Rosemount 5708 Series 3D Solids Scanner Integration with DeltaV

Transcription

1 Rosemount 5708 Series 3D Solids Scanner Integration with DeltaV Introduction page 1 Specifications page 1 Network setup page 2 Using direct connection to DeltaV with a serial card page 13 Configuring byte order for connection via serial card page 14 Workaround procedure page 15 Configuring serial card in DeltaV page 15 Configuring control strategies to obtain correct process values page Introduction This document indicates how to setup and configure Rosemount D Solids Scanner with DeltaV using two different methods. Configuration details are included for the physical network, DeltaV Explorer, 3DMultiVision Client, and VIMNet. The VIMNet application interfaces with the VIM card - a necessary component for one of the setups which DeltaV communicates with the 3DMultiVision server through. DeltaV Explorer configuration is performed on the DeltaV ProPlus Station; 3DMultiVision and VIMNet configuration is performed on an Application Station. After the configuration is complete, DeltaV and DMultiVision Server/Client will be able to run in parallel when using a VIM card. The level variables will be able to be accessed by the controller for indication and control by DeltaV. The application station will be able to use the 3DMultiVision software to setup the 3D Solids Scanner, show detail curves, and monitor values. 1.2 Specifications The configuration presented here has been verified with the following specifications: DeltaV versions and 12.3 VIMNet version VIM version DMultiVision version and above The average update time of the parameters is approximately 15 seconds when using the VIM card setup. The device can also be directly connected to a DeltaV serial card. The update time through the serial card was approximately 10 seconds. Connection through the serial card prevents the 3DMultiVision software from being used in parallel, and also requires manipulating the byte order manually to display the correct values. When using the VIM card, the byte manipulation is handled automatically.

2 Manual Supplement 1.3 Network setup To be able to run DMultiVision software simultaneously with DeltaV, set up the network as follows: 1. Setup a network switch connected to the DeltaV controller, the DeltaV ProPlus station, and the DeltaV Application Station. The DeltaV Application Station will be the station running the 3DMultiVision software. 2. Setup another, separate network switch connected to the VIM card, the DeltaV Application Station running 3DMultiVision, and the 3D Solids Scanner. Note The 3D Solids Scanner uses a serial communication link to the network. An RS485 to TCP/IP or RS485 to USB converter is required to connect the device to the network switch. Figure 1-1. Network Diagram A. 3DMultiVision B. DeltaV ProPlus C. DeltaV Operator Station D. VIMNet Explorer (Optional) E. Multiple 3D Solids Scanners 2

3 1.3.1 Configuring 3DMultiVision software 1. Launch the 3DVision Client application on the Application Server. 2. If necessary, create a new project and setup the device. a. Under Connection Type, select TCP/IP or select the COM port in which the RS485 to USB converter is connected to. b. In the Server IP Address box, type the IP address of the RS485 to TCP/IP converter connected to the 3D Solids Scanner. c. In the Server IP Port box, type the port of the RS485 to TCP/IP converter. 3. Establish communication between the 3DVision and the Scanner. 4. After the device is set up, navigate to Tools > Server Options > SCADA Configuration. 5. Set the Port, Type and 3D file path to enable the Modbus Communication between the 3DVision Server to the hosting SCADA system. The Port stands for a TCP Port that is available to use in the network, please consult with local IT for available TCP ports. Make sure that there are no other systems (like firewalls, antivirus and others) that prevent the communication using the selected port. Type stands for the Modbus communication type, it can be either Modbus TCP or Modbus RTU, make sure you set the corresponding communication type in the hosting SCADA system. The 3D image file path is a local folder on the computer running the 3DVision Server that will hold the generated file for the 3D image of the vessels configured in the system. 6. If a multidrop connection is used, all the devices should be setup in the 3DMultiVision software. Note that each scanner should be configured with a different polling address. Note Rosemount D Solids Scanner is recommending the CHIYU BF-430 as the RS485 to TCP/IP converter. 3

4 Manual Supplement 7. In a multi-scanner system, where a vessel in the 3DVision is configured with multiple scanners it is possible to view the vessel's data on the SCADA, use the vessel ID to set the connection between the DeltaV to the 3DVision. The Vessel ID can be seen in the hardware inventory table: in 3DVision go to Tools > Reports > Hardware Inventory Table. The Vessel ID appears in the right most column under the SCADA ID header Configuring VIMNet 1. Open VIMNet Explorer on the DeltaV Application Station. 2. Right-click on I/O Net and select New Controller. This will open a prompt for the name of the new controller. 3. Type the name of the new controller. The name of the new controller in VIMNet must match the name of the controller in DeltaV. 4. Right-click the controller that was added to VIMNet in 2, and select New IO VIM to open the Add Modbus/TCP Virtual I/O Module window and begin commissioning the VIM. 4

5 5. The IP Address of the VIM can be set to any available IP on the network; the availability of an IP can be checked using the Ping function at the bottom left of the pop up window. Select OK when all of the parameters are set correctly. This will create a new VIM connection for the controller emulating 4 serial I/O cards. Figure 1-2. Set the VIM Properties A. Any available IP will work B. Subnet mask set to match network C. Check IP availability here 6. Right-click the VIM which was just added and select Commission. A list will populate with Decommissioned VIMs on the network. 7. Select the desired VIM to be commissioned (an Identify VIM function is available in the bottom right of the window). 8. Check that the IP Address field matches the available IP address set in 4, and select OK. 9. Expand the VIM icon to see the emulated serial cards, numbered To begin the setup of the VIM, expand one of the cards and right-click on one of the serial ports assigned to the card. Select Add Device to open the Device Properties window. 5

6 Manual Supplement 10. Set the Device Address to the 3D Solids Scanner's polling address + 1. This first serial port (P01) can be configured to communicate with the DMultiVision server. For example, if the polling address of the 3D Solids Scanner is set to 0 then the Device Address field will be set to 1. Select Add to add the IP definition of the device. 11. Enter the IP Address of the DeltaV Application Station - the station running the 3DMultiVision Server. 12. In the Protocol list, select RTU via TCP. 13. In the Port box, type Figure 1-3. Configure the IP Definition for the Device A. 3DMultiVision PC goes here 14. If a multidrop connection is desired, then each scanner should be linked with a device instance under the associated virtual serial port. Repeat 7 to 10 to add each physical device; choose the appropriate Device Address to match the address of the physical devices. Note that each scanner should be configured with a different polling address. 6

7 15. Upload the new configuration. Right-click the desired VIM and select Upload Configuration to VIM. Confirm the upload to the VIM by selecting Yes in the window that will appear, and save the changes. Upon completion, a confirmation message should appear. The VIM configuration is now complete. Note Anytime the Upload Configuration to VIM routine is run, the 3DMultiVision server will stop communicating with DeltaV. The server must be restarted or the SCADA Configuration window must be opened and acknowledged to see values on DeltaV. The SCADA Definition can be found in the 3DMultiVision Client application under Tools > Server Options > SCADA Configuration. Simply open the SCADA Configuration tab and select Apply Configuring VIM card in DeltaV 1. Open DeltaV Explorer and navigate to the controller connected to the VIM module. 2. Expand the controller and right-click on I/O. 3. Select New Card to add the serial card emulated by the VIM module. The Add card window opens. 4. In the Card class list, select Serial Cards. 7

8 Manual Supplement 5. In the Card type list, select 2 Ports, Programmable RS232 RS In the Slot position list, select 57. Figure 1-4. Add a 2 Port Programmable RS232 RS485 Serial Card on Slots Repeat 3-4 for Slot position 58, 59, and 60. The VIM module emulates 4 serial cards in slots Note Cards can also be added via the DeltaV Explorer, using the Auto-sense I/O cards menu option. All four cards must be configured, even if you are not using all of them. In addition, disable all unused serial card ports. 8. Select the same serial card and port which was used during the VIMNet setup to add the 3D Solids Scanner device. 9. Expand the serial card, right-click on the port, and select Properties. 8

9 10. On the Port tab, select the Enabled check box. 11. On the Advanced tab, use the following settings: Mode: master Retry count: 1 Message timeout (ms): 1000 Transmit delay (ms): On the Communications tab, use the following settings: Port type: RS232 Baud rate: Parity: even Data bits: 8 Stop bits: 1 9

10 Manual Supplement 13. Select OK. 14. Right-click on the port which was just enabled and select New Serial device. This device will represent the 3D Solids Scanner device. The Properties window opens. 15. In the Properties window, enter any desired Description and the Device Address. The Device Address will be the 3D Solids Scanner's Polling Address + 1. Select OK when finished. 16. Expand the port with the newly added device. 17. Right-click on the new device and select New Dataset, see figure below. Add a new dataset to the device. 18. In the Dataset properties window, change the following parameters and select OK when finished. See Table 1-2 for an example configuration which displays all 13 parameters. a. On the General tab, in the Data direction list, select input. 10

11 b. On the DeltaV tab, in the DeltaV data type list, select the appropriate data type for the values which are to be retrieved. Table 1-1. Registers Number Register number Parameter Units Type & Avg. distance m Floating point & Min distance m Floating point & Max distance m Floating point & Volume % (*1000) Floating point & mA ma Floating point & SNR db Floating point & Temperature C Floating point & Temperature F Floating point & Avg. level m Floating point & Bulk density g/cm^3 Floating point & Mass customer unit Floating point & S/N number Long integer & Tag name First 4 chars 4 characters integer D N/A Floating point i. Select 32-bit unit w/status if using the "S/N" parameter in registers ii. iii. Select Floating point with status if using parameters in registers Select Sting w/status if using the "Tag Name" parameter in registers

12 Manual Supplement c. On the PLC tab, use the following settings: Device data type 3 Data start address: enter the start address. For example, if the first value should be 'Avg Distance', enter 0. If the first value should be Avg Level, enter 16. Number of values: enter the desired number of values to read. Note that reading the 'Tag Name' requires 2 values. d. On the Special data tab, use the following settings: No changes need to be made to Special data 1, Special data 3, Special data 4, or Special data 5 - the values should all remain 0. Special data 2 should be set to 1 only on the dataset to retrieve the 'Tag Name' parameter. For all other datasets the value should remain 0. For example, to configure all 13 parameters, construct 3 datasets with the following parameters: Table 1-2. Example Configurations Parameter Dataset 1 Dataset 2 Dataset 3 DeltaV data type Floating point with status 32-bit unit w/status String w/status Data start address Number of values Special data

13 19. If a multidrop connection is desired, each scanner should be linked with a device instance under the associated virtual serial port. Additionally, the required Datasets should be created. Repeat 14 through 17 to add each device; choose the appropriate Device Address to match the addresses of the physical devices. 20. All parameters in DeltaV are now set. To send this configuration to the DeltaV controller, I/O under the expanded controller menu must be right-clicked. Select Download -> I/O to begin the configuration download. Note Anytime a download to the controller or any of the cards occurs, the 3DMultiVision server will stop communicating with DeltaV. The server must be restarted or the SCADA Definition window must be opened and OK d to see values on DeltaV. The SCADA Definition can be found in the 3DVision application under Tools > Server Options > SCADA Configuration. Open the SCADA Definition and select OK. Figure 1-5. Download the Configuration 1.4 Using direct connection to DeltaV with a serial card If a direct connection to a DeltaV serial card is desired, the byte order will need to be manipulated in DeltaV to see the correct values. The 3D Solids Scanner's byte sending order is high to low; DeltaV assumes the byte sending order is low to high. The serial card is one of the card types in the DeltaV Explorer and is therefore configured like any other card. Each serial card has two ports, and each port can support as many as 16 serial devices. 13

14 Manual Supplement 1.5 Configuring byte order for connection via serial card Modbus is an application layer messaging protocol, positioned at level 7 of the OSI model, which provides client/server communication between devices connected on different types of buses or networks. Modbus bases its data model on a series of tables that have distinguishing characteristics ( 2012: 6). The four primary tables are: Table 1-3. Modbus Data model ( 2012: 6) Primary tables Object type Type of Comments Discrete Input Single bit Read-Only Can be provided by an I/O system Coils Single bit Read-Write Can be alterable by an application program Input registers 16-bit word Read-Only Can be provided by an I/O system Holding Registers 16-bit word Read-Write Can be alterable by an application program Since floating points and long integers (32-bit) are not embedded in Modbus, different methods have been used to send and receive data. The most common used method for the transfer of extended data types (floating point and long integers) is two consecutive 16-bit registers; however, the transmission sequence of the registers is not fixed. The Rosemount DLevel device sends the Most Significant Bit (MSB) in the first Modbus register and the Less Significant Bit (LSB) in the following register. Nevertheless, when DeltaV is set to read a 32-bit data register, it assigns the 16-bit world in the first Modbus register to the LSB data and the second register to the MSB. Figure 1-6. Modbus Word Order in Rosemount 5708 and DeltaV Rosemount D Solids Scanner DeltaV MSB LSB MSB LSB 16-bit word 16-bit word 16-bit word 16-bit word Register Low (4000X) Register High (4000X+1) Register Low (4000X) Register High (4000X+1) 16-bit word 16-bit word 16-bit word 16-bit word Modbus Data Modbus Data The discrepancy described above shows that the parameter data is not read correctly by DeltaV. 14

15 1.6 Workaround procedure 1. To order to get the correct values needed to decode each 16-bit word to individual bits, the words will be swapped to match with the transmission sequence used by the Rosemount D Solids Scanner. 2. Once the byte order has been swapped, the floating point parameters are converted from binary to IEEE 754 floating point using the following math equation: IEEE 754 = (-1) * Sign *(1 + Mantissa) * 2 (Exponent-127) 3. Once the byte order has been swapped, the long integer parameters can be retrieved by converting from binary to decimal. 1.7 Configuring serial card in DeltaV 1. Open DeltaV Explorer and navigate to the controller to which the Serial module is connected. 2. Expand the controller and right-click on I/O. 3. Select New Card to add the serial card. The Add Card window opens. 15

16 Manual Supplement 4. In the Card class list, select Serial Cards. 5. In the Card type list, select 2 Ports, Programmable RS232 RS In the Slot position list, select the slot position where the new serial card is attached and select OK. Once a serial card has been configured, the serial port properties can be set and serial devices can be added to the ports. 7. Expand the added serial card, right-click the port where 3D Solids Scanner is attached, and select Properties. 16

17 8. On the Port tab, select the Enabled check box. 9. On the Advanced tab, use the following settings: Protocol type: RTU Mode: Master Retry count: 1 Message timeout (ms): 1000 Transmit delay (ms): 0 17

18 Manual Supplement 10. On the Communications tab, use the following settings: Port type: RS422/RS485 half duplex Baud rate: Parity: even Data bits: 8 Stop bits: 1 Note Communication parameters in 13 were taken from the manual Different Ways of Connecting to 3D Solids Scanner II Version 3.0. Refer to the Rosemount 5708 Series 3D Solids Scanner Reference Manual (document number ) to confirm these parameters. 11. Select the port of the serial card (PO1 or PO2) where the 3D Solids Scanner is connected and where the communication parameters were set in the above steps. 12. Right-click and select New Serial device. 13. Set the device address to match the address of the physical 3D Solids Scanner connected to the serial card. The Device Address will be the 3D Solids Scanner s Polling Address

19 Note Device Address field should match the SCADA ID field from the 3DVision. The SCADA ID can be seen in the hardware inventory table: in 3DVision go to Tools > Reports > Hardware Inventory Table 14. If a multidrop connection is desired, each scanner must be linked with a device instance under the associated serial port. Repeat 11 through 13 for the second device. Set the address of the devices to match the address of the physical devices connected to the serial card. Note that each scanner should be configured with a different polling address. 15. Expand the port with the newly added device. 16. Right-click on the new device and select New Dataset. 19

20 Manual Supplement Note Repeat the last step to add more Datasets. When a multidrop connection is used, add the desired Datasets under each Device instance. To configure all 13 variables available for the 3D Solids Scanner, two datasets should be constructed. One dataset will be used to read the first 12 parameters; the other will read the Tag Name parameter. In master mode, the serial card exchanges data with the serial device through a dataset. A dataset is a collection of parameters associated with a serial device. The parameters in the dataset hold data values that correspond to registers or data in a serial device. The dataset defines the type and amount of data being sent to or received from the serial device. All the data values for a dataset have the same properties. Properties include the data type and data direction in addition to some other parameters. The data values in a dataset map to a contiguous series of serial device registers or data. As many as 16 datasets for each serial card port can be created. These 16 datasets can be allocated to the serial devices in several ways. For example, one serial device can be configured with 16 datasets, or 16 devices can be on the port, each having one dataset. 17. Right-click in the Create Datasets and select Properties. 18. Change the following parameters. See Table 1-2 for an example configuration which displays all 13 parameters and select OK when finished. a. On the General tab, in the data direction list, select input. b. On the DeltaV tab, in the DeltaV data type list, select the appropriate data type for the values which are to be retrieved. See figures on Example of the setup for a dataset constructed to read the first 12 parameters and Example of the setup for a dataset constructed to read the Tag Name parameter below. DeltaV data type: Enter the appropriate data type for the values which are to be retrieved. i. Select 16 bit unit w/status: use for the first 12 parameters in registers It will be referred to as Dataset1. ii. Select String w/status: use for the Tag Name parameter in registers It will be referred as Dataset2. 20

21 c. On the PLC tab use the following settings: i. PLC data type: holding registers (apply for both Datasets properties) ii. iii. PLC register offset: Enter the start address. For example, if the first value should be Avg Distance, enter 0. If the first value should be Avg. Level, enter 16. Number of values: Enter the desired number of values to read. Note that to read each parameter (Avg. Distance, Min Distance, Max Distance, etc.), two values are required. Example of the setup for a dataset constructed to read the first 12 parameters DeltaV tab. Setup DeltaV data type as 16 bit unit w/status. PLC tab. Setup the PLC data type as holding registers, PLC register offset as 0, and Number of values as 24. Example of the setup for a dataset constructed to read the Tag Name parameter DeltaV tab. Setup DeltaV data type as String w/status. PLC tab. Setup the PLC data type as holding registers, PLC register offset as 24, and Number of values as 2. Note The Dataset Tag can be modified to facilitate the data management. 21

22 Manual Supplement Table 1-4. Configuration for the Two Datasets which will Display a 3D Solids Scanner s 13 Parameters Parameter Dataset 1 Dataset 2 DeltaV data type 16 bit unit w/status String w/status PLC data type Holding registers Holding registers PLC register offset 0 24 Number of values All of the parameters in DeltaV are now set. To send this configuration to the DeltaV controller, I/O under the expanded controller menu must be right-clicked. Select Download -> I/O to begin the configuration download. 20. Right-click on Added device and select Diagnose to verify the communication status. Select a Dataset and double-click on StrtRegAddr to verify the values of the registers. 22

23 1.8 Configuring control strategies to obtain correct process values 1. The parameter Tag Name is read correctly by DeltaV. No additional configuration is required with regard to the value; it can be used directly from its Dataset. 2. For the first 11 parameters (Avg. Distance, Min Distance, Max Distance, Volume, 4-20mA, SNR, Temperature C, Temperature F, Avg. Level, Bulk Density, and Mass), the byte order must be swapped and converted from binary to floating point. A control strategy with the configuration shown below is used. 3. In the control strategy, set up the following parameters in the function blocks and variables (see Figure 1-7): a. AI1: For Device Tag use Browse to add the newly defined Dataset (Dataset1). For Parameter, assign the first Modbus register. b. AI2: For Device Tag use Browse to add the newly defined Dataset (Dataset1). For Parameter, assign the second Modbus register. c. PV: Parameter type should be defined as Floating point with status. d. SING: Parameter type should be defined as Floating point. e. MANTISSA: Parameter type should be defined as Floating point. f. EXPONENT: Parameter type should be defined as Floating point. g. CALC1: Enter the expression in Figure 1-8 and Figure 1-9. See APM 3DLevelScanner Integration with DeltaV docx 23

24 Manual Supplement Figure 1-7. Function Block Properties and Variables in the Control Strategy for Floating Points AI1. Set up the Dataset in the filed Device Tag and the first Modbus register in the field Parameter. PV. Parameter type should be Floating point with status. MANTISSA. Parameter type should be Floating point. AI2. Set up the Dataset in the filed Device Tag and the second Modbus register in the field Parameter. SING. Parameter type should be Floating point. EXPONENT. Parameter type should be Floating point. 24

25 Figure 1-8. Expression in CALC Block Control Strategy for Floating Points 4. For the parameter SN (Serial Number), the byte order must be swapped and converted from binary to long integer. A control strategy with the configuration shown in Figure 1-9 was used. Figure 1-9. Control Strategy for Long Integers 25

26 Manual Supplement 5. In the control strategy, set up the following parameters in the function blocks and variables: a. AI1: For Device Tag, use Browse to add the newly defined Dataset (Dataset1). For Parameter, assign the first Modbus register (40023). b. AI2: For Device Tag use Browse to add the newly defined Dataset (Dataset1). For Parameter, assign the second Modbus register (40024). c. PV: Parameter type should be defined as 32 bit unsigned integer. d. CALC1: Enter the expression as shown in Figure See APM 3DLevelScanner Integration with DeltaV docx Figure Properties for Function Blocks and Variables in the Control Strategy for Long Integers AI1. Set up the Dataset in the filed Device Tag and the first Modbus register (40023) in the field Parameter. PV. Parameter type should be 32 bit unsigned integer. AI1. Set up the Dataset in the filed Device Tag and the first Modbus register (40023) in the field Parameter. Figure Expression in CALC Block Control Strategy for Long Integers 26

27 1.9 Setting up 3DVison in DeltaV operate screen Assumption Modbus communications have been established between DeltaV and Rosemount 5708 Modbus register in the DVision server software is being read via Modbus The DVision server software has been installed and configured. Network permission between DeltaV operator interface and server running 3DVision software Add button in DeltaV operate configure 1. Launch DeltaV Operate (Configure). 2. Open desired operator pages. 3. Select Insert, then Push Button. 27

28 Manual Supplement Configure button 1. Double click the button and type a label. 2. Select and drag on arrows around button to resize. 3. Right click to launch context menu. 4. Select Edit Script. 28

29 Edit script 1. Select Edit Script to opens the Microsoft Visual Basic program. Place the cursor in the correct position to edit the script which runs when the button is pushed. The need for a script is to launch the viewer from a remote server so it is not resident on the DeltaV Pro Plus station. Modbus is used to make a read request for register 49990, which is seen by the 3DVision server software as a request to generate the 3D image from the 5708 transmitter. The script will launch the image viewer software and show the 3D image file from the remote server. The task kill command will close the image window so the operator will not have to manage the windows. When Edit Script is selected, a window will pop open and the cursor will be in the correct position to enter the following format: SHELL ( \\Server_Name\Path_to_Image_Viewer_Software \\Server_Name\Location_of_3D_Image\ Name of Image File ), vbnormalfocus SHELL ( taskkill.exe /im visualvision3dviewer.exe ) Below is the script command used in the Rosemount Lab: Shell ("\\usrtc-smartlab1\c\program files (x86)\3dvisionemrsn\binclient\bin\visualvision3dviewer.exe \\usrtc-smartlab1\c\3dvision 1"), vbnormalfocus Shell ("taskkill.exe /im visualvision3dviewer.exe") 29

30 Manual Supplement 2. Command line breakdown: Command Line \\usrtc-smartlab1 C (x86)\3dvisionemrsn\binclient\bin\ visualvision3dviewer.exe \\usrtc-smartlab1\c\3dvision 1 vbnormalfocus taskkill.exe /im visualvision3dviewer.exe Definition Name of Server Drive that contains 3DVision Server software program files Path to software Image display program. There must be a space after.exe! Location of image file as entered in 3DVision software server. Causes the image window to display in the foreground. Ends the image program when it is called again if the operator does not close it. The prevents multiple windows from being open in the background where the operator cannot get to them to close them. Testing 1. Once the script is entered, close Microsoft Visual Basic. 2. Press the Run button in DeltaV Operate Configure and the operator screen will open. 3. Select the new button and the 3D image window will open and the image will load. You will be able to maneuver the image with the mouse. 30

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