02) fam3 semina(recent advancements in control technologies)

Range-Free Multi-Controller

<Document Number>Copyright © Yokogawa Electric Corporation<date/time>

- 1 -- 1 -

Range-Free Multi-Controller

Ng Chye Wee

Netsol/PLC BU • Communication/Measurement & Netsol Marketing • Marketing Operations

Yokogawa Engineering Asia Pte Ltd

Introduction of FAM3, the involvement and solution of FAM3 within Automation Industry

About FAM3

• A versatile Control System, that come with flexibility to fit in both FA & PA yet a truly open system with simple engineering process.


- 2 -

FA PAFactory Automation Process Automation

About FAM3

Factory Automation Process Automation

PAFA


- 3 -

About FAM3

• A fusion product that integrate Sequence Control with Continuous Loop Control.


- 4 -

Sequence ControlContinuous Loop

Control

Executing Concurrently !

About FAM3

• With small size module and flexible configuration allow user the flexibility for planning of install space in cabinet.

• IO point can be added freely (by adding IO module) for expansion and with choice of 6 types of based unit, space planning never been so easy.

Down Sizing


- 5 -

with choice of 6 types of based unit, space planning never been so easy.

About FAM3

• Just one Software (Widefield 3) for Sequence CPU Programming, download, upload and debugging.

• Optional Software available to easy setting for special module like PID Control Module and Positioning Module.

Simple Engineering


- 6 -

Control Module and Positioning Module.

About FAM3

• Modular concept allow user to freely choose function/module that require for the control process, example:

– normal DI/DO

– Analog Input/Output

– Pulse Input

Minimum Cost


- 7 -

– Pulse Input

– PID Control/Temperature Control

– Temperature Monitoring

– Positioning Control

– Ethernet Communication

– RS232C Communication

– RS422/485 Communication

• Cost can be reduce due to fully optimize the function of the PLC system. Use only what you need.

About Control System

Control System Network

Operator

Station

Controller

HMI


- 8 -

Sensing Devices

Controller

Flexible Configuration/Installation (PA)

• It can construct a system which is adjusted to application and the installation space, example– In Central Monitoring System…..

SCADA software

+


- 9 -

CPU & I/O Modules

+


• In local control panel (at field or factory floor)….

Touch Operation Panel

CPU & I/O Modules

+


- 10 -

CPU & I/O Modules


• Integrate with DCS System


- 11 -

Flexible Configuration/Installation (FA)

• In Factory (Conveyor Belt System)


- 12 -


• In Machinery (Cutting Machine)


- 13 -


• In Precision Machine (Semiconductor-Pick & Place, Trim & Form)


- 14 -

Take A Closer Look at FAM3

Power Supply Module Sequence CPU Module

F3PU10-0SF3PU20-0SF3PU16-0NF3PU26-0N

F3SP21-0NF3SP28-3SF3SP38-6SF3SP53-4SF3SP58-6SF3SP59-7S

F3SP66-4SF3SP67-6SF3SP71-4SF3SP76-7S


- 15 -

IO Module

Special Module

Communication Module

F3XA08-1NF3XH04-3NF3XC08-0NF3XD16-3F

F3YC08-0NF3YC16-0NF3YD32-1PF3YP64-1P

F3XD16-3HF3XD32-3FF3XD64-3F

F3GB01-0NF3RS22-0NF3RS41-0NF3LE01-0TF3LE11-0T

F3LA01-0NF3LB01-0NF3LX02-1NF3LD01-0N

F3AD04-0VF3AD08-4RF3AD08-5R

F3CU04-1SF3CU04-0SF3CX04-0N

Scanning 100,000 steps within 1ms

The minimum scan time of 100µs is faster than microcomputer boards

Overview of FAM3


- 16 -

Range-free with max. 8192 digital I/Os and 856K device words

High performance and advanced functionality

All-in-one CPU

Ethernet. SD card and USB support are all condensed into a compact body

The minimum scan time of 100µs is faster than microcomputer boards

What is FA-M3 ?

• Range Free Multi-Controller

• Ultra Fast Speed CPU Processing

• Building Block Structure

• Scalable

• High Performance Special Module

Overview of FAM3


- 17 -

• Flexible

• Scalable

• Compact

• Able to Interface with various type of I/O (DI,DO,AI,AO)

• Able to support various Communication standard and Networking

Modules

Base Modules

CommunicationPower Supply

I/O Module

Types of Modules


- 18 -

CPUModule

CommunicationModule

Special Module

Power Supply Module

Sequence CPU (Ladder Logic Control)

Sub-System


GPIB DeviceNet

ASi PROFIBUS-DP UT Link

Ethernet Module (TCP/IP)

PC/DCS/Touch Screen/HUB

(Master)

(Slave)

PC/DCS/Touch Screen

PC Link Module

RS232C RS422/485

(Master)

(Slave)

FAM3 Block Diagram


- 19 -

Sequence CPU (Ladder Logic Control)

Transmitter

Control Valve

Temp

Control/P

ID

Module

RTD,Thermocouple,Voltage

Temperature Monitoring

Module

DI,DO,AI,AO

I/O Module

Sub-System

RS232C RS422/485

(Master)

(Slave)

Ladder Comm. Module

Motor Driver

Positioning Module

Pulse Voltage

Power

supply

module

Simply Combine Modules to Suit Your Applications!

CPU

module

Memory

card

module

High

speed

Data

aquisition

module

High

speed

counter

module

Positioning

module

ASI

Master

module

PROFIBUS-DP

interface

moduleFL-net

interface

module

DeviceNet

interface

moduleGPIB

communication

module

RS-232-C

communication

moduleEthernet

interface

module

Range Free


- 20 -

New

New

F3EM01-0N

F3HA08-0N

F3XP01-0H

F3XP02-0H

F3YP14-0N

F3YP18-0N

F3NC51-0N

F3NC52-0N

F3NC11-0N

F3NC12-0N

F3NC32-0N

F3NC34-0N

F3NC96-0N

F3LA01-0N

F3LB01-0N

F3LX02-1N

F3LD01-0N

F3GB01-0N

F3RS22-0N

F3RS41-0N

F3LE11-0TNew

New

F3PU10-0S

F3PU20-0S

F3PU16-0N

F3PU26-0N

F3SP21-0N

F3SP28-3S

F3SP38-6S

F3SP53-4S

F3SP58-6S

F3SP59-7S

F3SP66-4S

F3SP67-6S

F3SP71-4S

F3SP76-7S

New

Power

supply

module

Wide Range of High Performance Module !

CPU

module

16

points

Input

module

8

points

Relay

Output

module

64

points

Input

module

Personal

Computer

Link

module

FA

link

module

FA

Bus

module

64

points

Output

module

Analog

input

module

Range Free


- 21 -

F3XA08-1N

F3XH04-3N

F3XC08-0N

F3XD16-3F

F3XD16-3H

F3XD32-3F

F3XD64-3F

F3YC08-0N

F3YC16-0N

F3YD32-1P

F3YP64-1P

F3LC11-1F

F3LC12-1FF3LP01-0N

F3LP12-0N

F3LR01-0N

F3LR02-0N

F3LR02-1W

F3AD04-0V

F3AD08-1V

F3AD08-4R

F3AD08-5R

F3AD08-6R

Powersupplymodule

CPUmodule

Memorycard

module

HighspeedData

aquisitionmodule

Highspeedcountermodule

Positioningmodule

ASIMastermodule

PROFIBUS-DPinterfacemodule

FL-netinterfacemodule

DeviceNetinterfacemodule

GPIBcommunication

module

RS-232-Ccommunication

module

Ethernetinterfacemodule



- 22 -

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PowerSupplyModule

CPU CPU CPU CPU

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Powersupplymodule

CPUmodule

16pointsInput

module

8pointsRelayOutputmodule

64pointsInput

module

PersonalComputer

Linkmodule

FAlink

module

FABus

module

64pointsOutputmodule

Analoginput

module



- 23 -

1 2 3 4 5 6 7 8 9 10 11 12 13

PowerSupplyModule

CPU CPU CPU CPUModule

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Powersupplymodule

CPUmodule


8pointsRelayOutputmodule 64

pointsOutputmodule

Temperature Control/PID

module


Temperaturemonitoringmodule

32pointsInput

module



- 24 -

1 2 3 4 5 6 7 8 9

PowerSupplyModule

CPU CPU CPU CPUModule

Module

Module

Module

Module

Module

Module

Module

PowerSupplyModule

CPU

Module

Module

Module

Module

Module

Module

Module

Module

Power Supply

Module

CPU

Module

Module

Module

Module

Module

1 2 3 4 5 6 7 8 9



- 25 -

1 2 3 4 5 6

Power Supply

Module

Module

Module

Module

Module

Module

1 2 3 4

Power Supply

Module

CPU

Module

Module

Module

5 Types of Base Module


- 26 -

3 Basic item:

1. Base Unit

2. Power Supply Module

3. Sequence CPU

Not count as slot no.

Slot 1

Slot 2

Slot 3Slot 4

How to Construct a FAM3 Controller?


- 27 -

27

3. Sequence CPU

4. I/O Module

5. Positioning Module

6. Communication Module

Unit :0

Unit :1

FA

Bus

FA

Bus

Main

Sub

Max. 500m

per segment

CPU

Module

Module

Using 4 Slot Base UnitUsing 6 Slot Base UnitUsing 9 Slot Base UnitUsing 13 Slot Base UnitUsing 16 Slot Base Unit

Max. Total

Distance 1.4km

FAM3 Configuration (1 System)


- 28 -

Unit :2

Unit :7

FA

Bus

FA

Bus

Sub

Sub

Module

Module

Distance 1.4km

FA Bus

Main

Sub

Power Supply

Module

CPU

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

FA Bus

CPU

Max. 500m per segment

Unit:0

Power Supply

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

FA Bus

Module

Module Unit:1FA Bus

Expand as You Wish – Using FA Bus Module


- 29 -

Max. total distance 1.4Km

Power Supply

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

Module

FA Bus

Module

Module

FA Bus

Unit:7 Sub

FA Bus

FA-Link(1Km,500m,250m,100m) FA-Link

FA-Link

CPU

CPU CPU

CPUCPU CPU

FA-Link

FA-Link

FAM3 Configuration (Multiple System)


- 30 -

FA-Link

Max. 32 Station

CPU CPU

CPU

CPU

FA Link

Power Supply

CPU

Module

Module

FA Link

Module

CPU

Station:1

Module

Power Supply

CPU

Module

Module

FA Link

Module

CPU

Module

FA Link

Power Supply

CPU

Module

Module

FA Link

Module

CPU

Module

Station:2

Station:3

FA Link

FA Link

FA Link

FA Link

FA Link

FA Link

FA Link

FA Link

FA Link

Lin

k U

P as Y

ou W

ish –

Usin

g FA Lin

k M

odule

<Document Number>

Copyright © Yokogawa Electric Corporation

<date/time>

-31-

Max.

FA Link

FA Link

FA Link

FA Link

FA Link

Power Supply

CPU

Module

Module

FA Link

Module

CPU

Module

Station:32

FA Link

Y = Digital Output

Unit Number

Slot Number

Channel Number

CP

U

Slot No. 1 2 3 4

F3XD64-3

N

F3YD64-1

A

Y 0

0 4

0 1

to

Y 0

0 4

6 4

FAM3 I/O A

ddre

ssin

g S

yste

m

<Document Number>

Copyright © Yokogawa Electric Corporation

<date/time>

-32-

Y = Digital Output

Unit Number

Slot Number

F3XD64-3

N

X = Digital Input

Unit Number

Slot Number

Channel Number

X 0

0 2

0 1

to

X 0

0 2

6 4

All In One CPU

+Network Control Communication Data Handling+ +


- 33 -

Sequence CPU Memory

Card

ROM PAck

FTP Server Function

FTP Client Function

Modbus/TCP Client Function

Smart Access Function

- Accumulating routine data

- Saving error log

- Saving raw field data

Handling of large data

Instruction Faster speeds for bothbasic and application instructions

Process Focus on shared processing,etc., sensor control function

Response Shorter response time,faster response to interrupts

Scan Reduced total time required forcomputation and common processing

HighSpeed

High Speed

I

P

R

S


- 34 -

computation and common processing

High-speed Scan

High-speed Response

High-speed Instructions

High-speed Processing

S

Remote Maintenance of Equipment Made Easy through EmailOME = Operation, Maintenance, Engineering

Remote OME on Internet


- 35 -

Ethernet Module

F3LE11-0TF3LE01-5T

Long distance cable needed

About Remote I/O Solution


Operator

Station


- 36 -

Junction Box

Terminal

Junction Box

Multi-core cable

Multi-core cable

Long distance cable needed

About Remote I/O Solution


Operator

Station


- 37 -

Multi-drop (4 wire twisted pair) Multi-drop (4 wire twisted pair)

YHLS Master Module and Slave units

YHLSSlave Unit

YHLS Master ModuleF3LH01-1NF3LH02-1N

• 16 DI• 16 DO• 16 DI + 16 DO

Remote I/O Solution


- 38 -

Let’s Communicate!

There are many type of communication standard in the

industrial control market.

Each of them support of different organization and company.

Although each of them are different, but the objective is the

same.


- 39 -

Which is to provide a common communication platform so that

various I/O and equipment can be easily integrated together.

To achieve simplification of programming and shorten the

development time for the control system.

Let’s Communicate! Remote IO / Field Network

DeviceNet Profibus DP ASi


- 40 -

Personal Computer Link

ModuleF3LC11-1FF3LC12-1F


Serial

Ethernet

Master

SlaveClient


- 41 -

F3LC12-1FF3LC11-2F

Ethernet Interface ModuleF3LE01-0T -0N

Ideal for connecting to PCs or display

Ethernet

Server

Ladder Communication

ModuleF3RZ81-0FF3RZ82-0FF3RZ91-0F

RS232C Communication

ModuleF3RS22-0N

High-speed serial comm. Up to 115.2

kbps


Master


- 42 -

F3RS22-0NRS422/485


F3RS41-0N

Work with BASIC CPU using BASIC Programming Language

Sub System,

example:

Bar Code Reader

Weighing Machine

Displacement Machine

Serial

SlaveSerial

Master

Slave

GPIB Communication

ModuleF3GB01-0N

Optimal solution for automation of inspection system


GPIB


- 43 -

Oscilloscope

Power Meter

Multi-meter

& other Test & Measurement Instrument



- 44 -


DP


- 45 -

UT/UPController

Server for

8 pts Digital Input Module




Terminal Type

Connector Type

Connector Type

Terminal Type

Terminal Type

Basic I/O Module


- 46 -

8 pts Digital Output Module




Terminal Type

Connector Type

Connector Type

Terminal Type

Connector Type

FA-M3R Programming Tool WidefieldSF630-MCW

• Working in the Familiar Windows Environment

• Input Macro Function

Speeds Up All Kinds of Programming

E-mail functionincluded

For Sequence CPU

Versatile & User Friendly Programming Tools


- 47 -

• Input Macro Function• Input Completion Function

included•Object Ladder Increase Reusability

•Easy Debugging with Index View

• Powerful Find Function

• Sampling Trace Function

• User Log Function

Open Standard Engineering Language

Structured Text/Instruction List (ST / IL)Ladder Diagram (LD)

About IEC 61131-3 Programming Languages


- 48 -

Function Block Diagram (FBD) Sequential Function Chart (SFC)

Temperature Control/PID

ModuleF3CU04-0SF3CU04-1S

Temperature MonitoringModule

F3CX04-0N

Versatile control at high speed, accuracy and

resolution

Easy Temperature monitoring with superior cost-performance

SamplingUp to 144 Loops Supported

Superior, Easy Temperature/PID Control


- 49 -

Sampling

0.1s

Accuracy

±0.1%

Resolution

0.1 C

Up to 144 Loops Supported

• High-speed• High Accuracy• High-Resolution• Universal Input• Dynamic Auto-tunning

Toolbox for Temperature Control and Monitoring

ModuleSF661-ECWEasy Setup of Operation Parameters

Relentless Pursuit of Higher Speed and Richer Functionality

Versatile positioning control can be implemented using efficient setup tool

PositioningModule

(Pulse Output)F3NC32-0NF3NC34-0N

PositioningModule

(Mechatrolink-IIIInterface)F3NC97-0N

Drastically Reduced Tact Time


- 50 -

F3NC34-0N

For Fast, accurate, high-resolution and versatile positioning control

Open motion-control network interface

Relentless Pursuit of Higher Speed and Richer FunctionalityVersatile positioning control can be implemented using efficient setup tool

PositioningModule

(Multi-Channel Pulse Output)F3YP14-0N

Drastically Reduced Tact Time


- 51 -

F3YP14-0NF3YP18-0N

Use a single slot to control

8 axes

To Suit Every Application

High-speed Data

Acquisition Module

F3HA08-0N

Analog Input Module

F3AD04-##F3AD08-##

Four Built-in A/D converters

High-speed accuracy conversion with excellent noise

immunity

A Wide Selection of Modules !


- 52 -

Memory Card Module

F3EM01-0N

Analog Output Module

F3DA02-0NF3DA04-1NF3DA08-5N

Maintenance support without programming

High-speed Output Module

F3YD32-1H

Translates CPU performance into ultra high-speed output response

FAM3 Configuration

There are various configuration for FAM3 depends on the following factor:

a) Plant size

b) Process Units location/deployment

c) User Interface Requirement


- 53 -

53

c) User Interface Requirement

d) Control Room location

e) Field Instrument location /deployment

f) Cabling Layout (Copper Cable or Optical Cable)

g) Wireless adoption

Configuration Type 1

Simple control, 1 System, no HMI

Pow

er S

upply

CP

U

Module

Module

Module

StartStart StopStop

RunningRunning


- 54 -

Pow

er S

upply

CP

U

Module

Module

Module

Module

Typical Application :

Machinery

Conveyor Belt System

Packaging


1 System with Touch Screen

Pow

er S

upply

CP

U

Module

Module

Module

Module

Touch Screen


- 55 -

Pow

er S

upply

CP

U

Module

Module

Module

Module


Machinery


Packaging

Small Process Plant

Palm Oil Truck Loading System


1 System with HMI/SCADA Software Package (Running in a PC)

Pow

er S

upply

CP

U

Module

Module

Module

Module

HMI/ SCADA


- 56 -

Pow

er S

upply

CP

U

Module

Module

Module

Module


Machinery


Packaging

Small Process Plant

Palm Oil Truck Loading System


Multiple Systems with HMI/SCADA Software Package (Running in a PC located in Control Room)

HMI/ SCADA

ControlRoom HMI/

SCADA

EngineeringRoom

ManagementRoom


- 57 -


Small/Medium Process plant with wide area deployment

Water Treatment / Waste Water Treatment

Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

CP

U

Module

Module

Module

Module


Multiple Systems with only One System Communicate with HMI/SCADA Software Package

HMI/ SCADA

Pow

er S

upply

CP

U

Module

Module

Module

Module

Control Room


- 58 -




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

Module

Module

Module

Module

FA Link

or

FL Net

FA Link

or

FL Net


Multiple Systems with Remote Location(Using Radio Modem)

HMI/ SCADA

Pow

er S

upply

CP

U

Module

Module

Module

Module

Control Room

Rack Room/

Auxiliary RoomRadio Modem


- 59 -




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

Module

Module

Module

Module

Remote Location

Radio Modem


Multiple Systems with Remote Location (Using Lease Line)

HMI/ SCADA

Pow

er S

upply

CP

U

Module

Module

Module

Module

Control Room

Rack Room/

Auxiliary RoomModem


- 60 -




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

Module

Module

Module

Module

Remote Location

Modem


Multiple Systems with Remote Location At PC Side (Using Radio Modem)

HMI/ SCADA

Control Room

Radio Modem

Radio Modem


- 61 -

61




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

CP

U

Module

Module

Module

Module

Rack Room/

Auxiliary Room


Multiple Systems with Remote Location At PC Side (Using Lease Line)

HMI/ SCADA

Control Room

Modem

Modem


- 62 -




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply

CP

U

Module

Module

Module

Module

Rack Room/

Auxiliary Room


Remote Location within System

HMI/ SCADA

Pow

er S

upply

CP

U

Module

Module

Module

Module

Control Room

FA Link

or

FL Net


- 63 -63




Utility

Pow

er S

upply

CP

U

Module

Module

Module

Module

Pow

er S

upply FL Net

FA Link

or

FL Net

Ethernet Repeater

Ethernet Repeater

FAM3 Project Work Scope & Execution

Parties:

1) Yokogawa (PCI Sales)2) Yokogawa (System Sales, Project Sales)

3) Yokogawa (Project/Engineering Team)4) Yokogawa (Service Dept)

Work Scope:

• Supply of Hardware• Supply of Software• Programming of FAM3• Programming of HMI/SCADA Package/Touch Screen

For FAM3 project, there are various possible combination of work scope & responsibility cover by various party and how the project been executed.


- 64 -

64

4) Yokogawa (Service Dept)5) System Integrator (SI)6) Customer (SI)7) Customer (EPC)8) Customer (End User) 9) End User

Package/Touch Screen• Panel Engineering (Design, construct and installation)

• Factory Acceptance Test (F.A.T.)• Site Installation• Site Acceptance Test (S.A.T.)• Commissioning• Start-Up• Site Standby• Maintenance Contract

Plastic Machinery

Semicon. Eqpt Makers

Material Handling

Packaging

Electronic Prod. Machines

Automotives

AGV Manufacturers

Water TreatmentWaste Water TreatmentTank Storage TerminalFood ProcessingPharmaceuticalTextileIron & Steel

FAM3 Applications

PA (Process Automation) FA (Factory Automation)


- 65 -

AGV Manufacturers

(Aut. Guided Vehicle)Iron & Steel

Building Automation

Automatic Warehousing

Mail Transportation

Infrastructure

Remote Area

Local Area

Optic Fibre Repeater

Optic Fibre

OpticFibreCable

HMI/ SCADA

Ethernet(TCP/IP) orRS232C or RS422/485

HMI/ SCADA

Touch Screen

HMI/ SCADA

HMI/ SCADA

HMI/ SCADA

Phone Line

Modem

Modem

Router

Summary


- 66 -

66

WeigherMachine

PowerMeter

BarcodeReader

Push Button

LimitSwitch

Sensor Transmitter RTD Thermocouple

FlowComputer

MotorSolenoidValve

ControlValve

LocalIndicator

FA Link

Ethernet(TCP/IP)RS232C or

RS422/485

Optic Fibre Repeater

Router

Thank You !


- 67 -

02) fam3 semina(recent advancements in control technologies)

Documents