June 2012 Yokogawa Electric Corporation YOKOGAWA VIETNAM Copyright © Yokogawa Electric CO.LTD Corporation SERVICE DEPARTMENT Maintenance Course Yokogawa Vietnam Co Ltd Service Department YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE Maintenance Course Schedule for the day: Session Starts: 9:00 – 10:30 am Tea Break: 10:30 – 10:45 am Lunch: 12:00 – 1:00 pm Session Resume: Tea Break: Sessions Ends: YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE 1:00 – 3:00 3:00 – 3:15 5:00 pm pm pm Agenda CENTUM VP Maintenance Course Day Control Station Overview Types of FCS Components of FCS Cable Connections Internal power cabling Control Bus cabling Function of each unit in FCS Maintenance of FCS Common card replacement Hand on Exercise YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE Agenda CENTUM VP Maintenance Course Day Software compatibility Hardware setup prior to installation Software Environment Window set-up prior to installation (Vista/W7/Server) Centum VP installation Hands-on Exercises YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE Agenda CENTUM VP Maintenance Course Day Network Operation Vnet TCP/IP Communication Function HIS Communication Function Troubleshooting Vnet/IP Network Utility Vnet Utility Commands Troubleshooting of Overall Windows Back-Up Hands-On Exercise YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE 37 years History and the continuity 2008 2011 CENTUM VP CENTUM VP R5 2001 CENTUM CS 3000 R3 1998 1993 CENTUM CS 10 MBPS Dual PICS Redundant EWS Token Pass V net 1MBPS Dual Redundant Token Pass HF-Bus 1983 1988 CENTUM V CENTUM-XL COPS2 COPSV ENGS ICS CENTUM CS 3000 HIS HIS HIS ABC 2005 AVR FFCS PFCS Vnet/IP NFCS 1Gbps Dual Redundant FFCS LFCS KFCS EOPS 1975 CENTUM COPS CFCS2 CFCD2 CFFS F-Bus 250 KBPS Dual Redundant Token Pass CFCS CFCD YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE CFCS EFCD • CENTUM series has been keeping the operation continuity and the application compatibility for customers to use the CENTUM continuously for a long term • 20,000 + systems have been installed worldwide CENTUM VP System Configuration - Overview Client PC Operator Station (HIS) Asset management station for FF/HART devices PRM 3rd party wireless gateway Enclosed Display Open Display Style Console Style Console Desktop type TSE server HIS HIS HIS and/or ENG Dual Redundant Vnet/IP Real-time Control Network ProSafe-RS Plant Information Management System OPC server Exaquantum SENG Exaopc Ethernet FCS Sub system gateway Safety Instrumented System Controller ESD / F&G Field Network OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT ProSafe-RS SCS STARDOM -Vnet/IP: Real-time Control Network -Ethernet: Information Network -Exaopc: OPC Server - Exaquantum : Plant information management system Unified Gateway Station (UGS) 3rd party Sub systems An Example of Total Plant Control Solutions OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT FCS History of CS 3000 & CENTUM VP FFCS-L (Current) 32MB FFCS For FIO KFCS • 32MB Compact size • 16MB • For FIO For both small & large • For FIO • Compact size scale plants Redundant FF • For smaller • Vnet/IP Quick ESB bus scale plants & remote I/O • Vnet • • • • New FCS (FFCS-V) FCS • 16MB • For RIO KFCS2 • 32MB LFCS2 • 32MB 1998 2000 OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT 2002 2004 2006 2008 2010 2012 Replacing Input/Output Modules (2) Replacing the Running Module of a Pair of Dual-Redundantly Configured Modules It is necessary to switch the control right from the running module to the standby module adjacent to it Thus replacing the module can be performed with two steps Step 1: Switch the control right the dual-redundantly configure module (As described in next page, “Switching Control Right of Dual-Redundantly Configure Modules.”) Step 2: Replace the module in the same procedure of replacing a standby module (As described in previous step, “ Replacing the Standby Module of a Pair of DualRedundantly Configured Modules.”) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Plug In and Plug Out the Connectors The connectors need to be plugged in or plugged out in a stipulated sequence OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Removing from and Installing on Base Units Removal Procedure Remove the cables for external wiring and terminal block Remove the fixing screws in one place at the upper part and one place at the lower part of the I/OM Pull the I/O module forward and remove it from the base unit Installation Procedure Install the I/O module following the steps of the “Removal Procedure” in the reverse order The tightening torque of the fixing screws should be approximately 0.5 Nm Install the cables for external wiring and terminal block OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Procedures for Removing and Installing Connection Blocks Removal Procedure Remove the fixing screws There are two screws in the case of a terminal block or a MIL connector cover Pull the terminal block forward and remove it from the I/O module Installation Procedure Install the terminal block following the steps of the “Removal Procedure” in the reverse order The tightening torque of the fixing screws should be approximately 0.5 Nm OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Replacing Dual-Redundant Connection I/O Modules (1) Removal and Installation Procedure Check the LED displays of the pair of I/O modules in dual-redundant connection to see that the STATUS and DX LEDs are lit for both modules and ACT is lit for only one of them Remove the four screws at the upper and lower parts of the terminal block Remove the terminal block while supporting it so as not to apply too much stress to the flat cable While supporting the terminal block, remove the connector connected to the I/O module whose ACT LED is not lit Remove the two screws of the I/O module whose ACT LED is not lit, and replace it with an adjusted I/O module Fix the screws of the replaced I/O module Reinstall the flat cable connector Fix the screws of the terminal block OKOGAWA VIETNAM CO,LTD Download the setting information to the replaced I/O module Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Replacing Dual-Redundant Connection IO Modules (2) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Exchanging Local Node Procedure of Exchanging Local Node Check the status of the nodes on both sides, as well as the internal buses of I/O modules on the FFCS-L status display window Switch off the power supply of the node that to be exchanged Leave the ESB cable connected, then remove the connector unit for ESB bus from the SB401 for ESB bus Confirm on the FFCS-L status display window that there is no abnormality occurred other than the node to be exchanged Leave the ESB cable connected, then remove the connector unit for ESB bus from the SB401 for ESB bus Exchange the node And confirm that the SB401 address is correct Connect connector unit for ESB bus to the new SB401 Switch on the node power supply Confirm that the exchanged node is running properly on the FFCS-L status display window OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Exchanging Remote Node Procedure of Exchanging Remote Node Check the status of the nodes on both sides, as well as the internal buses of I/O modules on the FFCS-L status display window Switch off the power supply of the node that to be exchanged Leave the ER bus cable connected, then remove the T-type connector from the EB501 for ER bus Confirm on the FFCS-L status display window that there is no abnormality occurred other than the node to be exchanged Leave the ER cable connected, then remove the T-type connector from the EB501 for ER bus Exchange the node And confirm that the EB501 address is correct Connect T-type connector to the new EB501 Switch on the node power supply Confirm that the exchanged node is running properly on the FFCS-L status display window OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Parts Requiring Periodic Replacement (Parts having Defined Life Spans) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Parts Requiring Periodic Replacement (Parts having Defined Life Spans) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Replacing Battery Pack (1) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Remove Replacing Battery Pack (2) Procedure for Removing battery Open the front cover of the processor module Turn the battery ON/OFF switch to OFF position A stick of insulation material should be used to toggle the battery switch Disconnect the battery cable from the connector (displayed as CN2) The battery cable connector has a self-locking elastic clip When pulling out the connector, it is necessary to push the clip to unlock it Pull out the battery pack straightly Procedure for Installing battery Place the battery to the specified position on the processor module Connect the battery cable to the connector Make sure the connection is firm and the red wire is facing upward Turn the battery ON/OFF switch to ON position Put the front cover back Stick the battery expiration date label to the front cover OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Replacing Battery Pack (3) OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT Maintenance Parts List – AFV10S/D OKOGAWA VIETNAM CO,LTD Copyright © Yokogawa Electric Corporation ERVICE DEPARTMENT End of Presentation THANK YOU FOR YOUR ATTENTION YOKOGAWA VIETNAM CO.LTD CopyrightDEPARTMENT © Yokogawa Electric Corporation SERVICE ... 2008 2011 CENTUM VP CENTUM VP R5 2001 CENTUM CS 3000 R3 1998 1993 CENTUM CS 10 MBPS Dual PICS Redundant EWS Token Pass V net 1MBPS Dual Redundant Token Pass HF-Bus 1983 1988 CENTUM V CENTUM- XL... SERVICE Agenda CENTUM VP Maintenance Course Day Software compatibility Hardware setup prior to installation Software Environment Window set-up prior to installation (Vista/W7/Server) Centum VP installation... Agenda CENTUM VP Maintenance Course Day Control Station Overview Types of FCS Components of FCS Cable Connections Internal power cabling Control Bus cabling Function of each unit in FCS Maintenance