Remote Automation Solutions FB3000 Remote Terminal Unit (RTU) Step-by-Step Separator Configuration Guide

Emerson FB3000 Separator Configuration Guide

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Contents i

Emerson FB3000 Remote Terminal Unit (RTU)

Step-by-Step Separator Configuration Guide

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Contents ii

Device Safety Considerations

 Reading these Instructions

Before operating the device, read these instructions carefully and understand their safety implications.

In some situations, improperly using this device may result in damage or injury. Keep this manual in a

convenient location for future reference. Note that these instructions may not cover all details or

variations in equipment or cover every possible situation regarding installation, operation, or

maintenance. Should problems arise that are not covered sufficiently in the text, immediately contact

Customer Support for further information.

 Protecting Operating Processes

A failure of this device – for whatever reason -- may leave an operating process without appropriate protection and

could result in possible damage to property or injury to persons. To protect against this, you should review the

need for additional backup equipment or provide alternate means of protection (such as alarm devices, output

limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.). Contact Remote

Automation Solutions for additional information.

 Returning Equipment

If you need to return any equipment to Remote Automation Solutions, it is your responsibility to ensure that the

equipment has been cleaned to safe levels, as defined and/or determined by applicable federal, state and/or local

law regulations or codes. You also agree to indemnify Remote Automation Solutions and hold Remote Automation

Solutions harmless from any liability or damage which Remote Automation Solutions may incur or suffer due to

your failure to ensure device cleanliness.

 Grounding Equipment

Ground metal enclosures and exposed metal parts of electrical instruments in accordance with OSHA rules and

regulations as specified in Design Safety Standards for Electrical Systems, 29 CFR, Part 1910, Subpart S, dated: April

16, 1981 (OSHA rulings are in agreement with the National Electrical Code). You must also ground mechanical or

pneumatic instruments that include electrically operated devices such as lights, switches, relays, alarms, or chart

drives.

Important: Complying with the codes and regulations of authorities having jurisdiction is essential to ensuring

personnel safety. The guidelines and recommendations in this manual are intended to meet or exceed applicable

codes and regulations. If differences occur between this manual and the codes and regulations of authorities

having jurisdiction, those codes and regulations must take precedence.

 Protecting from Electrostatic Discharge (ESD)

This device contains sensitive electronic components which be damaged by exposure to an ESD voltage.

Depending on the magnitude and duration of the ESD, it can result in erratic operation or complete failure of the

equipment. Ensure that you correctly care for and handle ESD-sensitive components.

System Training

A well-trained workforce is critical to the success of your operation. Knowing how to correctly install, configure,

program, calibrate, and trouble-shoot your Emerson equipment provides your engineers and technicians with the skills

and confidence to optimize your investment. Remote Automation Solutions offers a variety of ways for your personnel

to acquire essential system expertise. Our full-time professional instructors can conduct classroom training at several of

our corporate offices, at your site, or even at your regional Emerson office. You can also receive the same quality

training via our live, interactive Emerson Virtual Classroom and save on travel costs. For our complete schedule and

further information, contact the Remote Automation Solutions Training Department at 800-338-8158 or email us at

education@emerson.com.

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Contents iii

Contents

Chapter 1. Introduction 1

1.1 FB3000 RTU ............................................................................................................................................ 1

1.1.1 Solutions ...................................................................................................................................... 2

1.1.2 Applications ................................................................................................................................. 2

1.2 Demo Overview ...................................................................................................................................... 2

1.2.1 Demo Folders .............................................................................................................................. 2

1.2.2 I/O Points ..................................................................................................................................... 3

1.3 Field Tools ............................................................................................................................................... 3

1.3.1 FBxConnect.................................................................................................................................. 3

1.3.2 FBxDesigner ................................................................................................................................. 4

Chapter 2. Field Tools & Connecting to RTU 5

2.1 Starting Field Tools .................................................................................................................................. 5

2.2 Field Tools Overview ................................................................................................................................ 7

2.3 Connecting to the RTU ............................................................................................................................ 8

Chapter 3. FBxConnect 11

3.1 FBxConnect Overview............................................................................................................................ 11

3.2 Guided Setup ........................................................................................................................................ 12

3.2.1 IO Setup & Communications ...................................................................................................... 14

3.2.2 History & Summary .................................................................................................................... 29

3.3 Math Blocks ........................................................................................................................................... 30

3.3.1 Simulating Liquid Level .............................................................................................................. 31

3.3.2 Simulating Pressure ................................................................................................................... 35

3.4 Action Blocks & Effects .......................................................................................................................... 38

3.4.1 Simulating the High Level Switch ............................................................................................... 39

3.4.2 Simulating the Low Level Switch ................................................................................................ 40

3.5 PID Loops .............................................................................................................................................. 43

3.5.1 Controlling the Pressure ............................................................................................................. 44

Chapter 4. FBxDesigner 47

4.1 FBxDesigner Overview ........................................................................................................................... 47

4.2 Creating a Project .................................................................................................................................. 49

4.2.1 Creating an FBD Program ........................................................................................................... 51

4.2.2 Creating an FBD Block with ST .................................................................................................... 60

4.2.3 Tasks, Compiling & BootProject ................................................................................................. 65

Chapter 5. FBxVue 69

5.1 FBxVue Overview ................................................................................................................................... 69

5.2 Building a Display with FBxVue .............................................................................................................. 72

Chapter 6. Applications 91

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Emerson FB3000 Separator Configuration Guide

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Introduction 1

Chapter 1. Introduction

This demo guide is an introductory exercise to familiarize you with the capabilities of the

FB3000 Remote Terminal Unit (RTU) and is organized into the following chapters:

 Chapter 1: Introduction:

Provides an overview of theFB3000 RTU, this demo, and the required software.

 Chapter2: Field Tools & Connecting to the RTU:

Details how to connect to the FB3000 using Field Tools.

 Chapter 3: FBxConnect:

Describes how to set up meters and controls using the FBxConnect software.

 Chapter 4: FBxDesigner:

Details how to create a control program using the FBxDesigner programming

environment.

 Chapter 5: FBxVue

Details how to create user displays using the FBxVue display builder.

 Chapter 6: Applications

Describes how to download and distribute the project and display as one packaged

application.

1.1 FB3000 RTU

The Emerson FB3000 Remote Terminal Unit (RTU) runs measurement and control

applications suitable for oil and gas, water, wastewater, and other industrial processes. It

combines the ease-of-configuration of the Emerson ROC/FloBoss RTUs and the flexible

programmability of the Emerson ControlWave PLCs.

Release 1 - Core Equipment

• 8 slot Chassis (CSA, ATEX, IEC Ex)

• 10.5-30Vdc Dual Power Supply

Cartridges

• 4 Serial + 1 USB Comm ports

• 2 independent Ethernet ports

• 32-bit Processor running at 792 MHz

• 256 MB flash storage for firmware &

reports

• 16 MB SRAM storage for historical data

• 1 GB DRAM execution memory

• Mixed I/O Card (8AI/DI/PI + 2AO + 2DO)

• Isolated Personality Modules (Terminal

Blocks)

• Hot-Swappable I/O

• Connectivity to 10 MVS per Comm port

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1.1.1 Solutions

The configuration, control and communication data in the RTU are saved in a hierarchy of

folders called a solution (with a file type of .zsl). A solution may also include up to eight

applications. You use FBxConnect to modify, upload, or download solutions.

Note

It is a good practice to always save backups of your solutions.

1.1.2 Applications

Applications add extra functionality to the FB3000. An application consists of a project

created in FBxDesigner and can include multiple displays built with FBxVue. Each

application runs in its own task and can be independently added, removed, started, or

stopped.

1.2 Demo Overview

In this demo you use an FB3000 to simulate and control a two-phase separator, including

the measurement of the outlet gas and liquid streams.

The gas is measured with a DP meter using API 21.1-compliant AGA 3 flow calculations

while the liquid is measured with a linear turbine meter. The liquid level of the separator is

measured by a guided wave radar device and monitored by high- and low-level switches. A

control valve on top of the separator regulates the gas flow to control pressure and a

control valve on the bottom of the separator regulates the liquid to control the liquid level.

During normal operation, a PID controls the gas control valve to maintain the pressure at a

setpoint. The liquid level control valve opens when the high-level switch activates and

closes when the low-level switch activates.

You use FBxConnect to build the FB3000’s standard configuration, which includes IO

configuration, meter set-up, and controls for the simulation of the separator; FBxDesigner

to build a program that opens and closes the liquid control valve; and FBxVue to build a

user display that includes a graphic of the separator liquid level, a gauge for the pressure,

and the status of the control valves and meters.

1.2.1 Demo Folders

This demo contains the following folders:

 Application:

Contains the Level_Control.zap file which is the packaged application created in this

demo, containing the FBxDesigner project and the FBxVue display.

 Display:

Contains the Separator Display.xml file which is the FBxVue display created in this

demo, and an images folder with the Sep_icon_2.png image used in the display.

 Documentation:

Contains this document, as well as a slideshow and video version.

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Introduction 3

 FBxDesigner Project:

Contains the Level_Control.mwt project file along with its accompanying project

folder/source code.

 Solution:

Contains the Separator_Demo.zsl solution file and its accompanying folder. This is the

solution created in this demo, which includes a copy of the application.

Note

This document is a complete guide to the demo; any other documents cited are

references.

1.2.2 I/O Points

The following table shows the I/O points to be used. You set up the inputs in override

mode and simulate them using the FB3000 control features.

I/O Type

Purpose

Signal Type

AI

Liquid Level 4—20 mA

DI

Hi-level Switch 24 Vdc input

DI

Lo-level Switch 24 Vdc input

AI

Pressure Setpoint 4—20 mA

AI

Pressure 4—20 mA

PI

Liquid Meter 24 Vdc input

Digital

MVS Gas Meter Dat RS-285 Serial

DO

Liquid Level Control Valve 24 Vdc output

AO

Gas Pressure Control Valve 4—20 mA

Note

This demo shows the I/O configuration using one 12-channel Mixed IO module (with 8

selectable AI/DI/PI inputs and 2 AO and 2 DO settings). Other types of I/O modules may be

used but are not show in this guide.

1.3 Field Tools

The Field Tools software suite establishes communications with the FB3000, stores

connection information, and contains several applications (primarily FBxConnect and

FBxDesigner).

1.3.1 FBxConnect

FBxConnect automatically opens when you connect to an RTU. Use to create and modify

solutions, download data, and other common tasks for the RTU. FBxConnect includes

configurable control features such as PID Loops, Math Blocks, and Action & Effects. It also

includes an integrated display builder, FBxVue, you use to create customized graphical

displays that can be combined with FBxDesigner projects into applications.

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4 Introduction

1.3.2 FBxDesigner

Note

FBxDesigner is a separate program in Field Tools that must be licensed to a PC.

Use FBxDesigner to program functions beyond what is offered in FBxConnect. FBxDesigner

supports the five IEC61131 programming languages by incorporating the industry-

standard MULTIPROG IEC 61131 programming tool and includes a library of predefined

function blocks tailored specifically for referencing data in the FB3000 RTU.

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Field Tools & Connecting to the RTU 5

Chapter 2. Field Tools & Connecting to RTU

Note

For this chapter, you must have already successfuly installed Field Tools and previously

licensed FBxDesigner.

2.1 Starting Field Tools

Click on the Field Tools desktop icon to start Field Tools.

If the Field Tools requirements window pops up, click Close.

If this is the first-time you have opened Field Tools, the default username is admin with no

password.

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Click Log in.

Click OK. The system requires that you change the password for the admin account.

To connect to a new FB3000, enter the default password of admin and click OK. Field Tools

starts.

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Field Tools & Connecting to the RTU 7

2.2 Field Tools Overview

Field Tools features a Connections List on the left-hand side of the screen, where you can

save multiple connections, sorted by site. You can open multiple connections at once, and

each selected connection opens a new instance of FBxConnect.

Field Tools has the following selections in the top menu:

 Connections:

Add Connections, Direct Connect, Import/Export Connections Lists.

 Configurations/Solutions:

Create new or open existing solutions with FBxConnect.

 Security:

Manage user accounts and passwords.

 Settings:

Edit system settings

 Help:

Access the online help system and view the version of Field Tools.

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8 Field Tools & Connecting to the RTU

2.3 Connecting to the RTU

To establish a connection with the FB3000 RTU, first ensure that the RTU is powered on

and connected to your computer using one of the comm ports (Ethernet, USB, or serial).

In Field Tools, click Connections > Add connection.

The Local connection to FBx device window displays; use it to create the new connection.

Enter a name for the connection. This will be the name in the Field Tools Connections List.

Select a Connection Type.

 If you are connecting through IP with an ethernet cable, enter the default IP address of

the ethernet port you are connecting to (either 192.168.1.10 for port 1 or

192.168.2.10 for port 2):

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Field Tools & Connecting to the RTU 9

Note

You may need to change your PC’s ethernet port adapter settings to have a similar IP

address and subnet mask.

 If you are connecting through Serial/USB, select the Comm port you are using.

After selecting your connection type, click Connect.

The system then shows the progress of the connection in the lower part of the Connection

parameters pane:

Once a connection establishes, an instance of FBxConnect automatically opens

(FBxConnect may take a few moments to load). When FBxConnect opens, it shows an

image of the FB3000:

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The status bar on the bottom of the screen shows that you are online, logged in as admin,

and indicates the IP address in use.

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FBxConnect 11

Chapter 3. FBxConnect

Use FBxConnect to create or modify a solution, which consists of the standard

configuration along with communication parameters and applications. In this section we

will create the Standard Configuration for the demo.

3.1 FBxConnect Overview

FBxConnect features a ribbon menu on the top of the screen:

The ribbon menu has the following tabs:

 File:

Upload/Download Solutions, save backup to Flash.

 Monitor:

View the status of I/O, system parameters, meters, logs, comm ports, etc.

 Configure:

Make changes to the Solution such as setting up Meters, IO, History, and control

functions.

 Services:

Upgrade firmware, warm/cold start the RTU, Calibrate I/O, manage User Security

profiles, and add licenses.

 Reports:

Download History, Configuration, and Miscellaneous reports.

 Applications:

Manage and view Applications.

 FBxVue:

Build and view user displays.

 Help:

Access the online Help system.

Note

For security purposes, you should change the default admin password (using the Services

tab) on the RTU after your initial login.

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12 FBxConnect

3.2 Guided Setup

The Guided Setup Wizard walks you through the screens needed to set up IO points, set

up meters, and configure history for those meters. Each of these actions can also be found

through other means.

To start the wizard, select the Configure tab and then click Guided Setup.

There are two ways to navigate the Guided Setup:

 Click Next or Apply on the bottom right to go to the next page.

 Click on a page in the Navigation Pane on the left to directly go to it (this option can

skip important configuration steps, so it is not recommended).

The Instructions page shows the steps in the configuration process and also allows you to

set the Device Info. Enter a Site Name.

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FBxConnect 13

Note

As show above, the system always highlights unsaved changes using yellow or amber.

Clicking Apply, Save, or Next saves the settings or changes on the current screen. If you

leave a screen without saving, the system displays a verification prompt reminding you to

save or discard the changes.

Click Synchronize Time.

You can either synchronize the date and time with your PC’s clock (you can select a

different time zone) or manually set a date and time.

Click OK, and then click Next.

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14 FBxConnect

3.2.1 IO Setup & Communications

Note

This section assumes you have installed a 12-channel Mixed IO module in slot 2 for all the

needed I/O. (The 12-channel Mixed IO module has 8 selectable AI/DI/PI inputs and 2 AO and

2 DO settings.)

The next few screens enable you to configure I/O on the RTU.

Select the Input types as shown below.

Enable Loop Power.

Click Apply.

On the next IO Setup screen, you can tag and define each I/O point in the module.

Complete the IO Setup screen according to the following table:

Inputs

Tag

Unit Type

Unit

Type

EU Scaling

Mode

Low

High

1

AI Liquid Leve Linear (Short) In Current EU Scaling 0 60

2

DI Hi Lvl Switch

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FBxConnect 15

Inputs

Tag

Unit Type

Unit

Type

EU Scaling

Mode

Low

High

3

DI Lo Lvl Switch

4

AI Pressure Setpoint Gauge Pressure psi(g) Current EU Scaling 0 30

5

AI Pressure Gauge Pressure psi(g) Current EU Scaling 0 30

6

PI Liquid Meter Frequency Hz Current

7

AI

8

AI

Outputs

Tag

Unit Type

Unit

Type

EU Scaling

Mode

Low

High

9

AO Gas Cntrl Valve Percentage % 0 100

10

AO

11

DO Lvl Cntrl Valve

12

DO

When you are done the screen should look like this:

On this screen you can also click Details for each I/O point to individually configure its

behavior. To simulate the separator later, we need to set all the inputs to Override mode.

Click Details for

Liquid Level (AI_2-1)

:

The system prompts you to save the changes on the current screen. Click Yes to continue.

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16 FBxConnect

The system displays a Configuration screen for the selected input:

Select the Override option in the Operation Mode pane and enter an Override Value of 30:

Select the Enable option in the Clipping Mode pane and enter a High Clipping Limit of 60:

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Remote Automation Solutions FB3000 Remote Terminal Unit (RTU) Step-by-Step Separator Configuration Guide

Remote Automation Solutions FB3000 Remote Terminal Unit (RTU) Step-by-Step Separator Configuration Guide

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