Technical Information

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

TI 34P02K35-02E

TI 34P02K35-02E © Copyright Apr. 2016 (YK) 1st Edition Apr.28.2016 (YK) 3rd Edition Jun. 6.2018 (YK)

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All Rights Reserved. Copyright © 2001, Yokogawa Electric Corporation TI 34P02K35-02E Jun. 6, 2018-00

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.

Related Documents - GS 34P02Q02-01E FCN-RTU Autonomous Controller Functions - GS 34P02Q03-01E FCN Autonomous Controller Functions (FCN-500) - IM 34P02P25-01E NPAS POU – Overview - IM 34P02Q01-01E STARDOM FCN/FCJ Guide - TI 34P02A13-01E FCN-500 Technical Guide - TI 34P02A14-01E FCN-RTU Technical Guide - TI 34P02K13-02E STARDOM FCN-500/FCN-RTU

Primer – Fundamental - TI 34P02K25-01E STARDOM Network Configuration Guide - TI 34P02Q91-01E STARDOM FCN/FCJ Installation Guide

IMPORTANT Notation in this document: - The term “FCN-500” refers to the autonomous controllers with NFCP501/NFCP502 CPU module. - The term “FCN-RTU” refers to the low power autonomous controllers with NFCP050 CPU module.

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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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CONTENTS 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

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

TI 34P02K35-02E 3rd Edition

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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 ......................................... 116 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 ................. 117

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

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

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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 FCN-500 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, FCN-RTU 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 in-house 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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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:

NPAS_POU's execution timeControl task interval

CPU load (%) = x 100%

• 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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● 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.

IMPORTANT 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.

Execution time

Scan cycle

Idle time

Execution time Scan cycle CPU load (%) ＝ ｘ 100 %

CPU load ≤ 60%

Executes communication and Duolet functions

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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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● 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. Execution time Scan cycle CPU load

70 ms 100 ms 70% 70 ms 200 ms 35%

IMPORTANT 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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● 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.

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)

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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-to-date. 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 non-volatile 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 up-to-date data values are always maintained so keeping retain data resident in non-volatile memory is the usual practice.

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

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

If a backup of retain data is saved on the flash memory, in case of event that data retained in non-volatile memory cannot be used for whatever reason, retained data values as at the time of saving will be restored from the system card. by doing so, it avoids the worst-case scenario where all retain data variables are initialized. Compared to keeping retain data resident in non-volatile memory, keeping retain data reside in volatile memory enables a shorter execution time, and hence a shorter scan cycle for FCN-500 or FCN-RTU operation. However, if the FCN-500 or FCN-RTU is powered off and on again, retain data values before power off is lost and retain data values are always restored from the flash memory. To prepare for unexpected contigency, save retain data to the flash memory regularly, and also by manually whenever retain data is modified.

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

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

SEE ALSO For details on time synchronization of FCN-500 or FCN-RTU, see: - Section B1.9.4, “Time Synchronization Function” of IM “STARDOM FCN/FCJ Guide” - Section 2.3.3, “Time Synchronization Function” of TI “FCN-500 Technical Guide” - Section 2.3.3, “Time Synchronization Function” of TI “FCN-RTU Technical Guide”

● For FCN-500 Running as SNTP Server After setting through FCN-500 maintenance page, the FCN-500 time

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

However, the FCN-500 cannot provide highly accurate time reporting as its reported time includes internal timer error of -17.5 to +12 seconds/day.

1. JEROS Basic Setting File (DOUNUS.PRP)

It specifies whether to start the SNTP server function. This setting is for only FCN-500 only. Specify YES to start SNTP Server.

Setting item: Start the SNTP server function (SntpServer) SntpServer = YES use the SNTP server function SntpServer = NO not use the SNTP server function,

default value

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

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

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

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

implemented at the following two locations. 1. JEROS Basic Setting File (DOUNUS.PRP) Configure for the use of SNTP client function. 2. SNTP Setting File (SNTP.PRP)

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

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

3.1 Resource Configurator Setting Among the hardware configuration items reviewed and described in Chapter 2, the following items are configured using Resource Configurator: - I/O module operation - Enabling/disabling of automatic loading of I/O modules - Duplexed operation - Enabling/disabling of hardware backup of retain data

SEE ALSO - Section 2.1.2,”Checking Operation Specifications of I/O Modules” - Section 2.1.3,”Checking Automatic Loading of I/O Modules” - Section 2.1.4,”Measures for Duplexing” - Section 2.2.5,”Retentive Variable (Retain Data) Considerations”

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

For details on the Resource Configurator and how to use the Resource Configurator Editor, read “STARDOM FCN-500/FCN-RTU Primer – Fundamental”（TI 34P02K13-02） and the Resource Configurator online help documentation.

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● Precautions When Using FCN-500 or FCN-RTU with No Actual I/O Modules Resource configurator R4.20 or later can maintain unimplemented I/O module definition. If FCN-500 or FCN-RTU is not installed with the required I/O modules and new hardware configuration us downloaded using Resource Configurator R4.10 or earlier, existing I/O module configuration already defined will be overwritten and lost.

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

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

● Using Resource Configurator Editor Resource Configurator works by first reading configuration information from a running FCN-500 or FCN-RTU, and then downloading new configuration information after it has been modified on a PC. As such, it cannot be used to perform hardware setup without a running FCN-500 or FCN-RTU. To perform hardware setup when an FCN-500 or FCN-RTU is not available, such as in the early phase of engineering or in a job involving modification of an existing system, use Resource Configurator Editor instead. Settings defined using Resource Configurator Editor can be saved to a file, and downloaded later using Resource Configurator when the FCN-500 or FCN-RTU is available for connection.

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

SEE ALSO - Section 8.2, “Checking Serial Communication Specification (Serial Communication Port Settings)” - Section 2.2.6, “Time Synchronization”

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

SEE ALSO For details on the operation and configuration items accessible on the maintenance homepage, see: - Chapter B2, “Advanced Settings Using Web Browser“ of IM “STARDOM FCN/FCJ Guide” - Section 4.1.6, “Settings of FCN/FCJ by Web Browser“ of TI “FCN-500 Technical Guide” - Section 4.1.6, “Settings of FCN/FCJ by Web Browser“ of TI “FCN-RTU Technical Guide”

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4. Control Application Creation Control applications executed by FCN-500 and FCN-RTU autonomous controllers are created using Logic Designer and then downloaded to the FCN-500 and FCN-RTU. This chapter describes precautions on Logic Designer setup, as well as basic principle, know-how and prohibitions on creating control applications. For details on basic user operations of Logic Designer, see TI “STARDOM FCN-500/FCN-RTU Primer – Fundamental" and the Logic Designer online help documentation.

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

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

● Template Types and Selection Criteria When creating a new project, the project type can be selected from the following three template projects.

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

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

As such, select this template only when creating an application that uses neither NPAS_POU nor PAS_POU.

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

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

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

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

● Adding Libraries Logic Designer allows libraries to be added to a project to expand the available functions. Similarly, an application using an APPF can be created by installing the required APPF from DVD-ROM to a PC running Logic Designer, and adding the relevant libraries to the project. Examples: - To create an application using NPAS POUs, select the STARDOM FCX template

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

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

SEE ALSO Section 2.1.5, "Required Licenses”

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

● General Limitations of Control Tasks All control tasks are subject to the following limitations. • Limit on number of tasks Up to 16 control tasks can be created for one FCN-500 or FCN-RTU. Running

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

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

with the following restrictions: - A task name cannot begin with a number. - A task name cannot contain two contiguous underscore (‘_’) characters. - A task name cannot end with an underscore (‘_’) character.

● Types of Control Tasks There are three types of control tasks with different behaviors.

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

used for most control applications. • Default A default task has the lowest execution priority among all control tasks. It is not

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

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

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

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

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

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Execution triggers (status change or error) for a system tasks can be selected from a list of predefined triggers.

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

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

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

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● Control Task Settings The Task Settings dialog is used for specifying the execution interval, execution priority, watchdog time and other settings of a control task. For details on the relationship between the execution interval, priority and watchdog time of a control task, and how these settings affect task execution, see Section 4.3.3, “Task Schedule” of TI “FCN-500 Technical Guide,” Section B4.3.3, “Task Schedule” of TI “FCN-RTU Technical Guide.”

1. Execution interval of control task Specify the execution interval of a control task in the [Interval] field on the Task Settings dialog. The default execution interval for a new project is 100 ms. Modify it according to the value decided as described in Section 2.2.4, ”Determining FCN/FCJ Scan Cycle.” 2. Priority When running multiple tasks concurrently on an FCN-500 or FCN-RTU, specify a value (ranging from 0 to 31 in decreasing priority) for [Priority] on the task settings dialog as the priority level of a task relative to other tasks during execution. Assigning different priority values to individual tasks running in multi-tasking mode is recommended. 3. Watchdog time When the actual execution time of a control task exceeds the specified [Watchdog Time], a watchdog error is generated and handled according to the setup described in Section 4.1.4, “Specifying Target FCN/FCJ.” Setting the watchdog time to 0 disables the watchdog timer. Set the watchdog time to the same value as the control task execution interval as described in Section 4.1.4, “Specifying Target FCN-500, FCN-RTU” is recommended 4. Other Settings The other settings on the Task Settings dialog including [Stack] and [Options] can be left unchanged at default values.

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

SEE ALSO For details on the behavior of the FCN-500 or FCN-RTU when multiple tasks are created, see Section 4.3.3, “Task Schedule” of TI “FCN-500 Technical Guide,” Section 4.3.3, “Task Schedule” of TI “FCN-RTU Technical Guide.”

● Considerations Multi-tasking Two possible reasons for considering implementing multi-tasking are given below: 1. To create control tasks having different execution intervals in an attempt to

reduce CPU load of the FCN-500 or FCN-RTU. For details, see Section 2.2.4, “Determining FCN-500, FCN-RTU Scan Cycle.”

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

level for sorting control tasks to be instantiated by function.

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

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

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

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

● Precautions When Multi-tasking Pay attention to some precautions when using multi-tasking.

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

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

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

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

● Defining Task Behavior upon a Watchdog Error Event How a control task behaves when its execution time exceeds the specified watchdog time described in Section 4.1.2, “Control Task Setup” differs whether the “The task aborts when the execution time...” checkbox described above is ticked or not. • Common behavior regardless of whether checkbox is ticked or not If the watchdog time described in Section 4.1.2, "Control Task Setup” is set to a

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

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

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

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

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

generated, and the control task continues execution.

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

● Watchdog Time Setting On the other hand, monitoring task execution time using watchdog time provides important diagnostic information about the current state of the system. Therefore, set the watchdog time described in Section 4.1.2, “Control Task Setup” to the same value as the scan cycle to enable monitoring of the execution time of a control task. In this way, a watchdog error will be generated and recorded in the system log file whenever a control task fails to complete execution within the specified duration. Moreover, as described in Section 2.2.3, “Checking FCN-500, FCN-RTU Performance,” control execution time increases as CPU load increases. In cases where an increased CPU load for whatever reason is expected to affect the entire system, set the watchdog time to a value between 80% and 90% of the scan cycle. With this setting, a watchdog error will be generated whenever the CPU load (%) exceeds 80% to 90%, thus providing an effective means for monitoring the CPU load.

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

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4.1.5 Multi-resource Project In Logic Designer applications, FCN-500s or FCN-RTUs are called resources and one FCN-500 or FCN-RTU controller maps to one resource. In the example shown in the figure below, a system comprises three FCN-500s so three resources are created. When creating projects for this system, you can choose either to create three resources within one project, as indicated by the solid line, or create three projects, one for each resource, as indicated by the dotted lines. In cases like this where there is more than one resource within a system, consider and decide whether to create one project containing multiple resources, or one project per resource.

FCN01 FCN02 FCN03

Project

Project01 Project02 Project03

When creating a multi-resource project, the number of resources that can be defined within one project of Logic Designer is limited to 100 as described in Section 4.1.6, “Application Size.” This system limit, though present, is actually large enough for most practical systems. On the other hand, creating one project per resource requires creating as many projects as the number of resources, which makes project management on the development PC more tedious. Hence, in principle, create only one project even if there are multiple resources within a system is recommended. However, having many resources within one project makes engineering work more tedious and may cause confusion. Therefore, we recommend limiting the maximum number of resources per project to between 5 and 10.

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

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

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

2. Maximum number of program instances in the resources: 1000 This is the maximum number of logical POUs that can be created as an instance in one resource (FCN-500 or FCN-RTU).

3. Maximum number of tasks in the resources: 16 This is the maximum number of tasks that can be defined for one resource (FCN-500 or FCN-RTU).

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

5. Maximum number of global variables: 15000

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

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7. Maximum value of code size in the logical POUs: 200KB This is the upper limit on the size of one logical POU. If the size of a logical POU exceeds 200 KB, a compiler error is generated. If the size exceeds 80% of 200 KB, a compiler warning is displayed.

8. Maximum number of input/output parameters of the functions/function blocks: 300

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

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

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

12.Maximum number of types of available functions/function blocks in the logical POUs: 620

13. Maximum number of available functions/function blocks in the logical POUs: 1024

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

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

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

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

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

4.2.1 Programming Languages Supported by Logic Designer Logic Designer supports 5 types of programming languages conforming to the IEC 61131-3 standard for creating applications. • FBD (Function Block Diagram) In FBD, functions, application blocks and NPAS_POUs are provided as blocks

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

• LD (Ladder Diagram) LD is the most widely used language for programming PLC applications, where

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

Besides offering a visual representation of data flow like FBD, LD allows not only analog signals but also digital signals to be represented visually using BOOL-type contacts and coils.

• SFC (Sequential Function Chart) An SFC consists of steps, transitions and actions. While a step is active, actions

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

SFC’s step-by-step processing makes it ideal for building process progress type applications and sequence control applications.

• IL (Instruction List) In IL, each line consists of one operator and its operands, so coded expressions

are unambiguous but it is cumbersome for coding complex logical relations. • ST (Structured Text) In ST, control applications are coded using text. ST allows conditionals, such as

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

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

FBD (Function Block Diagram)LD (Ladder Diagram)ST (Structured Text)IL (Instruction List)SFC(Sequential Function Chart)Step execution languages

Continuous execution languages

Graphical languagesText-based languages

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

4.2.2 Selecting a Programming Language

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

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

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

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

● Simple Application Creating an application that is easy-to-understand simplifies logic checking at the time of application creation. It increases the accuracy of desk debugging, and reduces the number of bugs during application creation. Moreover, a simple application is not only easily understood by the developer himself but also by other engineers. For ease of future job handover to other engineers as the development team grows, it is important to create simple applications that are easy-to-understand.

4.3.2 Example of a Simple Application We discuss the concept of simple application with a concrete example below.

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

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

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern A

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern B

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Segmentation pattern C

Analog input

NPAS_PID

Analog output

MV=0% sequence logic

PV value calculation processing

Logic for writing SV value

Unsegmented worksheet

As the logic for setting MV=0% and logic for writing SV value are relatively simple, including their codes into the same worksheet for analog I/O and NPAS_PID may increase ease of understanding. This option for worksheet creation is shown in segmentation pattern B above. Over segmentation may sometimes lead to a more complicated application. In segmentation pattern C, the analog I/O and NPAS_PID function is segmented into three pieces, namely, analog input, NPAS_PID, analog output. The figure below shows the actual view displayed in Logic Designer after creation.

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