indicates, it communicates with other modules on the same or other Local Control Networks and with process-connected devices on the Universal Control Networks and Data Hiways. Because of its position in the system architecture, the Application Module can accept inputs from multiple processconnected devices, as well as from other modules on the different Local Control Networks. It can also provide control outputs to control elements in the process or to other data points in modules on the different Local Control Networks, including itself. For more information on the role of the Application Module in the TPS system, refer to the System Technical Data. With at least one Application Module present in a TPS system, more advanced calculations and control strategies can be implemented. Each Application Module data point can have multiple inputs and outputs from many devices, and a single Application Module can handle many more data points than a single process-connected box. The Application Module features a full complement of control algorithms. The Control Language that executes in the Application Module makes it easy to develop custom point processing and special algorithms. The Application Module provides full cascade functionality between an AM point and any process data point resident in modules on different LCNs. Functional Description The relationships of the major functions of the Application Module are shown in Figure 2. Additional LCN Modules Fiber Optics Archive Replay Module Application Module History Module Universal Stations Network Gateway Plant Information Network Network Gateway Plant Network Module Universal Work Station LOCAL CONTROL NETWORK NO. 1 LOCAL CONTROL NETWORK NO. 2 LCN Extenders Hiway Gateway Network Interface Module Network Interface Module DATA HIWAY Data Hiway Boxes Process Manager Advanced Process Manager Advanced Process Manager UNIVERSAL CONTROL NETWORKS Logic Manager Advanced Process Manager Smartline 3000 Remote I/O Subsystem Figure 1 TotalPlant Solution (TPS) Architecture with Application Module

3 Page 3 Data Points The Application Module contains a process database made up of data points that the process engineer builds and assigns to it during configuration. Each data point is a collection of fixed and dynamic parameters that performs a specific function and is identified by a point name. Datapoint processing can use either preprogrammed or custom algorithms to calculate required information and/or initiate specific control action. BUILT-IN ALGORITHMS FAST PROCESSOR SLOW PROCESSOR CONTROL LANGUAGE EXECUTION INTERNETW0RK POINT PROCESSOR BACKGROUND CL In addition to regulatory data points that represent continuous variables in or related to the process, the Application Module also offers several utility datapoint types. These include the following: PROCESS DATABASE LOCAL CONTROL NETWORK Timers provide timing functions. Counters process counter inputs. Flags boolean variables. Numeric numeric variables. During configuration, the user defines the data-point name, point type, selected algorithms (if applicable), input sources (up to 16, from multiple sources), output destinations (up to 8), alarm trip points, and the processing schedule. Other information pertinent to the type of data point may also be entered, or standard default values may be used. Data Point Scheduling Each data point in an Application Module is processed according to a schedule defined by the process engineer during configuration. The engineer may assign a data point to a "fast" processor, a "slow" processor, or an internetwork point processor, and may choose from a variety of time intervals from 1 second to 24 hours. The fast processor has a higher priority, so data points assigned to it are processed at more regular intervals. Generally, Figure 2 Application Module Functions noncritical, low-frequency data points are assigned to the slow processor, so that they do not interfere with the processing of data points assigned to the fast processor. The internetwork point processor provides for closed loop control across the Network Gateway. The user can also schedule data points to be processed before or after another data point, on demand, or when some userdefined process event occurs. When a regulatory data point in an Application Module is processed, it goes through most or all of the steps in the sequence shown in Figure 3. Regulatory Control General Input Processing At the user's option, a regulatory data point can fetch values from the process database and update designated parameters within the data point before proceeding with the remainder of its processing. PV Processing A regulatory data point that uses PV processing fetches the designated PV inputs from a process-connected box or module on the Local Control Network before executing the specified PV algorithm (see Table 1), or custom algorithm (see the "Custom Control" description FUNCTIONS Scheduling of Data Point Processing Regulatory Control PV Processing Control Processing Control Output Processing Custom Control Control Language Execution Custom Data Point Processing Custom Data Segments Multipoint Strategies (Switch Data Point) Alarming

4 Page 4 PV CONTROL GENERAL INPUT PV INPUT INITIAL CONTROL CONTROL INPUT GENERAL OUTPUT PV ALGORITHM SET POINT AND TARGET ALARM DISTRIBUTION PV FILTERING DEVIATION ALARM CL Block Insertion points PV SOURCE SELECTION AND RANGE CHECK PV ALARM CONTROL ALGORITHM CONTROL OUTPUT 1173 Figure 3 Processing Sequence for Regulatory Data Point below). The PV is calculated, checks are made to determine if limits have been violated, and a value status (good, bad, or uncertain) is assigned. Control Processing A regulatory data point that uses control processing obtains the designated control inputs from PV processing, or elsewhere, before executing the selected control algorithm (see Table 2), or custom algorithm (see "Custom Control"). When configured to do so, such a data point can also store the output in other data points in the same or another Application Module or in some other LCN-based module or process-connected device. Multiloop control schemes are normally configured to provide bumpless transfers from one mode of operation to another. Control Output Processing Control output processing stores a whole value appropriate to the units of the destination parameter. It also accommodates any control constraints, including any output high/low limits, output increment limits, and integral high/low limits, as well as handling initialization, mode change, and antiwindup conditions. Alarming Alarms for regulatory data points can be selected by the user from the types of conditions listed below. If an alarm is detected as a data point is processed, that event is journaled, annunciated, and displayed in the same way as an alarm detected by a processconnected device.

5 Page 5 High/low deviations High/low PV High high/low low PV PV rate of change PV significant change Custom Control In addition to the built-in PV and control algorithms, the engineer may use the Control Language (CL/AM) to define his own algorithms and processing routines. Control Language can be written at a TPS Universal Station/Universal Work Station, or at a personal computer using an optional software package called Workbook, that runs under MS- DOS/PC-DOS. Programs are compiled at a Universal Station or Universal Work Station. Control Language algorithms and routines are inserted at specified points in the Application Module processing order. Control Language Control Language is designed specifically for the Process Engineer to use in implementing custom control schemes. This easy-to-use language employs a variety of general and process-oriented statements (see Table 3 and Figure 4) and provides a significant improvement in both security and throughput over previous customization techniques. Security features include checks to make sure that parameters and storage destinations are valid, and to protect against user-coded infinite loops. Custom Data Segments Custom Data Segments (CDS) are parts of a data point used for storing data that is to be used by Control Language programs. For example, the name of each parameter and its type, units, and change authority are included when the segment is defined. Once defined, and attached to specific data points, the custom segment data is automatically Table 1 PV Algorithms Algorithm Null Data Acquisition Flow Compensation Middle-of-Three Selector Hi/Lo Average Selector Summer Multiplier/Divider Sum of Products Variable Deadtime With Lead-Lag Totalizer General Linearization Control Language PV Algorithm available for displays and other functions. Foreground and Background CL Control Language programs can be assigned to execute in either the foreground or background mode. For foreground execution, insertion points are defined where blocks Table 3 Control Language for the AM Data Types Number Data Points Arrays Statements set go to loop exit Operators Arithmetic Logic Relational Functions and Subroutines Table 2 Regulatory Control Algorithms Algorithm Null Auto Manual PID With Options, Including GAP Nonlinear Gain Auto-Ratio Auto-Bias PID-External Reset Feedback PID-With Feedforward Incremental Summer Lead/Lag Summer Multiplier/Divider Ratio Override Selector Switch Ramp Soak Control Language Control Algorithms Discrete (Logical, Enumeration) Time Strings state change if/then/else repeat abort -, +,, /, mod, and, or, not, xor <, =, >, <=, >=, <> Sin, Cos, Tan, Atan, Ln, Log 10, Exp, Sqrt Abs, Max, Min, Avg, Sum Badval Exists Comm Error Set bad Now Date time of CL code can be executed during the standard processing sequence (see Figure 3). call send end Allow bad Self Round Int

6 Page 6 BLOCK dual_oxy (point CAI1515; & at pv alg) This block of CL code selects the higher of two recycle oxygen readings from dual oxygen analyzers and places that value as the PV of point CAI1515. If one of the analyzers is off scale, out of limits, or out of service, the other analyzer is selected. Also, if one of the analyzers is bad or out of service, the PV source for another loop in the control scheme is set to MANUAL. These statements define the variables. local aval, bval external AAR1515A, AAR1515B external CAA1515 the analyzers the other control loop These statements check out Analyzer A. if AAR1515A.PVHIFL or AAR1515A.PVLOFL or If the limits have been violated & badval(aar1515a.pv) or or the value is bad & not (AAR1515A.PTEXECST = active) or the analyzer not active & then (set CAA1515.PVSOURCE = MAN; set aval = 0) set source to manual else set aval = AAR1515A.PV otherwise use the PV These statements check out Analyzer B. if AAR1515B.PVHIFL or AAR1515B.PVLOFL or If the limits have been violated & badval(aar1515b.pv) or or the value is bad & not (AAR1515B.PTEXECST = active) or the analyzer not active & then (set CAA1515.PVSOURCE = MAN; set bval = 0) set source to manual else set bval = AAR1515B.PV otherwise use the PV These statements select the higher analyzer reading and end the CL block. set PVCALC = MAX (aval, bval) end dual_oxy Note: " " indicates a comment line included to help in understanding the program. All other lines are program statements. Figure 4 Sample Control Language Program Execution of a block might be triggered by a specific event, such as crossing an alarm threshold or when it becomes necessary to initialize a control loop. Background CL programs are attached to a data point and execute whenever CPU time is available. Consequently background routines do not slow down point processing execution. Control Language Algorithms The standard sets of both PV and control algorithms have "Control Language algorithm" as one of the choices, making it easy for the user to substitute his own algorithm in the standard pointprocessing scheme. Custom Multipoint Switch Strategies A Control Language switch data point can be used with user-written Control Language routines to monitor and direct control of strategies that involve different sets of data points. The multipoint Control Language routines respond to strategy changes requested by the process operator through a Universal Station.

7 Page 7 Control Language Extensions Accessing History Control Language Extensions provide for history access by reading historized data from the History Module. Up to 262 history values can be obtained with one call. Data being retrieved can be Absolute Snapshots, Relative Snapshots, or Absolute Averages of any historized point.parameter. The extensions can determine the collection rate for a specific point.parameter. Values can be specified in either ASCII or internal Form. The data can be used by CL programs and/or displayed on a Universal Station. Math Library A set of math subroutines are available for those AMs that are equipped with a high performance processor module with math coprocessor. The subroutines provide the following features: Standard deviation of an array Generate random numbers with both uniform (0-1) and pseudo-gaussian distribution Create single-dimension CDS array from two-dimension local matrix Create a two-dimensional local matrix from a single-dimension CDS array Matrix multiply, add, subtract, and transpose Matrix inversion and solution with right-hand/left-hand division options Maintenance of matrix work areas CPU usage calculations. Options Hardware Options The Application Module is available in a 5-card electronics module and a dual node electronics package. The 5-card module can be equipped with cards that use Motorola microprocessors and have a memory capacity of 2 Mw, or with cards that provide higher throughput using Motorola 68020s. The option is available with 2, 3, 4, 6, or 8 Mw of memory. The dual node package can also be supplied with 2, 3, 4, 6, or 8 Mw memory capacity. For additional information about the two types of enclosures, see the System Technical Data. Redundant AMs, including special software, can be provided for those applications where availability of the advanced AM functions is a prime consideration. Upon primary failure, the secondary will take over with a minimal delay (within 5 seconds) and without loss of alarms or messages. Redundant AMs are available in 5-card modules only. These are mounted adjacently in the same cabinet and are separately powered. Maximum memory that can be installed is 7 Mw. Multiple Application Modules can be connected to the Local Control Network to increase the point-processing capacity and/or for dedicated process unit applications. Application Programs Several powerful software application programs are available that take advantage of the AM custom programming capabilities. Included are: LOOPTUNE II optimally tunes PID control loops. HORIZON MULTIVARIABLE PREDICTIVE CONTROL a multiple input/ multiple output control algorithm capable of controlling loops that cannot be adequately controlled with PID algorithms. Real Time SPQC-II uses statistical control methods and a full range of control charting The maximum memory that can be addressed by software is 6 3/4 Mw. functions for early detection of quality problems. Your Honeywell representative will be pleased to provide you with details about these and other available applications packages. Physical Description When packaged as a 5-card module, the Application Module contains a Local Control Network Interface board, microprocessor/memory board(s), a power supply, and a fan assembly. If the AM is a member of a redundant pair, there is also a redundancy board. The dual node version of the Application Module contains a high-density K2LCN board, a power supply, and fan assembly. The boards and power supply are Optimum Replaceable Units for maintenance. Both types of electronics modules mount in a standard 19 (48 cm) RETMA rack and are typically mounted in a standard TPS system cabinet. The Local Control Network connects to the module through coaxial connectors. Optimum Replaceable Units (ORUs) are replaceable assemblies that provide the best trade-off between the cost of the ORU and the cost of attempting to isolate troubles to a smaller part of that ORU. Examples of ORUs include printed-circuit boards, power supplies, printers, and Winchester disk drives.

8 Page 8 Application Module Specifications Physical Characteristics Approximate Dimensions (5 Card and Dual Node) Approximate Weight Height 18.8 cm (7") 5-Card File 21 kg (46 lb) Width 48.3 cm (19") Dual-Node File with Depth 53.3 cm (21") Single Node 14.6 kg (32 lb) Two Nodes 18 kg (40 lb) Power Supply Universal AC Input: Vac (autoranging); Hz (frequency range) The Application Module operates without disruption through an interruption in the AC voltage of up to 40 ms duration. CE Conformity CE Conformity (Europe) Product Classification Installation Category Pollution Degree EMC Classification Method of Assessment This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other CE Mark Directive(s) shall not be assumed. Deviation from the prescribed procedures and conditions specified in the installation manuals may invalidate this product s conformity with the Low Voltage and EMC Directives. Class I: Permanently mounted, permanently connected Industrial Control Equipment with protective earthing (grounding). (EN ) Category II: Energy-consuming equipment supplied from the fixed installation. Local Level Appliances and Industrial Control Equipment. (EN ) Pollution Degree 2: Normally non-conductive pollution with occasional conductivity caused by condensation. (IEC ) Group 1, Class A, Industrial, Scientific and Medical (ISM) Equipment. (EN ; Emissions) EMC: Technical Construction File (TCF) LVD: Technical File (TF)

9 Page 9 Operating Characteristics Point Processing Capacity AMI (68000 microprocessor): Up to 60 data points per second, depending on point-type mix and model of HG AMII (68020 microprocessor): Up to 90 data points per second, depending on point-type mix and model of HG Data Point Capacity Point Scheduling Capability Varies widely with point-type mix and memory usage; for details, see Application Module Implementation Guidelines. Fast Processing: 1 sec, 2 sec, 5 sec, 10 sec, 15 sec, 30 sec, 1 min, 2 min, and On Demand Slow Processing: 1 min, 2 min, 5 min, 10 min, 15 min, 30 min, 1 hr, 8 hr, 12 hr, 24 hr, and On Demand Internetwork Point Processor: 5 sec, 10 sec, 15 sec, 30 sec, 1 min, 2 min, 5 min, 10 min, 15 min, 30 min, 1 hr, 8 hr, 12 hr, 24 hr, and On Demand Configuration Capability Maximum Number of Nonredundant AMs per LCN = 20 Maximum Number of Redundant AMs per LCN = 10

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12 Page 12 Copyright, Notices, and Trademarks Copyright by Honeywell Inc. While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customer. In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice. Honeywell and TotalPlant are U.S. registered trademarks of Honeywell Inc. LOOPTUNE II, HORIZON MULTIVARIABLE PREDICTIVE CONTROL, and Real Time SPQC-II are trademarks of Honeywell Inc. Other brand or product names are trademarks of their respective owners.