YOKOGAWA ProSafe-COM Manual

Technical

Information System Overview

ProSafe-COM 3.00 ProSafe-COM

TI48J01A00-00E-N

Yokogawa Europe Solutions B.V.

PO Box 163, 3800 AD, Amersfoort, The Netherlands

Tel: (31) 88-464 1000 Fax: (31) 88-464 1111

TI48J01A00-00E-N

4th Edition Oct 2010

System Overview ProSafe-COM 3.00 2 of 49

TABLE OF CONTENTS

Preface .......................................................................................................................................................... 4

About this manual.......................................................................................................................................... 5

1An introduction to ProSafe-COM............................................................................................................ 7

1.1 ProSafe-COM and the ProSafe family............................................................................................ 7

1.2 MODCOM / MULCOM versus ProSafe-COM................................................................................. 9

1.3 ProSafe-COM context................................................................................................................... 10

1.4 ProSafe-COM and CENTUM........................................................................................................ 13

1.5 Functions overview ....................................................................................................................... 14

1.6 Hardware overview ....................................................................................................................... 15

1.7 Interface overview......................................................................................................................... 16

2ProSafe-COM functions ....................................................................................................................... 18

2.1 Basic function................................................................................................................................18

2.2 Status acquisition.......................................................................................................................... 19

2.3 Sequence of events recording...................................................................................................... 20

2.4 Forcing statuses............................................................................................................................ 20

2.5 Configuring ProSafe-COM............................................................................................................ 21

3ProSafe-COM hardware....................................................................................................................... 25

3.1 Hardware concept......................................................................................................................... 25

3.2 19 inch housing with modules....................................................................................................... 25

3.3 Main board .................................................................................................................................... 26

3.4 V-net interface board..................................................................................................................... 26

3.5 M-BUS/M-NET interface board..................................................................................................... 26

3.6 Ethernet interfaces........................................................................................................................ 26

3.7 Serial interface board.................................................................................................................... 26

3.8 Y-net interface board..................................................................................................................... 26

3.9 ProSafe-COM and ProSafe safety system modules..................................................................... 27

4ProSafe-COM interfaces...................................................................................................................... 30

4.1 Access to status map and event list.............................................................................................. 30

4.2 Printer............................................................................................................................................ 31

4.3 User interface................................................................................................................................31

4.4 V-net interface............................................................................................................................... 31

4.5 M-BUS/M-NET interface ............................................................................................................... 32

4.6 Ethernet interface.......................................................................................................................... 32

4.7 Serial interfaces ............................................................................................................................ 33

4.8 Y-net interface............................................................................................................................... 34

5Functions and hardware design........................................................................................................... 35

5.1 Realisation of functions................................................................................................................. 35

5.2 Status acquisition on M-BUS / M-NET.......................................................................................... 35

5.3 ProSafe-PLC event storage.......................................................................................................... 36

5.4 ProSafe-PLC forcing statuses....................................................................................................... 37

5.5 Status acquisition on Y-net ........................................................................................................... 37

5.6 ProSafe-SLS event storage .......................................................................................................... 38

5.7 ProSafe-SLS forcing statuses....................................................................................................... 38

6Redundant configurations .................................................................................................................... 39

7Time distribution and synchronisation.................................................................................................. 40

7.1 Realisation of functions................................................................................................................. 40

7.2 Time distribution............................................................................................................................ 40

7.3 ProSafe-PLC event time stamp correction.................................................................................... 40

7.4 ProSafe-SLS event time stamping................................................................................................ 41

8ProSafe-COM System Engineering Tool ............................................................................................. 42

8.1 COM SET...................................................................................................................................... 42

8.2 Engineering................................................................................................................................... 42

8.3 Commissioning, test and maintenance......................................................................................... 43

9I/O emulation tool ................................................................................................................................. 45

9.1 EmuTool........................................................................................................................................ 45

Appendix A: Integrating DCS and ProSafe-COM........................................................................................ 46

Abbreviations............................................................................................................................................... 48

Glossary....................................................................................................................................................... 49

System Overview ProSafe-COM 3.00 3 of 49

LIST OF TABLES

Table 1: Main differences between MODCOM/MULCOM and ProSafe-COM.............................................. 9

Table 2: ProSafe-COM comunication modules........................................................................................... 27

Table 3: Supported Modbus codes.............................................................................................................. 33

LIST OF FIGURES

Figure 1: The ProSafe family members......................................................................................................... 7

Figure 2: Example of an operator screen on a CENTUM CS3000 ............................................................... 9

Figure 3: Context of ProSafe-COM ............................................................................................................ 10

Figure 4: ProSafe-PLC ................................................................................................................................ 11

Figure 5: ProSafe-RS .................................................................................................................................. 12

Figure 6: CENTUM and underlying systems............................................................................................... 13

Figure 7: ProSafe-COM functions ............................................................................................................... 14

Figure 8: ProSafe-COM application areas .................................................................................................. 15

Figure 9: ProSafe-COM interfaces.............................................................................................................. 16

Figure 10: Information flow of ProSafe-COM with surrounding systems .................................................... 18

Figure 11: Status acquisition and master-slave relations............................................................................ 19

Figure 12: Sequence of events recording ................................................................................................... 20

Figure 13: Forcing status............................................................................................................................. 21

Figure 14: Tag definition.............................................................................................................................. 22

Figure 15: Communication with tags........................................................................................................... 23

Figure 16: Tag file and event filtering.......................................................................................................... 24

Figure 17: ProSafe-COM IPC...................................................................................................................... 25

Figure 18: ProSafe-PLC: M-BUS and CCM modules.................................................................................. 27

Figure 19: ProSafe-PLC: M-NET, MBX module and CCM modules........................................................... 28

Figure 20: ProSafe-SLS: Safety system and matrix panel connections...................................................... 28

Figure 21: ProSafe-COM as Modbus master in a network with Modbus slaves......................................... 29

Figure 22: ProSafe-COM as Modbus/TCP master in a network with Modbus/TCP slaves ........................ 29

Figure 23: Interfacing ProSafe-COM........................................................................................................... 30

Figure 24: ProSafe-PLC status acquisition modules................................................................................... 35

Figure 25: ProSafe-PLC event list concept ................................................................................................. 36

Figure 26: Override facility in ProSafe-PLC ................................................................................................ 37

Figure 27: Status and event acquisition in Y-net (ProSafe-SLS)................................................................ 38

Figure 28: Redundant ProSafe-COM on V-net ........................................................................................... 39

Figure 29: ProSafe-COM engineering......................................................................................................... 42

System Overview ProSafe-COM 3.00 4 of 49

Preface

Company profile

A part of Yokogawa company is active in the field of design and engineering of control and safety

systems. The products are worldwide used as emergency shutdown, process shutdown or fire & gas

systems in oil and gas exploration, petrochemical and nuclear industries.

ProSafe safety systems

From its founding days, the safety division of Yokogawa Europe Solutions BV has enterprised solid-state

safety systems emerging in a product that is nowadays referred to as ProSafe-SLS. It is a unique, inherent

fail-safe technology. It combines a very high safety level with a very high availability level.

The ProSafe-SLS technology is TÜV AK-7 / SIL4 certified.

In 1997 the safety division of Yokogawa Europe Solutions BV introduced the ProSafe-PLC. ProSafe-PLC

is TÜV certified up to AK-6 / SIL3. It is highly scalable and can be easily tailored.

To enable communication between the ProSafe systems and other systems like e.g. a DCS, the safety

division of Yokogawa Europe Solutions BV has introduced the ProSafe-COM products in 1994.

COM is the abbreviation of ‘COMmunication’. A DOS version (MODCOM) and a Windows 2000 based

version (MULCOM) are available. The Windows 2000 version allows complete integration with the

Yokogawa CS3000 / VP system via V-net and easy linking with the ProSafe-PLC and ProSafe-SLS.

Since the functionality of MODCOM and MULCOM functionality partly overlap ProSafe-COM is now

introduced, a single platform which can be used to replace both MODCOM and MULCOM. The new

ProSafe-COM platform is headless (no moving parts) and comprises an embedded version of

Windows XP.

In May 2005 Yokogawa released ProSafe-RS, a new safety system which can be fully integrated with the

existing Yokogawa DCS products (CENTUM CS3000 and CENTUM VP).

ProSafe-RS directly connects to the CENTUM control bus, so ProSafe-COM is not required for the

integration of ProSafe-RS. However, ProSafe-COM may still be used to integrate legacy ProSafe

products with other DCS or SCADA systems.

System overview ProSafe-COM

This booklet is an introduction to ProSafe-COM. It briefly discusses the ProSafe products in general and

the context of ProSafe-COM. Thereafter, this booklet focuses on the functions, hardware set-up and

interfaces of ProSafe-COM.

Audience

This booklet addresses anyone who wants to get a quick overview of ProSafe-COM and its functions:

management, operator, service personnel, etc. This booklet also addresses the system engineer who has

to integrate ProSafe-COM into a DCS or SCADA system.

The System overview can be read, without prerequisite knowledge, from the beginning until the desired

level of detail is revealed. Though not required, some knowledge of instrumented safety systems is

recommended for understanding this booklet.

System Overview ProSafe-COM 3.00 5 of 49

About this manual

This System overview gives an introduction to ProSafe-COM. The booklet contains nine chapters, two

appendices and a glossary list. The basic structure of this booklet is as follows.

Chapter 2

An introduction to ProSafe-COM

Overview of the ProSafe family products and the main

characteristics of ProSafe-COM.

Chapter 3

ProSafe-COM functions

Detailed description of what data, in which way, can be exchanged

between ProSafe-COM and its surrounding systems.

Chapter 4 ProSafe-COM hardware

Description of available boards in ProSafe-COM.

Chapter 5

ProSafe-COM interfaces

Functions, hardware provisions and characteristics of:

•Printer

•User

interface

•V-net

interface

•OPC

Interface

•MODULE-BUS (M-BUS) / MODULE-NET (M-NET)

•Ethernet

interface

•Serial

interfaces

Chapter 6

Functions and hardware design

Explains in more detail how the ProSafe-COM functions are

implemented in the hardware.

Chapter 7

Redundant configurations

Function and characteristics of a redundant configuration.

Chapter 8

Time synchronisation

Function and realisation of time synchronisation.

Chapter 9

ProSafe-COM System Engineering Tool

A description of the tool COM SET, used for:

•Engineering ProSafe-COM

•Commissioning

•Test and maintenance

Chapter 10

EmuTool I/O emulation tool

A description of the tool EmuTool, used for:

Emulating I/O

Appendix A A description of how to integrate ProSafe-COM in the DCS system,

using tags.

This information is meant for the system engineer of the DCS

system that ProSafe-COM has to be integrated in.

Glossary A glossary of used terms

Note

This System overview describes the maximally possible configurations of ProSafe-COM and the ProSafe

safety systems. However, in practice ProSafe-COM and the ProSafe safety systems do not need to have

all components described.

System Overview ProSafe-COM 3.00 6 of 49

Other booklets on ProSafe-COM

The ProSafe-COM documentation consists of the following volumes:

•ProSafe-COM General Specification (2 versions)

•ProSafe-COM System overview

•ProSafe-COM Engineering manual

•ProSafe-COM Test & Maintenance manual

The ProSafe-COM General Specifications describe high level functionality.

The ProSafe-COM System overview gives an introduction for anyone interested in ProSafe-COM.

The ProSafe-COM Engineering manual guides engineers through the process of configuring and

programming ProSafe-COM. It describes the hardware, system tuning and possible configurations, and

points out the strategy for project engineering. The use of the engineering tools is explained in detail.

The ProSafe-COM Installation, Test & Maintenance manual provides information for hardware and

software installation, for maintenance and for trouble shooting.

Ordering information

The ProSafe-COM 3.0 system documentation can be obtained from any Yokogawa Europe Solutions BV

Sales & Marketing department using the volume title and document number:

•ProSafe-COM General Specification (PCI bus only) GS 48D62Z02-00E-N

•ProSafe-COM General Specification (PCI + PCI-E bus) GS 48D62A02-00E-N

•ProSafe-COM System overview TI 48J01A00-00E-N

•ProSafe-COM Engineering manual IM 48J01G01-00E-N

•ProSafe-COM Installation, Test & Maintenance manual IM 48J01H01-00E-N

System Overview ProSafe-COM 3.00 7 of 49

1 An introduction to ProSafe-COM

1.1 ProSafe-COM and the ProSafe family

ProSafe is short for Programmable Safety systems. ProSafe provides for today’s and tomorrow’s market

demand for sound safety solutions. ProSafe comprises a whole family of industrial safeguarding and

safeguarding associated products.

A ProSafe safety system can be used as emergency shutdown, process shutdown or fire & gas system in

the oil and gas exploration, petrochemical or nuclear industries, to mention some examples. A ProSafe

system works autonomously. It shuts down the guarded process (or part of it) without any operator’s

intervention when the input sensors detect an unsafe situation or when the ProSafe systems diagnose an

internal error which may prevent the Safety system from responding correctly when a demand comes from

the field.

The ProSafe family can be divided into systems with the following functions:

•Safeguarding

•Communication

•Supervising

ProSafe-COM

ProSafe-RS

Figure 1: The ProSafe family members

System Overview ProSafe-COM 3.00 8 of 49

Safeguarding

The kernel of the ProSafe family is the ProSafe safeguarding system. The ProSafe safety system works

autonomously, without intervention from operator or other systems. Therefore a ProSafe safety system

guarantees a safe industrial system.

The ProSafe safety system can comprise one or more of the following systems:

•ProSafe-SLS: a hard-wired safety system (Solid State Safety)

•ProSafe-PLC: a PLC-based safety system

•ProSafe-RS: a new generation programmable safety system

All these types of safety systems are fail-safe. They can perform the safeguarding function both

individually and integrated. Depending on client’s wishes, a ProSafe safety system can consist of one or

more types of safety systems.

Communication

ProSafe-COM handles the data communication between the ProSafe safety system and various external

systems, like CENTUM CS3000 / VP or other supervisory systems.

The data communication can be:

•from ProSafe safety system to ProSafe-COM, and further up to supervisory systems

•from supervisory systems down to ProSafe-COM, and further down to the ProSafe safety system

The basic function of ProSafe-COM is communication. In addition to this, ProSafe-COM can store events

(SOE = sequence of event recorder) and perform logical operations.

The engineering and maintenance tool for ProSafe-COM is the ProSafe-COM System Engineering Tool

(SET). During commissioning, test and maintenance ProSafe-COM SET is a powerful tool.

ProSafe-COM SET can be used for remote inspection and troubleshooting. Especially when long

distances need to be covered this can be very useful.

ProSafe-COM supersedes the DOS version (MODCOM) and the Windows NT/2000 version (MULCOM).

This booklet describes the ProSafe-COM Windows Embedded POSReady 2009 version.

Supervising

A ProSafe system can be supervised from the Yokogawa CENTUM CS3000 / VP system. Another

Distributed Control System (DCS) or SCADA system can be used also. An excellent SCADA solution is

provided by Yokogawa System Center Europe’s FAST/TOOLS.

ProSafe-COM handles the communication between the ProSafe safety system and the supervising

system. ProSafe-COM uploads all relevant process information from the ProSafe system to the

supervising system. The ProSafe-HMI (Human Machine Interface), DCS or SCADA system organises and

displays this information to the operator.

When connected to a CENTUM system, ProSafe-COM allows a complete integration of the safety system

within the CENTUM CS3000 / VP system. ProSafe-COM can automatically send event information to the

CENTUM system. Other manufacturer’s DCS or SCADA systems have to request for information from

ProSafe-COM using OPC or Modbus.

System Overview ProSafe-COM 3.00 9 of 49

Figure 2: Example of an operator screen on a CENTUM CS3000

1.2 MODCOM / MULCOM versus ProSafe-COM

ProSafe-COM supersedes two earlier versions: MODCOM and MULCOM.

MODCOM is realised on a DOS platform and the DCS interface is based on the Modbus RTU protocol.

MULCOM runs on Windows 2000 and supports multiple interfaces to DCSs (V-net, OPC, Modbus).

Table 1: Main differences between MODCOM/MULCOM and ProSafe-COM

MODCOM MULCOM ProSafe-COM

Supervising systems have to

request for event and tag

information from MODCOM

Full integration with the control

backbone of CENTUM (Vnet).

MULCOM can send event

information to the CENTUM

system without a request for it.

Full integration with the control

backbone of CENTUM (Vnet)

ProSafe-COM can send event

information to the CENTUM

system without a request for it.

Only RS232 Modbus

communication with ProSafe-PLC Full integration with ProSafe-

PLC, via M-BUS/M-NET Full integration with ProSafe-

PLC, via M-BUS/M-NET

Connection to ProSafe-SLS via a

single Y-net connection. Supports two separate Y-net

connections to ProSafe-SLS. Supports two separate Y-net

connections to ProSafe-SLS.

Only Modbus communication with

DCS or SCADA

Support of Modbus and OPC to

connect to OPC enabled

supervisory systems.

Support of Modbus and OPC to

connect to OPC enabled

supervisory systems.

Modbus supports only boolean

and 16 bits register types Modbus supports booleans, 16-

bits registers and single precision

floats.

Modbus supports booleans, 16-

bits registers and single precision

floats.

Built on dedicated headless

industrial PC using DOS OS. Built on standard industrial PC

(standard hard disk, power

supply and processor having

fans) using Windows 2000

Built on dedicated industrial PC

without moving parts. Flash disk,

24V only, no fans. Using

Windows XP compatible

Windows Embedded POSReady

2009.

ISA slots only PCI 2.1 / ISA slots PCI 2.1 / PCI-E slots

System Overview ProSafe-COM 3.00 10 of 49

1.3 ProSafe-COM context

ProSafe-COM

Figure 3: Context of ProSafe-COM

ProSafe-COM

ProSafe-COM is the central communication link between the ProSafe safety system and various other

systems. ProSafe-COM communicates data from and to the ProSafe safety system.

CENTUM CS3000 / VP

The CENTUM CS3000 / VP system is the Yokogawa Process Control System. In many projects the

ProSafe safety system is directly connected to the control backbone of the CENTUM CS3000 / VP

system. The CENTUM CS3000 / VP system retrieves data from the ProSafe safety system or sends data

to it. Sending data (override procedures) may be necessary in case of starting up processes or

maintenance.

DCS and SCADA systems

Through the use of the OPC protocol ProSafe-COM can be connected to OPC enabled supervisory

systems. OPC runs over TCP/IP Ethernet. Both Data Access and Alarm and Events are supported by the

ProSafe-COM OPC servers.

ProSafe-COM has up to 10 serial lines that can be used for Modbus communication with DCS or SCADA

systems other than CENTUM. For example, Yokogawa’s FAST/TOOLS can provide a SCADA solution.

These systems basically have the same functionality as the CENTUM CS3000 / VP system. However, the

DCS or SCADA system has to request for event information from ProSafe-COM. ProSafe-COM cannot be

fully integrated on the backbone of DCS and SCADA systems other than CENTUM.

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