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YS100 Series A Complete Process Control Solution!

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1 YS100 Series A Complete Process Control Solution!
YS170 Dual Loop Programmable Controller Wecome to Yokogawa Corporation of America YS100 Series Controllers Product Introduction

2 YS100 Control Room Instruments
YS150 Pre-configured single loop YS170 Programmable dual loop (plus YS150) YS110 Standby manual station YS131 Dual input indicator with alarms YS135 Auto/Manual Station SV Loader YS136 Auto/Manual Station MV Loader YSS20 Programming Software YS170 can control TWO independent loops Where cost effectiveness is a key issue Three pre-configured control strategies + custom programming YS150 does not require any custom programming All configuration is performed at the front panel display SINGLE, CASCADE & AUTO-SELECTOR control modes YS110 - bypass station used in the event of controller outage Any installation with critical control loops should have ONE standby station YSS20 software is required to write a custom YS170 program YS131 trends two inputs and has eight alarm functions Looks & feels just like the controllers YS135 can provide a set point to an external control device Local set point adjustment bypassing a master device YS136 permits MANUAL output adjustment Used with a DCS or PLC installation

3 YS100 Hardware Platform Surface mount technology: reliable & low power
Non-volatile memory (EEPROM) Up to 400 lines of programming (YS170) Modular construction with separate boards for: Power supply (auto sensing AC or DC voltage) Communications (RS485, DCS, Peer-to-Peer) Signal conditioning input Independent CPU’s for control and display 24VDC Power for two-wire transmitters Integral HARD MANUAL backup Surface mount allows a smaller FOOT PRINT Only 12.6 inches in length allows installation into smaller control panels Modular construction allows communication cards & signal conditioning cards to be easily field retrofitted The control output can be manipulated & observed on the front display if the main CPU fails Non-isolated loop power for two transmitters is available (60mADC maximum) Integral HARD MANUAL allows continuous operation even if the controller fails

4 YS150 Pre-Configured No programming Setup without PC
3 ready to go strategies Single PID Cascade PID Hi/Lo Auto Select

5 YS150 Single Loop Strategy
See page in binder

6 YS170 Programmable Dual Loop
All the YS150 functions 2 Independent PID loops 400 lines of custom code

7 YS150/170 Model Description

8 YS150/170 Inputs/Outputs Controller Inputs/Outputs YS150 YS170
Analog inputs 4-20mADC analog output 1-5VDC analog output Selectable 4-20mA/1-5V Discrete inputs fixed function DI/DO Discrete outputs fixed function (Software Selectable) Independent PID loops Multiple inputs/outputs for complex loop/logic applications Up to 5 analog inputs (1-5VDC or 4-20mADC) TWO independent control loop capability TWO 4-20mADC analog outputs typically for control ONE 1-5VDC output for ? YS170 discrete assignments are selected using YSS20 programming software Total of 6, function selectable as to inputs or outputs Dry inputs or powered up to maximum Solid state outputs rated up to maximum 24VDC interposing relay required to switch AC voltage

9 YS131 Dual Input Indicator
Tag Name FI-1076 FAIL FAIL & ALM Lamps LOOP 1 ALM GPM 300.0 Process Variable PV: 146.9 Set Point Identical hardware platform as the YS150/YS170 controllers Two analog inputs & 8 alarms (4 per input) Six solid state discrete outputs can be configured to alarms High, high-high alarms Low, low-low alarms TREND displays ALARM display DUAL displays Signal conditioning & RS485/YS-Net communication options CHANGE Key (Press to Observe HH/LL Alarm Value) CHG 0.0 PAGE key SHIFT YOKOGAWA

10 YS135 SV Auto/Manual Station
Process Variable FAIL & ALM Lamps CASCADE (Remote SV) /\ & \/ Local Set Point PAGE key MANUAL Mode Override Remote SV Tag Name Set Point M FAIL ALM YOKOGAWA HIC-1076 PV: SV: 146.9 150.0 GPM 300.0 0.0 C LOOP 1 SHIFT Same YS100 series hardware platform Used to send a set point value to a controller Two analog inputs Process variable Cascade set point (CSV) from a master device (DCS, PLC) One discrete input Cascade/local (MANUAL) switching Three solid state discrete outputs High & low alarms Cascade/local (MANUAL) status TREND display ALARM display Signal conditioning & RS485/YS-Net communication options

11 YS136 MV Auto/Manual Station
FAIL & ALM Lamps CASCADE (Remote MV) Control Input from External Device PAGE key MANUAL Mode (Override Remote MV) Tag Name Process Variable Manipulated Variable (Control Output) /\ or \/ Output Set Point M FAIL ALM YOKOGAWA HIC-1076 PV: MV: 146.9 77.7 C O GPM 300.0 0.0 LOOP 1 SHIFT Hardware platform looks familiar Used to override a control output from a supervisory device and locally apply the output (MV) Two analog inputs Process variable (PV) Cascade MV from a master device (DCS, PLC) Two control (MV) outputs One 4-20mADC One 1-5VDC One discrete input Cascade/ local (MANUAL) switching Three solid state discrete outputs High & low alarms Cascade/local (MANUAL) status TREND display ALARM display Signal conditioning & RS485/YS-Net communication options

12 YS110 Remote Standby Station
INPUT OUTPUT 50 100 BAT CHK OFF SET CONT INC DEC MAN YOKOGAWA Powered by three 9VDC batteries Provides 4-20mA output to control element Can be inserted into controller case Powered by 110VAC while installed in enclosure Used while removing a malfunctioning controller from its enclosure and installing a spare Up to 3 hours of battery life Indication of PV & MV Slides into controller enclosure to operate from AC voltage This provides additional security, whereby manual control of the final element is NEVER lost Each user should have one YS110 for the unlikely event of instrument failure

13 YS100 Signal Conditioning
One signal conditioning card per instrument mV (/A01) Universal thermocouple (/A02) RTD (/A03) Potentiometer (/A04) Input isolator (/A05) 2 wire transmitter input with isolation (/A06) Frequency (/A08) ONE signal conditioning card per instrument Available for ALL YS100 series instruments Integral loop power supply is limited to ONE field transmitter if a signal conditioning card is provided (card uses part of the available supply, just like a field transmitter). Most popular signal conditioning cards /A02 Universal Thermocouple Microprocessor-based for all common T/C types Configuration performed at the front panel display A06 Input Isolator Provides optically isolated input & 24VDC to a transmitter Internal 250 ohms input resistor /A08 Frequency Input Up to 10KHz Dry contact or up to 24VDC

14 YS100 Security Features Password protection
Prevents unauthorized changes Allows all parameters to be viewed but not changed Built-in HARD MANUAL backup station Used if controller fails Controls Y1 analog output ONLY (LOOP 1) Standard feature (specify it!) Password is a 4 digit number installed in a pull-down menu 0000 to 9999 HARD MANUAL provides an alternate control output ( mADC) bypassing the digital electronic circuitry Output adjusted by moving a knurled and graduated (0-100%) thumb wheel on the front display sub-panel Green LED illuminates providing a bumpless transfer

15 YS100 Display Display Technology Display Screens
Backlit high resolution LCD Blue background or white background Display Screens LOOP (1&2) TREND (1&2) ALARM DUAL (1&2) (YS150 & YS170 only) TUNING (PID values, alarm set points, etc.) ENGINEERING (Eng. units, tag name, etc.) Small fluorescent bulb provides illumination Easy replacement by removing a cover at the top of the front panel assembly Expected bulb life: ~2 years Display is visible without the bulb Reversible displays allow two loops to be shown differently LOOP 1 may have a blue background and white foreground LOOP 2 may be configured to show the reverse Provides instant recognition of which LOOP is being viewed Up to 7 operator displays (Configure for 3 if only one loop) LOOP 1 & 2 TREND 1 & 2 ALARM summary DUAL 1 & 2 (STYLE 4 only, after April 1997) Configuration displays TUNING Menu ENG 1 & 2 Menus

16 Wiring of 24VDC Loop Supply
Two-Wire Transmitter Terminal 13 Xn + Input Xn - Input +24VDC 4-20mADC Precision 250 ohms Resistor YS150/170 Controller EJA YEWFLOW EXA pH200 + - Analog Input Terminal # X1 Positive 1 X1 Negative X2 Positive 3 X2 Negative 4 X3 Positive 5 X3 Negative 6 X4 Positive 7 X4 Negative 8 X5 Positive 9 X5 Negative 10 Two transmitters can be powered... Direct Input Option: Reduces available power to ONE transmitter!! Terminal 13 is the 24Vdc power supply Remember to use high wattage 250 ohm resistors TWO transmitters maximum Direct input, ONE transmitter only 17

17 YS170/YS150 LOOP Display A M PF FIC-1076 PV: SV: MV: C O TMP 122.5
Set Point PF M A FAIL ALM YOKOGAWA FIC-1076 PV: SV: MV: 146.9 150.0 77.7 C O GPM 300.0 0.0 LOOP 1 TMP 122.5 OFF SHIFT ALARM-1 Tag Number or Descriptor FAIL & ALM Lamps Remote Set Point (CSV) Local Set Point (SV) & Automatic Manual Operation of Output (MV) DATA WINDOW Process Variable Set Point Value Control Output Increase Set Point (SV) Decrease Set Point (SV) Programmable Function Key PAGE Key ALARM Indication TAG: Up to 8 ASCII characters Process variable (PV) is the measurement being controlled Set point variable (SV) is the desired set point Manipulated variable (MV) is the control output C mode key allows a cascade (remote) set point (CSV) from an external device & automatic control A mode key allows local set point (SV) & automatic control M mode key allows manual adjustment of the controller output /\ key increases set point variable (SV) \/ key decreases set point variable (SV) PF key can be used in a custom program Start/stop, override, you name it! PAGE key allows access to the various operator screens < & > keys decrease or increase the control output SHIFT & PAGE allows access to the configuration screens TUNING Menu ENG 1 & 2 Menus Manual Output Keys (< & >) SHIFT to observe TUNING & ENG

18 YS170/YS150 TREND Display A M C FIC-1076 O Time base selectable
by configuration (CONFIG 2) 90 seconds to 45 hours 90 samples displayed Always active All keys operational as LOOP display PF M A FAIL ALM YOKOGAWA FIC-1076 C TREND 1 PV1: SV1: MV: 146.9 150.0 77.7 300.0 GPM O.O 1M O OFF SHIFT Real time trending 90 PV samples shown Time bases adjustable using a configuration screen 8 different time bases “TICK” mark represents the time base selected (1 MIN, 1 HR, etc.) Default is 1 minute, exhibits 90 seconds 1 MIN, samples once per second 5 MIN 10 MIN 30 MIN, samples once every 30 seconds 1 HR, sampling once per minute 5 HR 10 HR 30 HR, samples every 30 minutes Excellent for loop tuning ALL front panel keys operational as with LOOP displays

19 YS170/YS150 ALARM Display A M C FIC-1076 O PF Process Alarms
High, low, deviation, velocity System Alarms Open input, output, defective A/D, RAM, CPU STC Alarms (Self Tuning Control) Time out, high/low PB, TI, TD High lighted = active/unacknowledged alarm X1 PF M A FAIL ALM FIC-1076 C ALARM PROCESS SYSTEM STC CLR PL1 PH2 O YOKOGAWA SHIFT Upper left quadrant exhibits any specific process alarms PH1 & PH2: Process high alarms PL1 & PL2: Process low alarms DL1 & DL2: Deviation limit alarms VL1 & VL2: Velocity limit alarms Upper right quadrant shows system alarms Open inputs or outputs (X1, X2, Y1, etc.) Electronic circuitry diagnostics alarms (RAM, A/D, etc.) Self tuning control (STC) alarms High or low proportional band calculations Insufficient change in PV over a pre-determined time Inoperative if STC is not turned ON

20 Dual Loop Display A M FAIL & ALM Lamps FIC-1076 PF C O Tag Number or
Increase Set Point (SV) Decrease Set Point (SV) Programmable Function Key PAGE Key Remote Set Point (CSV) Local Set Point (SV) & Automatic Manual Operation of Output (MV) FAIL & ALM Lamps Tag Number or Descriptor of LOOP 1 PV1 & SV1 highlighted LOOP 1 operational LOOP 2 can be only viewed from DUAL 1 display Manual Output Keys (< & >) SHIFT + PAGE to observe TUNING & ENG Menus Set Point PF M A FAIL ALM YOKOGAWA FIC-1076 C O GPM 300.0 0.0 DUAL 1 OFF SHIFT 1 2 200.0 DEG PV: SV: PV: SV: MV: Available after April 1, 1997 Style 4 YS150 & YS170 controllers Style 2 YS131 dual input indicators New higher contrast LCD with larger viewing angle New display assembly can be retrofitted to older styles DUAL 1 display allows operation of LOOP 1 while viewing LOOP 2 DUAL 2 display operates LOOP 2 and shows LOOP 1 Dual bar graph displays are NOT available for older styles Changes to the mother board have been made... Added features at NO ADDITIONAL COST!!

21 Tuning/Engineering Group Menus
PF M A FAIL ALM FIC-1076 C TUNING MENU PID 1 PID 2 STC 1 STC 2 P&T REG I/O DATA SHIFT YOKOGAWA ENG.MENU 1 CONFIG 1 CONFIG 2 SMPL&BATCH SC MAINT PASSWORD FX TABLE Configuration displays Tuning Menu group display PID 1 & 2 function modules STC 1 & 2 operations P&T REG - read/write constants for computations I/O DATA shown for troubleshooting ENG 1 & 2 Menu group displays CONFIG 1 used to select control mode, etc. CONFIG 2 for eng. units, scaling the LOOP displays, etc. SMPL&BATCH are embedded application-specific PID modifiers SC MAINT used only with a signal conditioning card PASSWORD - install the password FX TABLE - function generator output assignments (FX1 & FX2) GX1 & GX2 - function generator with assignable inputs & outputs PGM SET - program generator used for ramp & soak PID TABLE - preset PID parameters for PID scheduling K CONSTANT - read only constants used in computations

22 Tuning Menu - PID 1 A M C O FIC-1076 200.0 PID 1 PID 2 STC 1 STC 2
PF M A FAIL ALM FIC-1076 C TUNING MENU PID 1 PID 2 STC 1 STC 2 P&T REG I/O DATA SHIFT YOKOGAWA PID1 STC OFF PV SV MV % DV TI S TD S SFA SFB GW % GG PH PL DL VL VT S MH % ML % MR % RB % PMV % O PB1 200.0% 200.0 CHG SAV From TREND 1 screen, press & hold SHIFT while pressing the PAGE key once Press the C key to observe the PID 1 pull-down menu Use the A key to scroll downward through the menu to PB1 Press the \/ key to change PB1 from to 200.0 Proportional band setting is now 200.0% * appears to the left of PB1 New value is being used in RAM, but not resident in EEPROM If power is removed, new value is saved for up to two weeks Press SAV (M key) until * disappears New value is now in EEPROM By pressing the CHG (PF key), the TREND display appears Press the C key to scroll upward through the display selections Press the A key to move downward Press the /\ key to increase a selected value Press the \/ key to decrease the value Press the PAGE key to return to the TUNING Menu group Another selection can now be made

23 to change CTL strategy:
ENG MENU - CONFIG 1 CONFIG 1 PANEL from ENG MENU 1 Press A button to SET... PRESS /\ key to allow ENABLE Press A to high light CTL... Press & hold /\ button to change CTL strategy: SELECT CASCADE SINGLE PROG PF M A FAIL ALM FIC-1076 C ENG.MENU 1 CONFIG 1 CONFIG 2 SMPL&BATCH SC MAINT PASSWORD FX TABLE YOKOGAWA SHIFT START TIM1 COMM COMWR ENBL ADRS STBIT PAR NO BPS ATSEL LOW LOOP LOOP TRND TRND ALARM DUAL DUAL DISP NAME PRM DISP NAME PRM PROG DEFAULT REV SET ENBL CTL PROG CTL CONFIG 1 From Tuning Menu, press & hold SHIFT key and press PAGE After accessing the ENG group Menu, press the C key to view the CONFIG 1 menu Press the A key once to highlight SET - INHB Press the /\ key until ENBL appears Now you can change data on this screen The controller STOPs running its program and is forced to MANUAL Press the A key to move downward through the menu to CTL This selection allows control mode - pre-configured control strategy or custom program Press the /\ key about 5 seconds until SINGLE appears The pre-configured SINGLE loop mode is installed Press the \/ key until PROG reappears LOOP1, LOOP2, etc. at the lower portion of the display 0 bypasses the specific operator display 1 provides blue background with white foreground 2 provides white background with blue foreground PROG provides file name of installed custom program

24 ENG MENU - CONFIG 2 A M C FIC-1076 SCH1 3 FIC-1076 CONFIG 1 CONFIG 2
PF M A FAIL ALM FIC-1076 C ENG.MENU 1 CONFIG 1 CONFIG 2 SMPL&BATCH SC MAINT PASSWORD FX TABLE YOKOGAWA SHIFT FIC-1076 SET ENBL 3 PROG CMOD BMOD BUM CNT PID ALG I-PD ACT RVS VDIR C-O SCH SCL SCDP SCDV UNIT GPM TRDT M TAG FIC-1076 CMOD BMOD BUM CNT PID ALG I-PD ACT RVS VDIR C-O SCH SCL SCDP SCDV UNIT % TRDT M TAG YS170- SCH1 CONFIG 2 Press PAGE key to return to the ENG group Menu Press A key to view CONFIG 2 display Press A key to highlight SET Press /\ key until ENBL appears Press A key to highlight 1 next to SCH1 Press the /\ key until 3 appears - SCH1 is 3000 Scale is now 300.0 Press PAGE to return to the ENG group Menu

25 Discrete inputs/outputs
Tuning Menu - I/O DATA PF M A FAIL ALM FIC-1076 C TUNING MENU PID 1 PID 2 STC 1 STC 2 P&T REG I/O DATA SHIFT YOKOGAWA FIC-1076 I/O DATA X X X X X Y % Y % Y % DI DI DI DI DO DO Shows analog inputs X1 - X5 Analog outputs Y1 - Y3 Discrete inputs/outputs DI or DO 0 = low 1 = high Excellent troubleshooting screen Shows analog inputs before any conditioning (raw ANI) X inputs can be scaled into engineering units (YS170 only) Analog outputs (Y numbers) in percentage Discrete inputs and/or outputs show 0 or 1 (low or high)

26 Pre-configured SINGLE Mode
CONFIG 1 PANEL from ENG MENU 1 Press A button to SET... PRESS /\ key to allow ENABLE Press A to high light CTL... Press & hold /\ button to change CTL strategy: SINGLE PF M A FAIL ALM FIC-1076 C ENG.MENU 1 CONFIG 1 CONFIG 2 SMPL&BATCH SC MAINT PASSWORD FX TABLE YOKOGAWA SHIFT START TIM1 COMM COMWR ENBL ADRS STBIT PAR NO BPS ATSEL LOW LOOP LOOP TRND TRND ALARM DUAL DUAL DISP NAME PRM DISP NAME PRM PROG DEFAULT REV SET ENB CTL SINGLE CTL CONFIG 1 From the LOOP 1 display, press & hold SHIFT and press PAGE key twice - ENG MENU 1 appears Press the C key to view the CONFIG 1 display Press the A key to highlight SET Press the /\ key to allow ENBL Press the A key to highlight CTL Press the /\ key until SINGLE appears You are now in the pre-configured SINGLE LOOP mode

27 PID Tuning Parameters A M C C O PID 1 Display from TUNING Panel
PF M A FAIL ALM FIC-1076 C TUNING MENU PID 1 STC 1 PARAMETER I/O DATA SHIFT YOKOGAWA FIC-1076 PID1 STC OFF PV SV MV % DV TI S TD S SFA SFB GW % GG PH PL DL VL VT S MH % ML % MR % RB % PMV % C O PB1 20.0% 20.0 CHG SAV PID 1 Display from TUNING Panel Press A button until PB1 is highlighted... Press \/ until PB1 is 20.0%. Change TI1 to 10 seconds. Press PAGE to return to TUNING menu. Select PARAMETER by pressing \/ button... Press A until PLG1 is highlighted... /\ until 1.0 is set... Return to the ENG MENU 1 display by pressing the PAGE key Press & hold the SHIFT key and press the PAGE key twice to view the TUNING MENU Press the C key to view the PID 1 menu Press the A key until PB1 is highlighted Press the \/ key until 20.0 is shown Press the A key to highlight TI1 Press the \/ key until 10 is shown Press the PAGe key to return to TUNING MENU Press the \/ key to view the PARAMETER list Press the \/ key until PLG1 is highlighted Press the /\ key until 1.0 is shown Press the PAGE key to return to the TUNING MENU Press & hold SHIFT and press PAGE twice to view LOOP 1 Place controller in AUTO by pressing the A key

28 RS485 Communications Option (/A31)
Set Point PF M A FAIL ALM YOKOGAWA u FIC-1077 PV: SV: MV: 246.9 250.0 77.7 C O GPM 5000.0 0.0 LOOP 1 TMP 172.5 OFF SHIFT FIC-1076 PV: SV: MV: 146.9 150.0 77.7 C GPM 300.0 0.0 LOOP 1 TMP FAIL ALM 122.5 C A M Up to 16 instruments/serial port PF PF OFF Available on ALL YS100 Series Instruments O SHIFT YOKOGAWA u 21

29 Peer-to-Peer Communications (/A33)
YS-NET PV1 SV1, Auto/Manual Status Up to 16 Instruments 4 transmitting 16 receiving MV1 Set Point PF M A FAIL ALM YOKOGAWA u FIC-1076 PV: SV: MV: 146.9 150.0 77.7 C O GPM 300.0 0.0 LOOP 1 TMP 122.5 OFF SHIFT 22

30 YSS20-210 Programming Software
Required to write a custom YS170 program Latest edition is Version 1.04 Required for peer-to-peer communications option (/A33 card) Required for 400 steps of programming Package includes two 3.5 inch diskettes and programming cable Required to create YS170 custom programs We CANNOT sell programming cables separately

31 YSS20 Programming Software
Write custom programs on PC Upload/download programs from PC to YS170 Data monitoring mode

32 Fundamentals Basic Features Location of important reference material
Library of 36 function modules (PID, function generators, math, boolean logic, etc.) 400 lines of program possible, with comments Flexible use of software flag registers Subroutines and conditional branching Location of important reference material YS170 Programming Manual is the best source TI 1B7C2-03E Control Functions Manual TI 1B7C1-01E TI 1B7C2-03E YS170 Programming Functions BSC on page 4-4 CSC on page 4-8 SSC on page 4-14 Control data registers on page 5-2 Control flags on page 5-16 System flags on page 5-25 Appendix 1 List of Program Functions

33 Programming Function Modules
PID Control (BSC, CSC & SSC) Math Functions (+, -, *, /, SQT & ABS) Program Constants (P, T & K) Boolean Logic (AND, OR, NOT, EOR) Alarms (HAL, LAL, DLM & VLM) Discrete Inputs/Outputs (DI/DO) Timers, Lead, Lag & Deadtime Functions (TIM, LED, LAG & DED) Function Generators (FX & GX) BSC1 & BSC2 Two independent PID computation function blocks. CSC (Cascade): Two PID blocks in series, i.e., the MV of the first PID block is softwired to the CSV of the second PID block. SSC (Signal Selector): Two PID blocks in parallel, each with an independent process variable (PV). The output (MV) is selected between the higher or lower of the two PID blocks.

34 Programmable Control Strategy Wiring Terminations
GS 1B7C2-01E YS170 Single-Loop Programmable Controller Analog Input 1 Terminals 1 & 2 Analog Input 2 Terminals 3 & 4 Analog Output 1 (4-20mADC) Terminals 22 & 23 Analog Output 2 (1-5VDC) Terminals 24 & 25 Discrete Input 1 Terminals 38 & 39 Discrete Input 2 Terminals 36 & 37

35 Programming using the PC
File management Program editing Parameter editing Communication Documentation printing File Management: TMP are working files TMP.HD is header (Program Description in File Management) TMP.PRG is source code (Program) TMP.PRM is parameters (Configuration Data) TMP.OBJ is object code (File Name) TMP is saved to NAMED file only when “SAVE FILE” is run

36 Stack Registers Operation
X1 + X2 = Y1 X1 LD X1 X2 LD X2 + A B C D X1+X2 Y1 ST Y1 I/O Registers Stack Lost 5 levels of storage LD command places register in STACK Operator performs a computation on register(s) in STACK ST command sends results to another register EXAMPLE: LD X1 Analog input 1 LD X2 Analog input 2 Add ST Y1 Analog output 1 Show last pages from programming TI.


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