Wireless System Setup (CENTUM VP) Procedure

OUTLINE

1.0 SOFTWARE
 Media
 PC minimum requirement
No. Operating System Service Pack
1 Windows Vista Business Edition 1 or 2
2 Windows XP Professional 3
3 Windows Server 2003 2
4 Windows Server 2003 R2 2
5 Windows Server 2008 Standard Edition 2

Note: Please refer to IM33M01A20-40E for more information. Tested using Windows XP Professional
SP 3.

 Licensing

2.0 HARDWARE
 Field Wireless Gateway / Backbone Router / System Manager

Field Wireless Transmitter
 CENTUM VP
 FCS (Tested using the following configuration)
 Model No.: AFV10S-S2-S31201 (Tested)
 Controller: CP451-10 S2
 I/O Module: ALE111
 Communication card
 VI702 Vnet/IP Card

 Peripherals

3.0 NETWORKING
 Basic setup of Transmitters
 Setting up IP Address
 Setting up the Gateway / Backbone Router / System Manager
 Communication Protocol

4.0 SYSTEM SETUP

 Basic Engineering
 APPENDIX 1
A) Modbus Mapping
B) Data Quality Flag Details
C) Device Diagnostics Details

APPENDIX 2
A) Transmitters Out of Service
B) Transmitters Sensor Failed
C) Transmitters Power Off (Battery Unplugged)

APPENDIX 3
A) Additional Information on ALE111 (taken from GS 33K50G11-50E)Transmitters Out of
Service

INTRODUCTION

This procedure is written to serve as a basic start up guide for System Engineers using CENTUM VP to
communicate with Yokogawa’s ISA100.11a Wireless System and with assumption that the wireless
transmitters have been successfully connected to the gateway (YFGW 710). Therefore, this manual
would be focusing on the implementation of the control and monitoring of the wireless transmitters’
status and process variables, with only minimal guidelines in setting up the wireless network from
gateway to devices.

1.0 SOFTWARE

1.1 Media
 CENTUM VP R4.02.30 and above (Tested using R4.03.00)

1.2 PC minimum requirement (For Centum VP)

No. Operating System Service Pack

1 Windows Vista Business Edition 1 or 2
2 Windows XP Professional 3
3 Windows Server 2003 2
4 Windows Server 2003 R2 2
5 Windows Server 2008 Standard Edition 2
 Note: Please refer to IM33M01A20-40E for more information. Tested using Windows XP Professional
SP 3.

1.3 Licensing
 Demo license used was supplied by PMK Dept. for unlimited time usage.
 Basic standard package required consist of:
 LFS2753.KCD

2.0 HARDWARE (TEST SETUP)

2.1 Field Wireless Gateway / Backbone Router / System Manager

 Field Wireless Gateway
 Model No.: YFGW710-S1
 Suffix No.: A02-S10DA/AC3A/FN17
 Version Revision: R1.01.00
 Backbone Router & System Manager are built in features of the field wireless gateway
(YFGW710)

2.2 Field Wireless Transmitter

 Temperature
 Model No.: YTA510-S1
 Suffix No.: L77DBAA/X2/FS17
 FCC ID: SGJ-WFC001
 IC: 8999A-WIC001
 Version Revision: R1.02.01
 Pressure
 Model No.: EJX530B-S1
 Suffix No.: LCS4N-07JDF/FS17/X2
 FCC ID: SGJ-WFC001
 IC: 8999A-WIC001
 Version Revision: R1.02.01
 2.3 CENTUM VP
 FCS (Tested using the following configuration)
 Model No.: AFV10S-S2-S31201 (Tested)
 Controller: CP451-10 S2
 I/O Module: ALE111
 Communication card
 VI702 Vnet/IP Card

2.4 Peripherals
 CAT5E / CAT6 UTP Cable
 L2SW (If more than 1 PC is connected to the gateway or FCU)
 24VDC Power cable (For Gateway YFGW710, which doesn’t come as standard accessory)
 PC running on the OS mentioned in section 1.2

Note: At press time, no dual redundant Yokogawa gateways & transmitters were available. A separate
Backbone Router from the gateway was planned to be released by end of Q4 year 2011. Besides,
Gateway – Gateway communication was not possible during the time of testing.

3.0 NETWORKING

3.1 Basic setup of Transmitters

 Use the Device Provisioning Tools plug-in to get information from Transmitters (To acquire
the model, EUI64 no., Join Key)
 Set the device tag and network ID (same network ID for all transmitters connected to one
gateway. For e.g. Network ID = 100)
 Download the information into the transmitters and save the Provisioning Information File

3.2 Setting up IP Address

 Prior to connecting the UTP cable from YFGW710 to the LAN port of PC, the IP address of the
port shall be set to be in the same domain as the gateway. Referring to Figure 2, the IP
address of the gateway is 192.168.0.101, subnet mask 255.255.255.0. Therefore, one
example of IP address that could be set in the PC’s LAN port is 192.168.0.100, subnet mask
255.255.255.0 as shown in Figure 1.
 Note: It is advisable to switch off the wireless port on the PC/Laptop as this might interfere
with the wireless transmitters. Otherwise, the channel used by the PC/Laptop’s wireless LAN
(ISM Band) has to be blacklisted in the Gateway (Channel 1 – 14)

3.3 Setting up the Gateway / Backbone Router / System Manager

 Login into the Field Wireless Configurator and setup the gateway (Network ID, IP Address,
Channels to be blacklisted if any, etc.)
 Add devices in the Device tab by uploading the Provisioning Information File obtained from
the Device Provisioning Tool
 Double click on the devices in Device Tab to edit device. After loading the CF/DD Files, the
required parameters to be sampled needs to be selected. This crucial step would enable the
sampled parameters to be configured in the Modbus Configuration tab.
 Modbus mapping shall be done by simply drag and drop method as shown in (Diagnostic
Status, PV). Each parameter would consume 3 words.
 Finally, download the configuration into the gateway.

3.4 Communication Protocol

 Modbus/TCP
Note: For detailed setup procedure of the gateway and wireless transmitters, please refer to the Wireless
System Setup Procedure (FAST/TOOLS).

3.5 System Architecture

Switch

Modbus/TCP

Legend:
CAT5E UTP Cable AFV10D
CAT6 UTP Cable ALE111

CP451
CP451
PW
PW
VI702

Vnet/IP

Note: The L2 Switch is optional and only required when the workstation needs to set up the wireless
network configuration using Wireless Configurator or to Monitor the wireless network using Wireless
Monitor software. There is a built in router in the wireless gateway and can be connected directly to
FCS’s IO Module/ Modbus Converter.

4.0 SYSTEM SETUP

4.1 Basic Engineering Guide

 Start System View. Create an FCS and HIS. Then define the ALE111 card.
Choose Ethernet Communication, ALE111.
Select a slot corresponding to the slot
where the card is installed physically on the
FCS.
 Choose WMODBUS Set the IP address of the ALE111 card.
Make sure it is in the same domain as the
YFGW (192.168.0.XXX) with subnet mask
255.255.255.0. No Paired Address Setting
is required if only a single ALE111 card is
used.

Set to Port 502.

 In mapping the Modbus/TCP Input Registers, the CommDataWW and the WBTagDef have to
be defined. The CommDataWW is used to map the modbus address to the %WW software
switches while WBTagDef is used to manipulate the individual bits in each data/status pulled
from the gateway (for e.g. use the specific bits to show diagnostic status of the device).
 In defining the parameters in the CommWWData, the following should be followed:
 Buffer = The size used by the programme.
 Program name: Kt-n-s-ProgramName
 K = FIO Identifier
 t = System Number (specify 1)
 n = Node Number
 s = Slot number
 ProgramName = WMODBUS
 Size = Number of words.
 Port = 1
 IP Address = The IP address of YFGW
 Station = Station no. of YFGW
 Device Address
 Starts from 300000
 Refer to Appendix 1(a) for more information on how to map the Modbus
Input Registers
%WB002101 refers to
Tag defined so that this bit could be
%WW0021, bit no. 1, as
used in logic (for e.g. Sequence table)
shown in the .PR below.

 In WBTagDef, the device diagnostics and the communication status flag could be defined.
Referring to Appendix 1(b) and (c), in order to detect any malfunction/errors in the device or
the communication between device and system, the individual bits are defined so that it
could be used in the logic later.
 In control drawing DR0001, all the %WW switches are mapped to the respective tags in a PVI
block. In order to scale the PV values, the Subsystem Communication Input shall be selected
in the Input Signal Conversion section instead of Linear.

To scale the value received from the ALE111 card, the gain and bias value shall be
amended. In this case, the YTA001’s scale will be from 0 – 400 degC. If the scale is -50 –
200degC, then the gain shall be 2.0 and the bias shall be -50.

 Converted Value (PV) = GAIN • (RAW Value) + BIAS

Of course, the high and low limit

shall be set to the desired limits
 In Control Drawing DR0002, some sequence tables were created to illustrate the device
diagnostics information as per the table shown in Appendix 1(b) and (c).
 The Initial sequence table is meant to change all ST to AUTO mode.
 The operator guide messages are also defined to display the messages when the conditions
are satisfied in the sequence table mentioned above. (Of course, there are other ways to
show the device diagnostics and the communication status)
 For the graphics, only minimal graphics were created to show the functionality and operation
of the wireless transmitters. They are:
 OV0001 – Overview
 GR_FW – Main Page
 GR0001 – Diagnostics
 GR0002 – Battery Status
 ISA100COMMAND – ISA 100 Command Base
 CG0001 – Control Group
 TG0101 – Trending
Appendix 1

A) Modbus Mapping

Input Registers in Field Wireless Configurator Input Registers in CENTUM VP

Process Variable (PV)

A Input register number (0 – 2) Device Address = 300000

0 300000
1 300001

2 300002

Connection Status/Data Quality Flag (DIAG_STATUS/AI Block) – Refer to Table 2 for details

B Input register number (12 – 14) Device Address = 300012 (- sign to acquire the
status flag of the data)

12 300012
13 300013
14 300014

Device Diagnostic Signal (DIAG_STATUS) – Refer table 3 for details

Input register number (15 – 17) Device Address = 300015

C

15 300015
16 300016
17 300017

Table 1: Modbus Mapping Table

 B) Data Quality Flag Details
No. Quality Substatus Binary Value Remarks
(Bit No.)
7 6 4 3 2
1 GOOD 1 0 0 0 0
2 BAD Non Specific 0 0 0 0 0
3 BAD Configuration Error 0 0 0 0 1
4 BAD Not connected 0 0 0 1 0
5 BAD Device Failure 0 0 0 1 1
6 BAD Sensor Failure 0 0 1 0 0
7 BAD No communication with last usable 0 0 1 0 1 Data not updated ~ 1 min / Transmitter
value loss of power supply 1
8 BAD No communication with no usable 0 0 1 1 0 Unstable / Initialization 2
value
9 BAD Out of Service 0 0 1 1 1
10 UNCERTAIN Sensor Conversion Inaccurate 0 1 1 0 0 Wrong input polarity @ transmitter
11 UNCERTAIN Range Limits Exceeded 0 1 1 0 1
Table 2: Data Quality Flag Details

Note 1: Once the battery was disconnected, the communication changed from 128
(ONLINE/NORMAL) to 20 in about 1 min. After 5 mins, if the power is not restored, the status
will change to 8.

Note 2: During initialization of the transmitter, the state will change from 8 (OFFLINE) to 24
(OFFLINE/INITIALIZING) in 1 min. After 8-10 mins, the status will change to 128
(ONLINE/NORMAL).

C) Device Diagnostics Details

Bit No. Description
00 Detail information available (1: available; 0: no available)
01 - 07 Vendor Specific Area
08 - 16 Reserved by WCI (Baseline Device Profile)
17 Simulation is Active
18 Software Update Incomplete
19 Power is low: Maintenance Need Mid-Term
20 Power is critically low: Maintenance Need Short
21 Fault Prediction: Maintenance Required
22 Environmental Conditions of Device Specification
23 Outside Sensor Limit
24 Out of Service
25 Installation, Calibration Problem
26 Faults in Sensor or Actuator Element
27 Faults in Electronic
28 Maintenance Required Status
29 Out of Specification Status
 30 Function Check Status
31 Failure Status
Table 3: Device Diagnostics Details

Appendix 2

A) Transmitters Out of Service

 The data quality flag shows 111 in
bit 2,3,4 when the transmitter is
set to O/S. Bit 0,1 shows 11 which
corresponds to Constant Limit
Condition

YTA001 is mapped to %WW0017

and the data flag is the subsequent
16 bits (%WW0019)
B) Transmitters Sensor Failed
 The data quality flag shows 100 in
bit 2,3,4 when the sensor failed.
Bit 0,1 shows 11 which
corresponds to Constant Limit
Condition

YTA001 is mapped to %WW0017

and the data flag is the subsequent
16 bits (%WW0019)
C) Transmitters Power Off (Battery Unplugged)
Normal / Communication
Established

No Comm. With Last

Usable Value
Offline

Battery plugged in and transmitter

attempts to join the network /
initialize
YTA001 Offline
 Connection Recovered

Appendix 3

A) Additional Information on ALE111 (taken from GS 33K50G11-50E)